Dodge - Dakota 2wd - Workshop Manual - 1997 - 1997

Factory Workshop Manual Make Dodge Model Dakota 2wd Engine and year V6-3.9L VIN X (1997) 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 Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Locations ABS Main Relay: Locations Anti-Lock Brake System (ABS) relays are located in the power distribution box in the engine compartment. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Locations > Page 7 ABS Main Relay: Description and Operation The Anti-Lock Brake System (ABS) has two relays, one for the system and one for the pump motor. The system relay is used for the solenoid valves and Controller Anti-Lock Brake (CAB). The system relay is connected to the CAB at the power control relay terminal. The pump motor relay is used for the pump motor only. The pump motor relay starts/stops the pump motor when signaled by the CAB. The relays are located in the power distribution box in the engine compartment. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 11 CAB Connectors Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > With Four Wheel Antilock Brakes Electronic Brake Control Module: Description and Operation With Four Wheel Antilock Brakes GENERAL INFORMATION The Controller Anti-Lock Brake (CAB) module is mounted on the top of the Hydraulic Control Unit (HCU). It operates the Anti-Lock Brake System (ABS) and is separate from other vehicle electrical circuits. CAB voltage comes through the ignition switch in the RUN position. The CAB contains dual microprocessors. A logic block in each microprocessor receives identical sensor signals. These signals are processed and compared simultaneously. OPERATION The module is used to monitor wheel speeds and modulate (control) hydraulic pressure in each brake channel. The modulated hydraulic pressure is used to prevent wheel lockup during braking. Brake switch input is monitored to determine whether or not to prepare for possible anti-lock braking. Wheel speed sensors are monitored to determine when a wheel is beginning to lock up. The CAB will operate the valves in the HCU to control braking pressure during anti-lock braking. SELF-DIAGNOSTIC FEATURES 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 Diagnostic Readout Box (DRB) scan tool. ABS faults remain in memory until cleared, or until after the vehicle is started approximately 50 times. Stored faults are not erased if the battery is disconnected. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > With Four Wheel Antilock Brakes > Page 14 Electronic Brake Control Module: Description and Operation With Rear Wheel Antilock Brakes GENERAL INFORMATION The Controller Anti-Lock Brake (CAB) is a microprocessor which monitors and controls the Anti-Lock Brake System (ABS) operation. It has a 14 terminal connector to deliver power and ground and to connect all inputs and outputs associated with the system. The CAB primary functions are: ^ Detect wheel locking tendencies. ^ Control the application of brake fluid pressure to the rear brakes during ABS braking. ^ Monitor the Rear Wheel Anti-Lock (RWAL) brake system for proper operation. ^ Perform self-check diagnostics. The CAB continuously monitors the speed of the differential ring gear by monitoring signals generated by the rear wheel speed sensor. The CAB determines a wheel locking tendency when it recognizes the ring gear decelerating too rapidly. When a wheel-locking tendency is detected, the CAB energizes the isolation solenoid in the RWAL valve. When the isolation solenoid is energized, hydraulic pressure cannot be increased to the rear wheel cylinders. If the rear wheel speed sensor still indicate that the ring gear is decelerating too rapidly, the CAB then energizes the dump solenoid to reduce pressure at the rear wheel cylinders. The CAB continues this action until the wheel-locking tendency no longer exists. ON-BOARD DIAGNOSTICS When a fault is detected, the CAB will generate and store diagnostic trouble codes. Only one code can be stored at any one time. If the CAB senses a fault in any one of its monitored circuits, it will illuminate the red brake warning and ABS warning lamps. It will then generate a Diagnostic Trouble Code (DTC) and store it in memory. In general, the diagnostic trouble code will remain in memory when the ignition key has been turned Off. The exception to this is Diagnostic Trouble Codes 9 and 11, which are erased any time the key has been turned to the Off position. Also, Diagnostic Trouble Code 11 will be removed from memory when the ignition switch is in the Run or Accessory positions if the malfunction has been eliminated. If the malfunction remains, Diagnostic Trouble Codes 9 and 11 will be reset on the next ignition key cycle to On. INPUTS The CAB monitors the following inputs to determine when a wheel locking tendency may exist: ^ Rear Wheel Speed Sensor ^ Brake Lamp Switch ^ Brake Warning Lamp Switch ^ Reset Switch ^ 4WD Switch (If equipped) OUTPUTS The CAB controls the following outputs for anti-lock braking and brake warning information: ^ RWAL Valve ^ ABS Warning Lamp ^ Brake Warning Lamp POWER SUPPLY & GROUND Ignition voltage is provided to the CAB through connector pin 3 and is protected by a 20 amp fuse. Ignition voltage is supplied when the ignition switch is in the Run or Accessory positions. The CAB requires ignition voltage to be able to operate the anti-lock brakes. Battery voltage is provided to the CAB through pin 9 and is protected by a 20 amp fuse. This circuit supplies power to the memory cells so that the CAB can retain diagnostic information. Except for Diagnostic Trouble Codes 9 and 11, the CAB stores DTCs in the battery fed volatile memory. Volatile memories only retain information as long as power is supplied to the memory. If a DTC is stored in the battery fed volatile memory, the DTC can Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > With Four Wheel Antilock Brakes > Page 15 be cleared from the memory by disconnecting the battery supply to the CAB. Diagnostic Trouble Codes 9 and 11 are also in a volatile memory but their memories are fed with ignition voltage. A ground is provided to the CAB through pin 12 of the 14-way connector. It is required by the CAB to be able to operate any of its circuits. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Four Wheel Antilock Brake System Electronic Brake Control Module: Service and Repair Four Wheel Antilock Brake System Pump Motor Connector REMOVAL 1. Disconnect harness connector from the Controller Anti-Lock Brake (CAB). 2. Remove screws attaching CAB to the Hydraulic Control Unit (HCU). 3. Lift the CAB up off the HCU and disconnect the pump motor connector. 4. Remove the CAB. INSTALLATION 1. Position controller over the HCU and connect the pump motor harness. NOTE: Ensure the CAB seal is in position before installation. 2. Place the CAB onto the HCU and install the mounting screws. 3. Connect the harness to the CAB. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Four Wheel Antilock Brake System > Page 18 Electronic Brake Control Module: Service and Repair Rear Wheel Antilock Brake System Trim Panel RWAL Controller REMOVAL 1. Remove the trim panel, Data Link Connector (DLC) and knee blocker. 2. Remove bolts attaching module to the left side of the steering column support. 3. Disconnect wiring and remove module from vehicle. INSTALLATION 1. Connect wiring to control module. 2. Position module on steering column support. 3. Install control module mounting bolts. 4. Install the knee blocker, DLC and trim panel. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations Blower Motor Relay: Locations Fig 40 Power Distribution Center The blower motor relay is located in the PDC in the engine compartment. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 23 Blower Motor Relay: Description and Operation Blower Motor Relay Fig 40 Power Distribution Center The blower motor relay is a International Standards Organization (ISO)-type relay. The relay is a electromechanical device that switches battery current from a fuse in the Power Distribution Center (PDC) to the blower motor, whenever the ignition switch is in the On position. This arrangement reduces the amount of battery current that must flow through the ignition switch. When the ignition switch is in the On position, the relay is energized by a fused battery feed signal to the relay coil. The relay control circuit is protected by a fuse located in the junction block. When the relay is de-energized, the blower motor receives no battery feed. See the Diagnosis and Testing section of this group for more information on the operation of the relay. The blower motor relay is located in the PDC in the engine compartment. The relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 24 Blower Motor Relay: Testing and Inspection Blower Motor Relay Fig 40 Power Distribution Center RELAY TEST Remove the blower motor relay from its wire harness connector as described to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK. go to Step 2. If not OK, replace the faulty relay 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 +/- 5 ohms. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, see the Relay Circuit Test procedure. If not OK, replace the faulty relay. RELAY CIRCUIT TEST 1. The relay common feed terminal cavity (30) is connected to battery voltage and should be hot at all times. If OK, go to Step 2. If not OK, repair the open circuit to the fuse in the PDC as required. 2. The relay normally closed terminal cavity (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3. 3. The relay normally open terminal cavity (87) is connected to the blower motor. When the relay is energized, terminal 87 is connected to terminal 30 and provides full battery current to the blower motor. There should be continuity between this cavity and the blower motor relay output circuit cavity of the blower motor wire harness connector at all times. If OK, go to Step 4. If not OK, repair the open circuit to the blower motor as required. 4. The coil battery terminal cavity (86) is connected to the electromagnet in the relay It is energized when the ignition switch is in the On position. Check for battery voltage at the cavity for relay terminal 86 with the ignition switch in the On position. If OK, go to Step 5. If not OK, repair the open circuit to the ignition switch through the fuse in the junction block as required. 5. The coil ground terminal cavity (85) is connected to ground. This terminal supplies the ground for the relay electromagnetic coil. There should be continuity between the cavity for relay terminal 85 and a good ground at all times. If not OK, repair the open circuit as required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 25 Blower Motor Relay: Service and Repair Fig 40 Power Distribution Center 1. Disconnect and isolate the battery negative cable. 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC for blower motor relay identification and location. 4. Unplug the blower motor clutch relay from the PDC. 5. Install the blower motor relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 6. Install the PDC cover. 7. Connect the battery negative cable. 8. Test the relay operation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Component Locations Compressor Clutch Relay: Component Locations Power Distribution Center Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Component Locations > Page 30 Power Distribution Fig 27 Power Distribution Center Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Component Locations > Page 31 Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 32 Compressor Clutch Relay: Description and Operation Fig 27 Power Distribution Center The compressor clutch relay is a International Standards Organization (ISO) micro-relay The terminal designations and functions are the same as a conventional ISO relay However, the micro-relay terminal orientation (footprint) is different, the current capacity is lower and the relay case dimensions are smaller than on the conventional ISO relay. The compressor clutch relay is a electromechanical device that switches current to the compressor clutch coil when the Powertrain Control Module (PCM) grounds the coil side of the relay The PCM responds to inputs from the heater-A/C mode control switch, the low pressure cycling clutch switch, and the high pressure cut-off switch. The compressor clutch relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the PDC label for relay identification and location. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 33 Compressor Clutch Relay: Testing and Inspection Compressor Clutch Relay RELAY TEST The compressor clutch relay is located in the Power Distribution Center (PDC). Refer to the PDC label for relay identification and location. Remove the relay from the PDC to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2. If not OK, replace the faulty relay. 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 +/-5 ohms. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, SEE the Relay Circuit Test. If not OK, replace the faulty relay. RELAY CIRCUIT TEST 1. The relay common feed terminal cavity (30) is connected to fused battery feed. There should be battery voltage at the cavity for relay terminal 30 at all times. If OK, go to Step 2. If not OK, repair the open circuit to the 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 Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 34 Compressor Clutch Relay: Service and Repair Fig 27 Power Distribution Center 1. Disconnect and isolate the battery negative cable. 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC for compressor clutch relay identification and location. 4. Unplug the compressor clutch relay from the PDC. 5. Install the compressor clutch relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 6. Install the PDC cover. 7. Connect the battery negative cable. 8. Test the relay operation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Locations Central Timer Module ( CTM ) Low Option: Locations Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions Central Timer Module ( CTM ) Low Option: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 41 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 Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 42 Electrostatic Discharge Symbol All Electrostatic Discharge (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, especially 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. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 43 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 44 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 45 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 46 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 47 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 48 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 49 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 50 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. 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. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 51 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 52 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 53 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 54 Central Timer Module ( CTM ) Low Option: Diagnostic Aids 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 in 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 and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 55 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. 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 every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. 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 fuse circuit. 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 the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 56 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools 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 - This instrument is 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 vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. 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 non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 57 Central Timer Module ( CTM ) Low Option: Connector Views Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 58 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 59 Central Timer Module ( CTM ) Low Option: Electrical Diagrams Central Timer Module (Part 1 Of 10) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 60 Central Timer Module (Part 2 Of 10) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 61 Central Timer Module (Part 3 Of 10) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 62 Central Timer Module (Part 4 Of 10) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 63 Central Timer Module (Part 5 Of 10) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 64 Central Timer Module (Part 6 Of 10) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 65 Central Timer Module (Part 7 Of 10) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 66 Central Timer Module (Part 8 Of 10) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 67 Central Timer Module (Part 9 Of 10) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 68 Central Timer Module (Part 10 Of 10) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Page 69 Central Timer Module ( CTM ) Low Option: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR- BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY . Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Page 70 Central Timer Module ( CTM ) Low Option: Description and Operation CENTRAL TIMER MODULE Two versions of the Central Timer Module (CTM) are available on this vehicle a base version and a high-line version. The base version of the CTM is used on base models of the vehicle. The base version of the CTM combines the functions of a chime/buzzer module an intermittent wipe module and an ignition lamp time delay relay in a single unit. The high-line version of the CTM is used on high-line vehicles. The high-line CTM provides all of the functions of the base version CTM but also is used to control and integrate many of the additional electronic functions and features included on the high-line models. The high-line version of the CTM contains a central processing unit and interfaces with other modules in the vehicle on the Chrysler Collision Detection (CCD) data bus network. The CCD data bus network allows the sharing of sensor information. This helps to reduce wire harness complexity reduce internal controller hardware and reduce component sensor current loads. At the same time this system provides increased reliability enhanced diagnostics and allows the addition of many new feature capabilities. Some of the functions and features that the CTM supports or controls include: Chimes for the following conditions: ^ Headl amps on with ignition off and driver door open warning ^ Key in ignition with ignition off and driver door open warning ^ ABS lamp warning (if the vehicle is so equipped) ^ Airbag lamp warning ^ Check engine lamp warning ^ Check gauges lamp warning ^ Low fuel lamp warning ^ Low washer fluid lamp warning ^ Seat belt reminder lamp warning ^ Transmission oil temperature lamp warning ^ Ignition key lamp timer ^ Intermittent wipe control ^ Courtesy lamp time-out (high-line only) ^ Enhanced accident response (high-line only) ^ Horn chirp upon door lock with RKE (programmable) (high-line only) ^ Illuminated entry (high-line only) ^ Power door lock control (high-line only) ^ Power lock inhibit (high-line only) ^ Remote Keyless Entry (RKE) (high-line only) ^ Rolling door locks (programmable) (high-line only) ^ Speed sensitive intermittent wipe (high-line only) ^ Vehicle Theft Security System (VTSS) (high-line only) (if the vehicle is so equipped) Both versions of the CTM are mounted under the passenger side end of the instrument panel behind the instrument panel top cover and outboard of the glove box opening. For diagnosis of the base version of the CTM Refer to Chime/Buzzer Warning Systems. See: Instrument Panel, Gauges and Warning Indicators/Audible Warning Device For diagnosis of the high-line version of the CTM or the CCD data bus, the use of a DRB scan tool and the proper Diagnostic Procedures manual are recommended. The CTM cannot be repaired and if faulty or dam aged it must be replaced. For additional information on the Central Timer Module, See: Relays and Modules - Powertrain Management/Relays and Modules - Computers and Control Systems/Central Timer Module ( CTM ) High Option Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Page 71 Central Timer Module ( CTM ) Low Option: Testing and Inspection NOTE: The following tests may not prove conclusive in the diagnosis of the high-line version of the Central Timer Module (CTM). The most reliable, efficient, and accurate means to diagnose the high-line CTM requires the use of a DRB scan tool. For additional information on the Central Timer Module, refer to Powertrain Management / Computers and Control Systems / Body Control Module. See: Relays and Modules - Powertrain Management/Relays and Modules - Computers and Control Systems/Central Timer Module ( CTM ) High Option 1. Check the fuses in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the Power Distribution Center (PDC) as required. 3. Disconnect and isolate the battery negative cable. Remove the Central Timer Module (CTM) from its mounting bracket to access the CTM wire harness connectors. 4. Unplug the wire harness connectors from the CTM. Check the wire harness connectors and the receptacles in the CTM for loose, corroded, or damaged terminals and pins. If OK, go to Step 5. If not OK, repair as required. 5. Probe the ground circuit cavity of the 14-way CTM wire harness connector and check for continuity to a good ground. Repeat the check between the ground circuit cavity of the 18-way CTM wire harness connector and a good ground. In each case, there should be continuity. If OK, go to Step 6. If not OK, repair the open circuit(s) to ground as required. 6. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the 14-way CTM wire harness connector. If OK, go to Step 7. If not OK, repair the open circuit to the junction block as required. 7. Probe the door lock switch output (lock) circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as you actuate each power lock switch to the Lock position. If OK, go to Step 8. If not OK, repair the open circuit from either or both power lock switch(es) to the CTM as required. 8. Probe the door lock switch output (unlock) circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as you actuate each power lock switch to the Unlock position. If OK, go to Step 9. If not OK, repair the open circuit from either or both power lock switch(es) to the CTM as required. 9. Plug the wire harness connectors back into the CTM. Backprobe the door lock driver circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as either power lock switch is moved to the Lock position. Repeat the test pressing the Lock button of the Remote Keyless Entry (RKE) transmitter. If OK, go to Step 10. If not OK using the power lock switch, but OK with the RKE transmitter, see the test for the Power Lock Switch in Body and Frame/Locks/Power Locks. If not OK using the RKE transmitter, but OK with the power lock switch, see the test for the Remote Keyless Entry Transmitter in Body and Frame/Locks/Keyless Entry. If not OK, with the power lock switch or the RKE transmitter, replace the faulty CTM. 10. Backprobe the door unlock driver circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as the power lock switch is moved to the Unlock position. Repeat the test pressing the Unlock button of the RKE transmitter. If OK, see the test for the Power Lock Motors in Body and Frame/Locks/Power Locks. If not OK using the power lock switch, but OK with the RKE transmitter, see the test for the Power Lock Switch. If not OK using the RKE transmitter, but OK with the power lock switch, see the test for the Remote Keyless Entry Transmitter in Body and Frame/Locks/Keyless Entry. If not OK, with the power lock switch or the RKE transmitter, replace the faulty CTM. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Page 72 Central Timer Module ( CTM ) Low Option: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the glove box as described. Central Timer Module Remove/Install 3. Remove the three screws that secure the outboard glove box opening bracket to the instrument panel. 4. Remove the two screws that secure the Central Timer Module (CTM) mounting bracket to the outboard glove box opening bracket. 5. Remove the outboard glove box opening bracket from the instrument panel through the glove box opening. 6. Pull the CTM and mounting bracket into the glove box opening far enough to disengage the wire harness retainer from the CTM mounting bracket. 7. Unplug the wire harness connector(s) (one connector for low-line models, two connectors for high-line models) from the CTM. 8. Remove the CTM from the instrument panel. 9. Reverse the removal procedures to install. Be certain to engage the mounting tab on the outboard side of the CTM mounting bracket with the slot in the instrument panel end bracket. Tighten the CTM and mounting bracket screws to 2.2 N.m (20 in. lbs.). NOTE: If a new high-line Central Timer Module is installed, the programmable features must be enabled and/or disabled to the customer's preferred settings. Use a DRB scan tool and the proper Diagnostic Procedures to perform these operations. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Description and Operation Daytime Running Lamp Control Unit: Description and Operation GENERAL INFORMATION The headlamps on vehicles sold in Canada, will go on when the ignition is turned ON. The module must also receive a signal from the engine controller. This provides a constant Lights On condition while the vehicle is rolling. The lamps illuminate at less than 50 % of normal intensity. CIRCUIT OPERATION On vehicles built for sale in Canada, the low-beam headlamps operate when the ignition switch is in the RUN position and the park brake switch OPEN. Circuit L20 from the headlamp switch connects to DRL module. Circuit L20 is HOT at all times and protected by a 15 Amp fuse located in the Power Distribution Center (PDC). The ignition RUN feed is provided on circuit L10. This circuit is protected by a 15 Amp fuse located in the junction block. Circuit L4 powers the low beams of the left and right headlamps. When the headlamp switch is OFF, the DRL module powers the low beams on circuit L4. When the headlamps are ON, the multi-function switch powers the low beams on circuit L4. Circuit L3 feeds the high beams of the headlamps and connects to DRL module. When the operator flashes the headlamps with the stalk of the multi-function switch, the DRL senses voltage on circuit L3. When it senses voltage on circuit L3, the DRL module stops supplying power to the low beams on circuit L4. The park brake switch input is provided on circuit G11. Circuit Z1 provides ground for the DRL module. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Description and Operation > Page 77 Daytime Running Lamp Control Unit: Service and Repair REMOVAL The Daytime Running Lamp Module is located on the left inner fender. Daytime Running Lamp Module 1. Remove the bolt attaching the module to the inner fender. 2. Disconnect the electrical connector. INSTALLATION 1. Connect the electrical connector. 2. Insert the tab on the DRLM into the slot on the left inner fender. 3. Install the bolt attaching the module to the left inner fender. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Power Distribution Center Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 81 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Description and Operation Headlamp Relay: Description and Operation SYSTEM OPERATION The headlamp relay is a International Standards Organization (ISO) micro-relay The terminal designations and functions are the same as a conventional ISO relay However, the micro-relay terminal orientation (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than on the conventional ISO relay. The headlamp relay is a electromechanical device that switches current to the headlamps when the high-line Central Timer Module (CTM) grounds the relay coil. The headlamp relay is located in the junction block, behind the fuse access panel on the left end of the instrument panel in the passenger compartment. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Description and Operation > Page 85 Headlamp Relay: Testing and Inspection Relay Terminals The horn relay is located in the Power Distribution Center (PDC) in the engine compartment. The headlamp relay is located in the junction block in the passenger compartment. Each of these relays can be tested as described in the following procedure, however the circuits they are used in to vary. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Remove the relay from the PDC or junction block as described to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2. If not OK, replace the faulty relay. 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, test the relay circuits. If not OK, replace the faulty relay. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Description and Operation > Page 86 Headlamp Relay: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the fuse access panel by unsnapping it from the left end of the instrument panel. Headlamp Relay Remove/Install 3. Unplug the headlamp relay from the junction block. 4. Install the headlamp relay by aligning the relay terminals with the cavities in the junction block and pushing the relay firmly into place. 5. Connect the battery negative cable. 6. Test the headlamp relay operation. 7. Install the fuse access panel. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Power Distribution Center Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 90 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 91 Horn Relay: Description and Operation SYSTEM OPERATION The horn relay is a International Standards Organization (ISO) micro-relay The terminal designations and functions are the same as a conventional ISO relay. However, the micro-relay terminal orientation (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than on the conventional ISO relay. The horn relay is a electromechanical device that switches current to the horn when the horn switch on the steering wheel is depressed. The horn relay is located in the Power Distribution Center (PDC), in the engine compartment. Refer to the PDC label for horn relay identification and location. If a problem is encountered with a continuously sounding horn, it can usually be quickly resolved by removing the horn relay from the PDC until further diagnosis is completed. The horn relay cannot be repaired and, if faulty, it must be replaced. The horn relay is a electromechanical device that switches current to the horn when the horn switch or the high-line Central Timer Module (CTM) grounds the relay coil. The horn relay is located in the Power Distribution Center, in the engine compartment. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 92 Horn Relay: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Horn Relay Relay Test The horn relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the PDC label for horn relay identification and location. Remove the horn relay from the PDC as described to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2. If not OK, replace the faulty relay 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 3. If not OK, replace the faulty relay 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, see the Relay Circuit Test. If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity 30. is connected to battery voltage and should be hot at all times. If OK, go to Step 2. If not OK, repair the open circuit to the PDC 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 horn. There should be continuity between the cavity for relay terminal 87 and the horn relay output circuit cavity of the horn wire harness connector at all times. If OK, go to Step 4. If not OK, repair the open circuit to the horn as required. 4. The coil battery terminal (86) is connected to the electromagnet in the relay It is connected to battery voltage and should be hot at all times. Check for battery voltage at the cavity for relay terminal 86. If OK, go to Step 5. If not OK, repair the open circuit to the PDC fuse as required. 5. The coil ground terminal (85) is connected to the electromagnet in the relay It is grounded through the horn switch when the horn switch is depressed. It can also be grounded by the high-line Central Timer Module (CTM) in response to inputs from the Vehicle Theft Security System (VTSS) or the Remote Keyless Entry (RKE) system. Check for continuity to ground at the cavity for relay terminal 85. There should be continuity with the horn switch depressed, and no continuity with the horn switch released. If not OK, see the diagnosis for the Lighting and Horns/Horn/Horn Switch. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 93 Horn Relay: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Power Distribution Center 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC for horn relay identification and location. 4. Unplug the horn relay from the PDC. 5. Install the horn relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 6. Install the PDC cover. 7. Connect the battery negative cable. 8. Test the relay operation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations Trailer Lighting Relay: Locations Power Distribution Center Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 97 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations Power Distribution Center Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 102 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Locations > Data Link Connector DLC Location Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Locations > Data Link Connector > Page 109 Module Locations Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Locations > Data Link Connector > Page 110 Module Locations Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Locations > Data Link Connector > Page 111 Module Locations Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions Central Timer Module ( CTM ) High Option: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 114 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 Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 115 Electrostatic Discharge Symbol All Electrostatic Discharge (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, especially 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. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 116 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 117 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 118 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 119 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 120 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 121 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 122 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 123 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. 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. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 124 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 125 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 126 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 127 Central Timer Module ( CTM ) High Option: Diagnostic Aids 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 in 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 and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 128 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. 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 every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. 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 fuse circuit. 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 the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 129 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools 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 - This instrument is 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 vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. 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 non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 130 Central Timer Module ( CTM ) High Option: Connector Views Data Link Connector Pinout ABCM Connector Pinout Passenger Airbag Connector Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 131 Drivers Airbag Squib Connector Pinout Clockspring 2-Way Connector Pinout Central Timer Module (CTM) Connector "A" Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 132 Central Timer Module (CTM) Connector "B" Pinout Left Instrument Cluster Connector "A" (Black) Pinout Right Instrument Cluster Connector "B" (Gray) Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 133 Overhead Console Compass/Mini-Trip Computer Pinout Ambient Temperature Sensor Connector Pinout Door Jamb Switch Connector Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 134 Door Disarm Switch Connector Pinout Power Door Lock Switch Connections Door Lock Actuator Connector Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 135 Key-In Ignition Connector Pinout Multifunction Switch Connector Pinout Windshield Wiper Motor Connector Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 136 Central Timer Module ( CTM ) High Option: Electrical Diagrams Airbag System Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 137 Chrysler Collision Detection (CCD) Bus System Compass/Mini-Trip Computer System Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 138 Central Timer Module Block Diagram Power Lock System Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 139 Windshield Wiper System Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Service Precautions > Technician Safety Information Central Timer Module ( CTM ) High Option: Technician Safety Information Technician Safety Information DANGER!!! Engines produce carbon monoxide that is odorless, causes slower reaction time, and can lead to serious injury. When the engine is operating, keep service areas WELL VENTILATED or attach the vehicle exhaust system to the shop exhaust removal system. Set the parking brake and block the wheels before testing or repairing the vehicle. It is especially important to block the wheels on front-wheel drive vehicles; the parking brake does not hold the drive wheels. When servicing a vehicle, always wear eye protection, and remove any metal jewelry such as watchbands or bracelets that might make an inadvertent electrical contact. When diagnosing a body system problem, it is important to follow approved procedures where applicable. Following these procedures is very important to the safety of individuals performing diagnostic tests. 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. Servicing Sub-Assemblies SERVICING SUB-ASSEMBLIES Some components of the body system are intended to be serviced in 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 Service and Repair procedures should be serviced. DRB III Safety Information DRBIII SAFETY INFORMATION WARNING: Exceeding the limits of the DRB 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 DRB 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 function for the measurement. Do not try voltage or current measurements that may exceed the rated capacity. DRB III Safety Limits - Do not exceed the limits shown in the table below: - Voltage between any terminal and ground must not exceed 500v DC or 500v peak AC. - Use caution when measuring voltage above 25v DC or 25v AC. - The circuit being tested must be protected by a 10A fuse or circuit breaker. - Use the low current shunt to measure circuits up to 10A. Use the high current clamp to measure circuits exceeding 10A. - 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Service Precautions > Technician Safety Information > Page 142 - 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 DRB away from spark plug or coil wires to avoid measuring error from outside interference. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Service Precautions > Technician Safety Information > Page 143 Central Timer Module ( CTM ) High Option: Vehicle Damage Warnings Vehicle Damage Warnings 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. Road Testing A Complaint Vehicle ROAD TESTING A COMPLAINT VEHICLE 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 screen while in motion. Do not hang the DRB from the rear view mirror or operate it yourself. Have an assistant available to operate the DRB. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Service Precautions > Page 144 Central Timer Module ( CTM ) High Option: Application and ID GLOSSARY OF ACRONYMS ACM ..................................................................................................................................................... ....................................... Airbag Control Module CAB ........................................................................ ................................................................................................................ Controller Anti-lock Brake CCD ................................................................................................................................... Chrysler Collision Detection (Vehicle Communications Bus) CMTC ................................................................. ................................................................................................................ Compass/mini-trip Computer CTM .................................................................................................................................... .......................................................... Central Timer Module DAB ....................................................... ...................................................................................................................................................... Driver Airbag DLC ............................................................................................................................... ................................................................... Data Link Connector DTC ............................................... ............................................................................................................................................ Diagnostic Trouble Code MIC ............................................................................................................................... ................................................... Mechanical Instrument Cluster PAB ................................................ ........................................................................................................................................................ Passenger Airbag PCM ....................................................................................................................... ................................................................ Powertrain Control Module PDC ........................................ .................................................................................................................................................. Power Distribution Center RKE ...................................................................................................................... ......................................................................... Remote Keyless Entry SQUIB ................................................................................................................................... Also Called Initiator (Located In Rear Of Airbag Module) VTSS ............................................................................ ..................................................................................................... Vehicle Theft Security System Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System Central Timer Module ( CTM ) High Option: Description and Operation Airbag System Airbag System Description AIRBAG SYSTEM The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front end collision. The system is most effective when used in conjunction with the seat belt system. The airbag control module (ACM) is an electronic module that monitors the airbag system for proper operation, stores Diagnostic Trouble Code (DTCs), controls the airbag warning lamp, monitors the pressure in the passenger airbag module 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 the diagnostic information DTCs to the technician through the DRB III via the CCD bus. Some circuits are tested continuously; others are checked only under certain circumstances. The warning lamp is driven with messages relayed to the Mechanical Instrument Cluster (MIC) from the ACM via the CCD bus. The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be observed by the customer. Whenever the ignition key is turned to the run or start" position, the airbag control module performs a lamp check by turning the AIRBAG warning lamp on for 6-8 seconds. If the lamp remains off, it means that the ACM has checked the system and found it to be free of discernible malfunctions. If the lamp remains on, there could be an active fault in the system or the circuit that operates the lamp may be shorted to ground. If the lamp comes on and stays on for a period longer than 6-8 seconds, then goes off, there is usually an intermittent problem in the system. Perform the WARNING LAMP CIRCUIT OPEN procedure in this book to find the cause of any customer complaint regarding the AIRBAG warning lamp, such as: Warning Lamp Does Not Illuminate - Warning Lamp Stays Illuminated WARNING! The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must first disconnect and isolate the battery negative (ground) cable. Then wait two minutes for the system capacitor to discharge before further system service. This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Never strike or kick the airbag control module, as it can damage the impact sensor or affect its calibration. If an airbag control module is accidentally dropped during service, the module must be scrapped and replaced with a new unit. Airbag Diagnostic Trouble Codes AIRBAG DIAGNOSTIC TROUBLE CODES Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Always begin by reading the diagnostic trouble codes using the DRB. This procedure begins with AIRBAG TEST 1A - Identifying Airbag System Problems. This will direct you to the specific test(s) that must be performed. Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures within this manual, diagnostic trouble codes are used as a diagnostic tool. ACTIVE CODES The codes become 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 are automatically erased 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 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 147 "Loss of Ignition Run Only" code which is an active code only. A "stored" code indicates that there was an active code present at some time. However, the code currently may not be present as an active code, although another code could be. When a trouble code occurs, the airbag warning lamp illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. If a malfunction is detected a diagnostic trouble code is stored and will remain stored as long as the malfunction exists. When and if the malfunction ceases to exist, and ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of that same malfunction, the diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. If no obvious problems are found, erase stored codes, and with the ignition "on" wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 148 Central Timer Module ( CTM ) High Option: Description and Operation Interior Lighting INTERIOR LIGHTING The courtesy lights are controlled by the CTM. The door switches are inputs to the CTM and the courtesy lights are outputs. The glove box lamp and the ash receiver lamp (if equipped) are not controlled by the CTM. They are hardwired to individual switches and fuses. The ignition key halo lamp is controlled by the CTM and will remain on for thirty seconds after the door is closed. The Highline CTM also provides for an illuminated entry option. If the CTM detects an unlock signal from the RKE transmitter, a door disarm switch input or the door jamb switch input, the interior courtesy lights will be turned on. The illuminated entry function is cancelled if the CTM senses an ignition "on" condition or the "lock" command from a valid key fob. If a door is left open or the dome lamp switch is left in the "on" position for more than fifteen minutes, the CTM will extinguish the lamps to avoid discharging the battery. If the lamps are turned on by rotation of the headlamp panel dimmer switch, the CTM will not be able to turn them off. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 149 Central Timer Module ( CTM ) High Option: Description and Operation Central Timer Module INTRODUCTION Central Timer Module The Central Timer Module (CTM) is used to supply the vehicles occupants with visual and audible information, control various vehicle functions, and provide a centralized power distribution for the passenger compartment. To both provide and receive vehicle information the BCM is interfaced to the CCD Bus. Power for the CTM is supplied from three sources. Circuit F12 supplies power to the CTM in the START and RUN position. This circuit is protected by a 10 Amp fuse located in the junction block. Power is also supplied to the CTM on circuit F35. This circuit is HOT at all times and protected by a 20 Amp fuse located in the junction block. In the RUN position circuit V6 provides battery power to the CTM. This circuit is protected by a 20 Amp fuse located in the junction block. Ground for the ECM is provided by circuits Z1 and Z2. CCD Bus interface is accomplished on circuits D1 and D2. The D1 circuit is used for Bus (+), and D2 is for Bus (-). SYSTEM OPERATION Central Timer Module Two versions of the Central Timer Module (CTM) are available on this vehicle, a base version and a high-line version. The base version of the CTM is used on base models of the vehicle. The base version of the CTM combines the functions of a chime/buzzer module, an intermittent wipe module, and an ignition lamp time delay relay in a single unit. The high-line version of the CTM is used on highline vehicles. The high-line CTM provides all of the functions of the base version CTM, but also is used to control and integrate many of the additional electronic functions and features included on the high- line models. The high-line version of the CTM contains a central processing unit and interfaces with other modules in the vehicle on the Chrysler Collision Detection (CCD) data bus network. The CCD data bus network allows the sharing of sensor information. This helps to reduce wire harness complexity, reduce internal controller hardware, and reduce component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. The power lock and Remote Keyless Entry (RKE) systems are two of the systems that the high-line CTM controls. The high-line CTM receives hard-wired inputs from the power lock switches, CCD message inputs from the Powertrain Control Module (PCM) and Airbag Control Module (ACM), and coded radio signal inputs from the RKE transmitters. In response to those inputs, the internal programming of the CTM sends the proper outputs to control the power lock motors, the horn relay, and the courtesy lamps. Some of the features and functions of the power lock and Remote Keyless Entry (RKE) systems made possible because of the communication of the CTM on the CCD data bus network include: - A door-lock inhibit feature which prevents the power lock system from being energized with a power door lock switch if the key is in the ignition and/or the headlamps are on. However, the locks can still be operated manually with a key or energized with the RKE transmitter. - An enhanced accident response feature will prevent the doors from locking, then unlock both doors after receiving a CCD message from the ACM indicating a frontal impact requiring airbag deployment. This feature will also turn on the courtesy lamps ten seconds after receiving the ACM deployment message, if the CCD vehicle speed message from the PCM indicates the vehicle is not moving. Of course, these responses are dependent upon functional battery power and wiring circuitry following the impact. - Rolling door locks is a programmable feature of the power lock system. This feature will automatically lock all of the doors after the vehicle reaches a speed of about 24 kilometers-per-hour (15 miles-per-hour) or greater. This feature will also lock the doors if a door is opened, then closed again at any speed above 24 kilometers-per-hour (15 miles-per-hour). This feature can be enabled or disabled using the DRB scan tool and the proper Diagnostic Procedures. - A programmable feature of the RKE system is the enabling or disabling of the horn chirp following the RKE Lock function. This feature can be enabled or disabled using the DRB scan tool and the proper Diagnostic Procedures. The horn relay is one of the outputs that the high-line CTM can control. The high-line CTM is programmed to energize or de-energize the horn relay in response to certain inputs from the Vehicle Theft Security System (VTSS) and the Remote Keyless Entry (RKE) system. One of the features that the high-line CTM supports and controls is the Vehicle Theft Security System (VTSS). In the VTSS, the CTM receives hard-wired inputs from the door jamb, door lock cylinder, and ignition switches. The programming in the CTM allows it to process the information from these inputs and send control outputs to energize or de-energize the headlamp relay, horn relay, and the Security lamp. The CTM also sends CCD data bus messages to the Powertrain Control Module (PCM) to control the engine no-run feature of the VTSS The CTM also contains the receiver and control logic for the power lock and Remote Keyless Entry (RKE) systems, which are integrated into the arming, disarming, and triggering functions of the VTSS. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 150 Both versions of the CTM are mounted under the passenger side end of the instrument panel, behind the instrument panel top cover and outboard of the glove box opening. For diagnosis of the base version of the CTM, refer to Wiper and Washer Systems or Chime/Buzzer Warning Systems. For diagnosis of the high-line version of the CTM or the CCD data bus, a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 151 Central Timer Module ( CTM ) High Option: Description and Operation Chime System CHIME SYSTEM The chime system is built into the CTM. The system also supports an external chime request from the instrument cluster. This feature allows the instrument cluster to request a chime from the CTM for gauge problems and tell-tale warnings. There are two chime rates, Low; 50 chimes per minute for reminders and High; 180 chimes per minute for serious conditions that require immediate attention. The high rate chime sounds when the key is left in the ignition and the doors are open or the headlights are left on. The low rate chime sounds for any of the other conditions. There is a variable rate feature that allows the chime to sound continuously for key-in and headlamp warning as long as the door is open. The seat belt warning chime is activated for six seconds, and all other chime conditions will activate the chime once at the time the warning light on the cluster is illuminated. The chime will sound for the following conditions: - Ignition oft, key in ignition, driver's door open - Ignition oft, headlamps on, driver's door open - Seat belt warning - Check engine lamp illuminated (after prove-out) - Airbag lamp illuminated (after prove-out) - Anti-lock lamp illuminated (after prove-out if equipped) - Check gauges lamp illuminated - Low fuel - Low washer fluid - Engine temp critical - Engine oil press too low CIRCUIT OPERATION Seat Belt Warning Chime The seat belt chime is used to indicate to the operator that the seat belt is not fastened when the ignition switch is in the RUN position. The seat belt switch is normally OPEN with the seat belt buckled. Circuit G10 is connected between the Central Timer Module (CTM) and the switch. Ground for the switch is provided on circuit Z1. Exterior Lamp-On Warning Chime The exterior lamp ON chime is used to indicate to the operator that the lamps are ON with the drivers door OPEN and the key removed from the ignition. The Central Timer Module (CTM) uses information from circuit G26 to determine if the lamps are ON, and circuit G16 for drivers door ajar. Key-In Ignition Warning Chime The Key-In chime is used to indicate to the operator that the key is in the ignition with the driver's door OPEN. If the key is in the ignition, a ground path is completed from the G26 circuit at the Central Timer Module (CTM), through the CLOSED switch, to the Z1 circuit. The Z1 circuit is the ground circuit. When the driver's door is open the normally OPEN door ajar switch CLOSES completing a path to ground on circuit G16. The CTM processes this information and turns on the chime. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 152 Central Timer Module ( CTM ) High Option: Description and Operation Airbag System Description AIRBAG SYSTEM The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front end collision. The system is most effective when used in conjunction with the seat belt system. The airbag control module (ACM) is an electronic module that monitors the airbag system for proper operation, stores Diagnostic Trouble Code (DTCs), controls the airbag warning lamp, monitors the pressure in the passenger airbag module 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 the diagnostic information DTCs to the technician through the DRB III via the CCD bus. Some circuits are tested continuously; others are checked only under certain circumstances. The warning lamp is driven with messages relayed to the Mechanical Instrument Cluster (MIC) from the ACM via the CCD bus. The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be observed by the customer. Whenever the ignition key is turned to the run or start" position, the airbag control module performs a lamp check by turning the AIRBAG warning lamp on for 6-8 seconds. If the lamp remains off, it means that the ACM has checked the system and found it to be free of discernible malfunctions. If the lamp remains on, there could be an active fault in the system or the circuit that operates the lamp may be shorted to ground. If the lamp comes on and stays on for a period longer than 6-8 seconds, then goes off, there is usually an intermittent problem in the system. Perform the WARNING LAMP CIRCUIT OPEN procedure in this book to find the cause of any customer complaint regarding the AIRBAG warning lamp, such as: Warning Lamp Does Not Illuminate - Warning Lamp Stays Illuminated WARNING! The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must first disconnect and isolate the battery negative (ground) cable. Then wait two minutes for the system capacitor to discharge before further system service. This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Never strike or kick the airbag control module, as it can damage the impact sensor or affect its calibration. If an airbag control module is accidentally dropped during service, the module must be scrapped and replaced with a new unit. Airbag Diagnostic Trouble Codes AIRBAG DIAGNOSTIC TROUBLE CODES Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Always begin by reading the diagnostic trouble codes using the DRB. This procedure begins with AIRBAG TEST 1A - Identifying Airbag System Problems. This will direct you to the specific test(s) that must be performed. Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures within this manual, diagnostic trouble codes are used as a diagnostic tool. ACTIVE CODES The codes become 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 are automatically erased 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 153 A "stored" code indicates that there was an active code present at some time. However, the code currently may not be present as an active code, although another code could be. When a trouble code occurs, the airbag warning lamp illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. If a malfunction is detected a diagnostic trouble code is stored and will remain stored as long as the malfunction exists. When and if the malfunction ceases to exist, and ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of that same malfunction, the diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. If no obvious problems are found, erase stored codes, and with the ignition "on" wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Interior Lighting INTERIOR LIGHTING The courtesy lights are controlled by the CTM. The door switches are inputs to the CTM and the courtesy lights are outputs. The glove box lamp and the ash receiver lamp (if equipped) are not controlled by the CTM. They are hardwired to individual switches and fuses. The ignition key halo lamp is controlled by the CTM and will remain on for thirty seconds after the door is closed. The Highline CTM also provides for an illuminated entry option. If the CTM detects an unlock signal from the RKE transmitter, a door disarm switch input or the door jamb switch input, the interior courtesy lights will be turned on. The illuminated entry function is cancelled if the CTM senses an ignition "on" condition or the "lock" command from a valid key fob. If a door is left open or the dome lamp switch is left in the "on" position for more than fifteen minutes, the CTM will extinguish the lamps to avoid discharging the battery. If the lamps are turned on by rotation of the headlamp panel dimmer switch, the CTM will not be able to turn them off. Central Timer Module INTRODUCTION Central Timer Module The Central Timer Module (CTM) is used to supply the vehicles occupants with visual and audible information, control various vehicle functions, and provide a centralized power distribution for the passenger compartment. To both provide and receive vehicle information the BCM is interfaced to the CCD Bus. Power for the CTM is supplied from three sources. Circuit F12 supplies power to the CTM in the START and RUN position. This circuit is protected by a 10 Amp fuse located in the junction block. Power is also supplied to the CTM on circuit F35. This circuit is HOT at all times and protected by a 20 Amp fuse located in the junction block. In the RUN position circuit V6 provides battery power to the CTM. This circuit is protected by a 20 Amp fuse located in the junction block. Ground for the ECM is provided by circuits Z1 and Z2. CCD Bus interface is accomplished on circuits D1 and D2. The D1 circuit is used for Bus (+), and D2 is for Bus (-). SYSTEM OPERATION Central Timer Module Two versions of the Central Timer Module (CTM) are available on this vehicle, a base version and a high-line version. The base version of the CTM is used on base models of the vehicle. The base version of the CTM combines the functions of a chime/buzzer module, an intermittent wipe module, and an ignition lamp time delay relay in a single unit. The high-line version of the CTM is used on highline vehicles. The high-line CTM provides all of the functions of the base version CTM, but also is used to control and integrate many of the additional electronic functions and features included on the high- line models. The high-line version of the CTM contains a central processing unit and interfaces with other modules in the vehicle on the Chrysler Collision Detection (CCD) data bus network. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 154 The CCD data bus network allows the sharing of sensor information. This helps to reduce wire harness complexity, reduce internal controller hardware, and reduce component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. The power lock and Remote Keyless Entry (RKE) systems are two of the systems that the high-line CTM controls. The high-line CTM receives hard-wired inputs from the power lock switches, CCD message inputs from the Powertrain Control Module (PCM) and Airbag Control Module (ACM), and coded radio signal inputs from the RKE transmitters. In response to those inputs, the internal programming of the CTM sends the proper outputs to control the power lock motors, the horn relay, and the courtesy lamps. Some of the features and functions of the power lock and Remote Keyless Entry (RKE) systems made possible because of the communication of the CTM on the CCD data bus network include: - A door-lock inhibit feature which prevents the power lock system from being energized with a power door lock switch if the key is in the ignition and/or the headlamps are on. However, the locks can still be operated manually with a key or energized with the RKE transmitter. - An enhanced accident response feature will prevent the doors from locking, then unlock both doors after receiving a CCD message from the ACM indicating a frontal impact requiring airbag deployment. This feature will also turn on the courtesy lamps ten seconds after receiving the ACM deployment message, if the CCD vehicle speed message from the PCM indicates the vehicle is not moving. Of course, these responses are dependent upon functional battery power and wiring circuitry following the impact. - Rolling door locks is a programmable feature of the power lock system. This feature will automatically lock all of the doors after the vehicle reaches a speed of about 24 kilometers-per-hour (15 miles-per-hour) or greater. This feature will also lock the doors if a door is opened, then closed again at any speed above 24 kilometers-per-hour (15 miles-per-hour). This feature can be enabled or disabled using the DRB scan tool and the proper Diagnostic Procedures. - A programmable feature of the RKE system is the enabling or disabling of the horn chirp following the RKE Lock function. This feature can be enabled or disabled using the DRB scan tool and the proper Diagnostic Procedures. The horn relay is one of the outputs that the high-line CTM can control. The high-line CTM is programmed to energize or de-energize the horn relay in response to certain inputs from the Vehicle Theft Security System (VTSS) and the Remote Keyless Entry (RKE) system. One of the features that the high-line CTM supports and controls is the Vehicle Theft Security System (VTSS). In the VTSS, the CTM receives hard-wired inputs from the door jamb, door lock cylinder, and ignition switches. The programming in the CTM allows it to process the information from these inputs and send control outputs to energize or de-energize the headlamp relay, horn relay, and the Security lamp. The CTM also sends CCD data bus messages to the Powertrain Control Module (PCM) to control the engine no-run feature of the VTSS The CTM also contains the receiver and control logic for the power lock and Remote Keyless Entry (RKE) systems, which are integrated into the arming, disarming, and triggering functions of the VTSS. Both versions of the CTM are mounted under the passenger side end of the instrument panel, behind the instrument panel top cover and outboard of the glove box opening. For diagnosis of the base version of the CTM, refer to Wiper and Washer Systems or Chime/Buzzer Warning Systems. For diagnosis of the high-line version of the CTM or the CCD data bus, a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. Chime System CHIME SYSTEM The chime system is built into the CTM. The system also supports an external chime request from the instrument cluster. This feature allows the instrument cluster to request a chime from the CTM for gauge problems and tell-tale warnings. There are two chime rates, Low; 50 chimes per minute for reminders and High; 180 chimes per minute for serious conditions that require immediate attention. The high rate chime sounds when the key is left in the ignition and the doors are open or the headlights are left on. The low rate chime sounds for any of the other conditions. There is a variable rate feature that allows the chime to sound continuously for key-in and headlamp warning as long as the door is open. The seat belt warning chime is activated for six seconds, and all other chime conditions will activate the chime once at the time the warning light on the cluster is illuminated. The chime will sound for the following conditions: - Ignition oft, key in ignition, driver's door open - Ignition oft, headlamps on, driver's door open - Seat belt warning - Check engine lamp illuminated (after prove-out) - Airbag lamp illuminated (after prove-out) - Anti-lock lamp illuminated (after prove-out if equipped) - Check gauges lamp illuminated - Low fuel - Low washer fluid - Engine temp critical - Engine oil press too low Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 155 CIRCUIT OPERATION Seat Belt Warning Chime The seat belt chime is used to indicate to the operator that the seat belt is not fastened when the ignition switch is in the RUN position. The seat belt switch is normally OPEN with the seat belt buckled. Circuit G10 is connected between the Central Timer Module (CTM) and the switch. Ground for the switch is provided on circuit Z1. Exterior Lamp-On Warning Chime The exterior lamp ON chime is used to indicate to the operator that the lamps are ON with the drivers door OPEN and the key removed from the ignition. The Central Timer Module (CTM) uses information from circuit G26 to determine if the lamps are ON, and circuit G16 for drivers door ajar. Key-In Ignition Warning Chime The Key-In chime is used to indicate to the operator that the key is in the ignition with the driver's door OPEN. If the key is in the ignition, a ground path is completed from the G26 circuit at the Central Timer Module (CTM), through the CLOSED switch, to the Z1 circuit. The Z1 circuit is the ground circuit. When the driver's door is open the normally OPEN door ajar switch CLOSES completing a path to ground on circuit G16. The CTM processes this information and turns on the chime. Compass Mini-Trip Computer (CMTC) SYSTEM OPERATION A mini trip computer is available on this model to provide several electronic functions and features. The trip computer contains a central processing unit and interfaces with other modules in the vehicle on the Chrysler Collision Detection (CCD) data bus network. The CCD data bus network allows the sharing of sensor information. This helps to reduce wire harness complexity, reduce internal controller hardware, and reduce component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. Some of the functions and features that the trip computer supports and/or controls, include the following display options: Compass and temperature - Trip odometer (ODO) - Average fuel economy (AVG ECO) - Instant fuel economy (ECO) - Distance to empty (DTE) - Elapsed time (ET) - Blank display Momentarily depressing and releasing the Step button when the ignition switch is in the On position will cause the overhead console display to step sequentially through the listed display options. Momentarily depressing and releasing the U.S./Metric button toggles the display between U.S. and Metric measurements. For more information on the trip computer features and functions, refer to the owner 5 manual in the vehicle glove box. The push button (Step and U.S./Metric) switches and the compass flux-gate unit are integral to the trip computer, compass, and thermometer display module unit. The ambient temperature sensor is hard-wired to the module. Data input for all other trip computer functions is received through CCD data bus messages. The trip computer uses its internal programming and all of these inputs to calculate and display the requested data. If the data displayed is incorrect, perform the self-diagnostic tests as described. If these tests prove inconclusive, the use of a DRB scan tool and the proper Diagnostic Procedures are recommended for further testing of the trip computer and the CCD data bus. The trip computer, compass, and thermometer display module cannot be repaired, and are only available for service as a unit. If faulty or damaged, the complete module must be replaced. COMPASS MINI-TRIP COMPUTER (CMTC) This system, located in the overhead console, displays information on outside temperature, compass direction and trip information. Compass And Temperature Display This display provides the outside temperature and one of eight compass readings to indicate the direction the vehicle is facing. Trip Odometer (ODO) Shows the distance travelled since the last reset. Average Fuel Economy (AVE ECO) Shows the average fuel economy in MPG (miles per gallon) or L/100Km since the last reset. Instantaneous Fuel Economy Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 156 Shows the fuel economy for the last few seconds in MPG or L/100Km. Distance to Empty (DTE) Shows the estimated distance that can be travelled with the fuel remaining in the tank. This is calibrated using the MPG for the last few minutes. Elapsed Time (ET) Shows the accumulated ignition on time since the last reset. Step Button Press this button to cycle through all the mini-trip computer displays. US/M Button Press this button to convert all vehicle displays from US to metric to US. To Reset the Display Press the Step and US/M buttons simultaneously for at least two seconds and all resettable conditions will be rest. This will occur only if a resettable function (AVG ECO, ECO, ET) is currently being displayed. Automatic Compass Calibration This compass is self-calibrating which eliminates the need to manually set the compass. When the vehicle is new, the compass may appear erratic and the CAL symbol will be displayed. After completing three 360° turns in an area free from large metal or metallic objects, the CAL symbol will turn off and the compass will function normally. Compass Variance Compass Variance is the difference between Magnetic North and Geographic North. In some areas of the country, the difference between Magnetic and Geographic North is great enough to cause the compass to give false readings. If this occurs, the compass variance must be set. Enhanced Accident Response (Highline CTM only) If the Airbag Control Module (ACM) deploys the airbags, a message is transmitted over the CCD bus to the CTM module to unlock the doors. The interior lights will be turned on when the vehicle speed message on the CCD bus indicates 0 mph or the message is not present. In addition to unlocking the doors, the door lock feature will be disabled for a predetermined amount of time following the deployment. Once the ignition key has been cycled to the "off" position, normal operation will resume. Disclaimers DISCLAIMERS All information, illustrations, and specifications contained in this database are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice. Glossary of Terms/Acronyms GLOSSARY OF ACRONYMS ACM ..................................................................................................................................................... ....................................... Airbag Control Module CAB ........................................................................ ................................................................................................................ Controller Anti-lock Brake CCD ................................................................................................................................... Chrysler Collision Detection (Vehicle Communications Bus) CMTC ................................................................. ................................................................................................................ Compass/mini-trip Computer CTM .................................................................................................................................... .......................................................... Central Timer Module DAB ....................................................... ...................................................................................................................................................... Driver Airbag DLC ............................................................................................................................... ................................................................... Data Link Connector DTC ............................................... ............................................................................................................................................ Diagnostic Trouble Code MIC ............................................................................................................................... ................................................... Mechanical Instrument Cluster PAB ................................................ ........................................................................................................................................................ Passenger Airbag PCM ....................................................................................................................... ................................................................ Powertrain Control Module PDC ........................................ .................................................................................................................................................. Power Distribution Center RKE ...................................................................................................................... ......................................................................... Remote Keyless Entry SQUIB ................................................................................................................................... Also Called Initiator (Located In Rear Of Airbag Module) VTSS ............................................................................ ..................................................................................................... Vehicle Theft Security System Introduction SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION The body system consists of four modules that communicate over the (CCD) bus (Chrysler Collision Detection multiplex system). There are two additional modules, the Powertrain Control Module (PCM) and the Controller Anti-lock Brake (CAB) that are not part of the body system, but do utilize the CCD bus for communication. The CAB also utilizes the bus for diagnostics. The PCM sends and receives messages on the CCD bus, Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 157 however diagnostics are performed through the Serial Communication Interface or (SCI), the same as last year. All of the information about the functioning of all the systems is organized, controlled, and communicated by the CCD bus. Through the CCD bus, information about the operation of vehicle components and circuits is relayed quickly to the appropriate module(s). All modules receive all the information transmitted on the bus even though a module may not require all information to perform it's function. It will only respond to messages "addressed" to it through a binary coding process. This method of data transmission significantly reduces the complexity of the wiring in the vehicle and the size of the wiring harnesses. Mechanical Instrument Cluster (MIC) MECHANICAL INSTRUMENT CLUSTER (MIC) The MIC is available in 4 different versions. Two of the versions are Canadian clusters. There is a Highline and a low line cluster available. The difference between Highline and low line is the addition of a tachometer in the Highline. In order to accomplish this, the fuel level gauge is reduced in size and the oil pressure gauge is relocated. The cluster positions it's gauges with bus messages received from the Powertrain Control Module (PCM). The odometer is a Liquid Crystal Display (LCD). The cluster will provide bus bias and the PCM provides termination. The MIC has an internal self-test routine that can be accessed by pushing and holding the trip odometer and rotating the key to the on position. The cluster will then place all the gauges at their calibration points and will light all the CCD driven tell-tales. It will also light all the segments of the LCD display for a visual verification check. All of the red warning symbols are non-replaceable LED's, amber tell-tales are serviceable incandescent bulbs. The MIC is not addressable with the DRB. All diagnostics are performed with the on-board sequence described above. If there are faults found during the diagnostic routine, the cluster will report them on the LCD odometer display. For further information about the diagnostic routine and the explanation of faults, please refer to Powertrain Management/Computers and Control Systems/Testing and Inspection/. Power Door Lock System POWER DOOR LOCKS The CTM controls the door lock actuator assemblies to handle locking and unlocking with the key fob or interior switch. There is also a door lock inhibit feature that prevents power locking of the doors if the ignition is off and the key is in the ignition. Automatic or "rolling locks" are included as a DRB programmable feature. If the vehicle is moving approximately 15 mph and approximately 10 degrees of throttle opening is seen by the PCM, (the PCM will send this info to the CTM via the CCD bus) indicating acceleration, the CTM will cycle the lock actuators. Remote Keyless Entry (RKE) /Vehicle Theft Security System (VTSS) INTRODUCTION Remote Keyless Entry System The Remote Keyless Entry (RKE) system is a radio frequency system that allows the use of a remote transmitter to control the power lock and illuminated entry systems. If the vehicle is so equipped, the RKE transmitter can also control the vehicle theft alarm system. The RKE system consists of the remote key fob transmitter and a receiver with program logic, which is integral to the high-line version of the Central Timer Module (CTM). The RKE system can retain the vehicle access codes of up to four transmitters. The transmitter codes are retained in memory, even if the battery is disconnected. If a transmitter is faulty or lost, new transmitter vehicle access codes can be programmed into the system using a DRE scan tool and the proper Diagnostic Procedures. The high line Central Timer Module (CTM) provides for Remote Keyless Entry (RKE) and the Vehicle Theft Security System (VTSS). The base CTM is not able to provide these functions. The presence of either of these options dictates that the vehicle be equipped with a Highline CTM. The VTSS system monitors the door jamb switches and ignition switch to detect unauthorized entry into the vehicle. Once the vehicle is "armed", any one of these inputs can cause the VTSS system to be tripped. Once tripped, the horn and lights will pulse for 3 minutes and if an attempt is made to start the engine, it will start and stall. If the trigger condition is still present, the lights will continue to flash for an additional 15 minutes. After 15 minutes the system will stop pulsing the lights and return to the "armed" state. The cause of the last 4 alarm triggers is stored by the CTM and may be retrieved by the DRB. The system may be disarmed by either an unlock command from a valid RKE key fob or by using a key in either door. Both front door key cylinders are equipped with disarm switches. There is also a VTSS lamp on the dash that provides information to the driver about the state of the vehicle theft system. The RKE system is placed in the programming mode by the DRB. The system will stores up to four key fob codes. Through the DRB, programming of one key fob without deleting the others is possible. If the key fob is stolen, all the fob codes stored previously may be erased to provide the owner of the vehicle with an extra sense of security. Wiper System SPEED SENSITIVE INTERMITTENT WIPERS The Dakota trucks equipped with a Highline Central Timer Module (CTM) will utilize speed sensitive intermittent wipers. Only a Highline CTM will be able to support this feature. A base CTM will provide for intermittent wipers without the speed sensitive feature. The low and high speeds Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 158 are controlled through the wiper stalk switch. The intermittent portion of the wiper control is handled by the CTM through the intermittent wiper relay. When the module detects a decrease in delay time as selected by the driver, an immediate wipe of the windshield takes place and the new delay interval is implemented. This feature is present only on the Highline CTM. hen the vehicle is moving at speeds at or below 10 mph, the delay time ranges from 1 to 36 seconds. When the speed rises above 10 mph, the delay times are cut in half for a range of 1/2 to 18 seconds. The speed signal is provided to the CTM from the PCM over the CCD bus. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Central Timer Module ( CTM ) High Option: Initial Inspection and Diagnostic Overview VEHICLE COMMUNICATION The Chrysler Collision Detection multiplex system (CCD bus) consists of a twisted pair of wires. These wires run from one module to another. They receive and deliver coded information between the modules. The information is coded to identify the message as well as the importance of the message. When there are multiple messages trying to access the CCD bus at one time, the code determines the message that has higher priority, and is then allowed to access the bus first. The two wires of the twisted pair that make up the CCD multiplex system are called "bus+" (bus plus) and "bus-" (bus minus) respectively. Each wire has a measurable voltage level of roughly 2.5 volts. In order to maintain the 2.5 volts on each line and provide a means of transportation for the coded messages, there is a "voltage divider network" located in the module that supplies bus bias or voltage. Along with the module that supplies bias, some modules provide termination. Bias is the voltage necessary to make the bus operational. At least one point of termination is necessary, some systems use more than one. Some modules are capable of biasing and terminating the bus by themselves. Termination in the circuitry (a 120 ohm resistor placed across the bus) is required to complete the voltage divider network and also provides some electromagnetic protection for the bus. In this vehicle, the bias is supplied by the instrument cluster and termination is provided by the Powertrain Control Module (PCM). Without termination, voltage on the bus goes to approximately 5 volts on one wire and 0 volts on the other wire. In this application, the instrument cluster supplies bus bias and termination and the PCM supplies an additional point of termination. NOTE: Communication over the bus is essential to the proper operation of the vehicle's on-board diagnostic systems and the DRB. Problems with the operation of the bus or DRB must be corrected before proceeding with diagnostic testing. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 161 Central Timer Module ( CTM ) High Option: Component Tests and General Diagnostics DIAGNOSTICS The Central Timer Module (CTM) is fully addressable with DRB III and it is the recommended method for diagnosis. The CTM reports 6 Diagnostic Trouble Codes. All of the inputs to the CTM can be read with DRB and the outputs can be actuated. If the inputs are OK and the outputs can be cycled with the DRB, the problem is "USUALLY" the Central Timer Module. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 162 Central Timer Module ( CTM ) High Option: Scan Tool Testing and Procedures DRB III Does Not Power Up (Blank Screen) DRB III ERROR MESSAGES AND BLANK SCREEN Under normal operation, the DRB will display one of only two error messages: - User-Requested WARM Boot - User-Requested COLD Boot If the DRB should display any other error message, record the entire display and call the MDS Hotline, or call for information and assistance at 1-800-825-8737. This is a sample of such an error message display: VER: 2.14 date: 26 Jul93 file: key_itf.cc date: Jul 26 1993 line: 548 err. Ox1 User-Requested COLD boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. DRB III DOES NOT POWER UP (BLANK SCREEN) 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. If all connection are proper between the DRB and the Vehicle or other devices, and the vehicle battery is fully charged, an inoperative DRB may be the result of faulty cable of vehicle wiring. Perform Vehicle Communication TEST 1A. DRB III Safety Limits WARNING: Never exceed DRBIII safety limits! Display Is Not Visible DISPLAY IS NOT VISIBLE Low temperatures will effect the visibility of the display. Adjust the contrast to compensate for this condition. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Adjustments > Setting the Compass Central Timer Module ( CTM ) High Option: Adjustments Setting the Compass SETTING THE COMPASS The compass/mini-trip module is self-calibrated and requires no adjustment. The word CAL will be displayed to indicate that the compass is in the fast calibrating mode. CAL will turn off after the vehicle has gone in three complete circles without stopping, in an area free of magnetic disturbance. If the module displays the temperature while the compass is blank or shows a false reading, the vehicle must be demagnetized. If the compass still goes blank after the vehicle is demagnetized, the compass/mini-trip module must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Adjustments > Setting the Compass > Page 165 Central Timer Module ( CTM ) High Option: Adjustments Setting the Variance SETTING THE VARIANCE Setting The Variance Variance is the difference between magnetic north and geographic north. To determine the variance for the area you are in, refer to the zone map provided. The number shown for your area is the variance number for your area. 1. Set the Compass/Mini-Trip Console (CMTC) to compass/temperature mode. 2. Press and hold down the reset button for 5 seconds. NOTE: If the buttons are held for 10 seconds instead of 5, the CMTC will set the variance to 8 and enter the fast calibration mode. 3. The VAR light will come on and the last variance setting will be displayed. 4. Press the STEP button to set the zone number. 5. Press the US/M button and resume normal operation. NOTE: Do not attach any magnetic device such as a magnetic CB antenna to the vehicle. This can cause the compass to give false readings. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Service and Repair > Maintenance and Service Information Central Timer Module ( CTM ) High Option: Service and Repair Maintenance and Service Information MAINTENANCE AND SERVICE INFORMATION When replacing a blown fuse, it is important to use only a fuse having the correct amperage rating. The use of a fuse with a rating other than indicated may result in a dangerous electrical system overload. If a properly rated fuse continues to blow, it indicates a problem in the circuit that must be corrected. When replacing any bulbs, do not touch the new bulb with your fingers. Oil contamination will severely shorten bulb life. If the bulb comes in contact with an oily surface, clean the bulb with rubbing alcohol. WARNING: Failure to have the airbag system properly serviced by an authorized dealer may lead to possible injury in the event of an accident. Aside from the maintenance required in response to the airbag lamp conditions, an inspection of the mechanical and electrical components of the system is included in the regular maintenance service recommended for every 3 years or 30,000 miles. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Service and Repair > Maintenance and Service Information > Page 168 Central Timer Module ( CTM ) High Option: Service and Repair Setting the Compass SETTING THE COMPASS The compass/mini-trip module is self-calibrated and requires no adjustment. The word CAL will be displayed to indicate that the compass is in the fast calibrating mode. CAL will turn off after the vehicle has gone in three complete circles without stopping, in an area free of magnetic disturbance. If the module displays the temperature while the compass is blank or shows a false reading, the vehicle must be demagnetized. If the compass still goes blank after the vehicle is demagnetized, the compass/mini-trip module must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Service and Repair > Maintenance and Service Information > Page 169 Central Timer Module ( CTM ) High Option: Service and Repair Setting the Variance SETTING THE VARIANCE Setting The Variance Variance is the difference between magnetic north and geographic north. To determine the variance for the area you are in, refer to the zone map provided. The number shown for your area is the variance number for your area. 1. Set the Compass/Mini-Trip Console (CMTC) to compass/temperature mode. 2. Press and hold down the reset button for 5 seconds. NOTE: If the buttons are held for 10 seconds instead of 5, the CMTC will set the variance to 8 and enter the fast calibration mode. 3. The VAR light will come on and the last variance setting will be displayed. 4. Press the STEP button to set the zone number. 5. Press the US/M button and resume normal operation. NOTE: Do not attach any magnetic device such as a magnetic CB antenna to the vehicle. This can cause the compass to give false readings. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Service and Repair > Page 170 Central Timer Module ( CTM ) High Option: Tools and Equipment REQUIRED TOOLS AND EQUIPMENT DRB III (diagnostic read-out box) Jumper Wires Ohmmeter Voltmeter Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 18-13-97A > Jun > 97 > PCM - Cold Engine Idle Fluctuation Powertrain Control Module: Customer Interest PCM - Cold Engine Idle Fluctuation NO: 18-13-97 Rev.A GROUP: Vehicle Performance DATE: Jun. 13, 1997 SUBJECT: Cold Engine Idle Fluctuation THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-13-97 DATED MAR. 14, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL CHANGES ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES PART NUMBER AND MODEL ADDITIONS. MODELS: **1997 (AB) Ram Van/Wagon ** 1997 (AN) Dakota **1997 (BR) Ram Truck** NOTE: THIS BULLETIN APPLIES TO 1997 VEHICLES WITH A 3.9L ENGINE BUILT PRIOR TO THE FOLLOWING DATES: (AB) JUN. 2, 1997 (MDH 0602XX), (AN) FEB. 19, 1997 (MDH 0219XX) (BR) JUN. 2, 1997 (MDH 0602XX). SYMPTOM/CONDITION: The vehicle may exhibit an idle fluctuation following a cold engine start. This condition is most noticeable while the transmission selector is in either the park or neutral position. The incidence for idle fluctuation increases with lower engine start temperatures and is less likely to occur in a warm engine. DIAGNOSIS: Verify that the vehicle engine and powertrain control module are close to ambient temperature. Set the vehicle parking brake, place the transmission selector in Park or Neutral, and start the engine. Without giving the engine any throttle assist, allow time for the fuel system to enter "closed loop" fuel control and warm to normal operating temperatures. The engine idle speed should gradually decrease as the engine warms. If the engine exhibits idle fluctuation during engine warm-up, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves replacing the Powertrain Control Module (PCM) with revised parts. 1. Following service manual procedures, replace the PCM. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 18-13-97A > Jun > 97 > PCM - Cold Engine Idle Fluctuation > Page 179 2. Type the necessary information on the Authorized Modification Label p/n 04275086. Attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-03-92 0.7 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 18-21-98 > Jun > 98 > Powertrain Control Module - Service Precaution Powertrain Control Module: All Technical Service Bulletins Powertrain Control Module - Service Precaution NO: 18-21-98 GROUP: Vehicle Performance DATE: Jun. 5, 1998 SUBJECT: Powertrain Control Module (PCM) Service Caution MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1997 - 1998 (TJ) Wrangler 1996-1998 (XJ) Cherokee 1996-1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (European Market) DISCUSSION: Whenever any connector on the PCM is disconnected, the ignition switch must be in the "OFF" position for a minimum of 5 seconds before connector removal. It has been found under certain key "ON" or momentary key "OFF" conditions, when the black connector is unplugged, the PCM may attempt to write information to the EEPROM processor within the PCM. Sometimes this inadvertent write will set the target charging voltage to 0 (zero) volts. The result will prevent the charging system from charging the battery. If this occurs, the only correction is PCM replacement. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 18-13-97A > Jun > 97 > PCM Cold Engine Idle Fluctuation Powertrain Control Module: All Technical Service Bulletins PCM - Cold Engine Idle Fluctuation NO: 18-13-97 Rev.A GROUP: Vehicle Performance DATE: Jun. 13, 1997 SUBJECT: Cold Engine Idle Fluctuation THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-13-97 DATED MAR. 14, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL CHANGES ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES PART NUMBER AND MODEL ADDITIONS. MODELS: **1997 (AB) Ram Van/Wagon ** 1997 (AN) Dakota **1997 (BR) Ram Truck** NOTE: THIS BULLETIN APPLIES TO 1997 VEHICLES WITH A 3.9L ENGINE BUILT PRIOR TO THE FOLLOWING DATES: (AB) JUN. 2, 1997 (MDH 0602XX), (AN) FEB. 19, 1997 (MDH 0219XX) (BR) JUN. 2, 1997 (MDH 0602XX). SYMPTOM/CONDITION: The vehicle may exhibit an idle fluctuation following a cold engine start. This condition is most noticeable while the transmission selector is in either the park or neutral position. The incidence for idle fluctuation increases with lower engine start temperatures and is less likely to occur in a warm engine. DIAGNOSIS: Verify that the vehicle engine and powertrain control module are close to ambient temperature. Set the vehicle parking brake, place the transmission selector in Park or Neutral, and start the engine. Without giving the engine any throttle assist, allow time for the fuel system to enter "closed loop" fuel control and warm to normal operating temperatures. The engine idle speed should gradually decrease as the engine warms. If the engine exhibits idle fluctuation during engine warm-up, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves replacing the Powertrain Control Module (PCM) with revised parts. 1. Following service manual procedures, replace the PCM. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 18-13-97A > Jun > 97 > PCM Cold Engine Idle Fluctuation > Page 189 2. Type the necessary information on the Authorized Modification Label p/n 04275086. Attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-03-92 0.7 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 080197 > Feb > 97 > PCM Wire Harness Connector Repair Package Technical Service Bulletin # 080197 Date: 970203 Discussion NO: 08-01-97 GROUP: Electrical EFFECTIVE DATE: Feb. 3, 1997 SUBJECT: JTEC Powertrain Control Module Wiring Harness Connector Repair Packages MODELS: 1996 - 1997 (AB) Ram Van 1996 - 1997 (AN) Dakota 1996 - 1997 (BR) Ram Truck 1996 - 1997 (SR) Viper/Viper GTS 1997 (TJ) Wrangler 1996-1997 (XJ) Cherokee 1996-1997 (ZJ) Grand Cherokee 1996 - 1997 (ZG) Grand Cherokee (International Markets) DISCUSSION: The following Jeep/Truck Engine Controller (JTEC) Powertrain Control Module (PCM) electrical connector and terminal repair components are available to aid in powertrain electrical wiring repairs. These components allow repairs of individual wiring circuits without the need to replace the entire engine harness. If you have determined that a powertrain customer complaint could be related to a poor electrical connection, the PCM connectors should be inspected. The following diagnosis and inspection can be utilized to determine the condition of the PCM connectors and their terminals. Diagnosis Inspection of the connector begins with a thorough inspection of the insulator. 1. Record the radio station presets. 2. Disconnect and isolate the battery negative cable (both batteries should be disconnected if the vehicle is equipped with a 5.9L Cummins Diesel). 3. Disconnect the connector from the PCM. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 080197 > Feb > 97 > PCM Wire Harness Connector Repair Package > Page 194 4. Inspect the connector lock tab on the side of the insulator (Figure 1) for damage and replace the insulator if damaged is identified. 5. Gently pull on the wires of the connector one at a time. The initial and final locks will need to be inspected if the wire pulls out of the insulator. 6. Push in the single lock tab on the side of the insulator (Figure 2). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 080197 > Feb > 97 > PCM Wire Harness Connector Repair Package > Page 195 7. Then, insert the probe of special tool 6934 (Figure 3) into the back of the insulator cavity. 8. Grasp the wire and tool 6934 and slowly remove the wire and terminal from the insulator (Figure 4). Then, remove the strain relief and wire seal (Figure 1). 9. Inspect the initial and final locks of the insulator (Figure 1) for damage. Replace the insulator if there are any signs of damage. 10. Inspect all wire terminals for corrosion. If corrosion is evident, replace the terminal ends and the insulator. 11. To verify how secure the cavity of the terminal fits onto the PCM pins, insert and remove the wire end terminal onto the mating pin of the PGM. Then, rotate the terminal 90°, 180°, and 270° while inserting and removing the terminal from the pin. If any connection is loose, replace the wire end terminal. 12. Inspect and replace the PCM connector cover or connector plug if the locking tabs are damaged. Perform the following Repair Procedure if damage or wear is identified in any component of the insulator or terminals (including corrosion on the terminal). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 080197 > Feb > 97 > PCM Wire Harness Connector Repair Package > Page 196 PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves replacing either the insulator or terminals of the PCM connectors. Insulator Replacement NOTE: THIS PROCEDURE ASSUMES THAT THE WIRE END TERMINALS WERE ALREADY REMOVED WHEN THE DIAGNOSIS WAS PERFORMED. 1. Utilizing the appropriate insulator (see Parts Required list), install the wire and terminal into the appropriate cavities of the insulator. Refer to the appropriate Service Manual, Group 8W-80, for proper terminal-to-cavity locations in the connector. Fully seat all terminals into the insulator. 2. Push in the two lock tabs on the side of the connector (Figure 5). 3. Install the connector into the proper cavity of the PCM. 4. Connect the battery negative cable (both batteries should be connected if the vehicle is equipped with a 5.9L Cummins Diesel). 5. Reset the clock and reprogram the radio stations to the presets recorded in step 1 of the Diagnosis. Wire End Terminal Replacement NOTE: THIS PROCEDURE ASSUMES THAT THE DAMAGED OR CORRODED WIRE END TERMINAL WAS ALREADY REMOVED WHEN THE DIAGNOSIS WAS PERFORMED. 1. The wire of the terminal end that needs repaired will need to be cut and discarded. Measure approximately three inches down the wire from the end of the terminal and cut the wire. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 080197 > Feb > 97 > PCM Wire Harness Connector Repair Package > Page 197 2. Cut one of the wires with terminal ends from package P/N 04882087 in half. This action will allow for two repairs if necessary. 3. Remove approximately one inch of insulation from the wires that are being spliced together. 4. Place a piece of heat shrink tubing over one of the wires. Make sure the tubing will be long enough to cover and seal the entire repair. 5. Spread the strands of the wire apart on each part of the exposed wire (Example 1) (Figure 6). 6. Push the ends of the two wires together until the strands of wire are close to the insulation (Example 2) (Figure 6). 7. Twist the wires together (Example 3) (Figure 6). 8. Solder the connection together using rosin core type solder only. Do not use acid core solder. 9. Center the heat shrink tubing over the joint and heat the tubing using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 10. Secure the wires to the existing harness to prevent chafing or damage to the insulation. 11. Install the wire terminal end into the appropriate cavity of the insulator. Fully seat all terminals into the insulator. 12. Push in the single lock tab on the side of the connector (Figure 5). 13. Install the connector into the proper cavity of the PCM. 14. Connect the battery negative cable (both batteries should be connected if the vehicle is equipped with a 5.9L Cummins Diesel). 15. Reset the clock and reprogram the radio stations to the presets recorded in step 1 of the Diagnosis. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 18-21-98 > Jun > 98 > Powertrain Control Module - Service Precaution Powertrain Control Module: All Technical Service Bulletins Powertrain Control Module - Service Precaution NO: 18-21-98 GROUP: Vehicle Performance DATE: Jun. 5, 1998 SUBJECT: Powertrain Control Module (PCM) Service Caution MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1997 - 1998 (TJ) Wrangler 1996-1998 (XJ) Cherokee 1996-1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (European Market) DISCUSSION: Whenever any connector on the PCM is disconnected, the ignition switch must be in the "OFF" position for a minimum of 5 seconds before connector removal. It has been found under certain key "ON" or momentary key "OFF" conditions, when the black connector is unplugged, the PCM may attempt to write information to the EEPROM processor within the PCM. Sometimes this inadvertent write will set the target charging voltage to 0 (zero) volts. The result will prevent the charging system from charging the battery. If this occurs, the only correction is PCM replacement. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 080197 > Feb > 97 > PCM - Wire Harness Connector Repair Package Technical Service Bulletin # 080197 Date: 970203 Discussion NO: 08-01-97 GROUP: Electrical EFFECTIVE DATE: Feb. 3, 1997 SUBJECT: JTEC Powertrain Control Module Wiring Harness Connector Repair Packages MODELS: 1996 - 1997 (AB) Ram Van 1996 - 1997 (AN) Dakota 1996 - 1997 (BR) Ram Truck 1996 - 1997 (SR) Viper/Viper GTS 1997 (TJ) Wrangler 1996-1997 (XJ) Cherokee 1996-1997 (ZJ) Grand Cherokee 1996 - 1997 (ZG) Grand Cherokee (International Markets) DISCUSSION: The following Jeep/Truck Engine Controller (JTEC) Powertrain Control Module (PCM) electrical connector and terminal repair components are available to aid in powertrain electrical wiring repairs. These components allow repairs of individual wiring circuits without the need to replace the entire engine harness. If you have determined that a powertrain customer complaint could be related to a poor electrical connection, the PCM connectors should be inspected. The following diagnosis and inspection can be utilized to determine the condition of the PCM connectors and their terminals. Diagnosis Inspection of the connector begins with a thorough inspection of the insulator. 1. Record the radio station presets. 2. Disconnect and isolate the battery negative cable (both batteries should be disconnected if the vehicle is equipped with a 5.9L Cummins Diesel). 3. Disconnect the connector from the PCM. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 080197 > Feb > 97 > PCM - Wire Harness Connector Repair Package > Page 207 4. Inspect the connector lock tab on the side of the insulator (Figure 1) for damage and replace the insulator if damaged is identified. 5. Gently pull on the wires of the connector one at a time. The initial and final locks will need to be inspected if the wire pulls out of the insulator. 6. Push in the single lock tab on the side of the insulator (Figure 2). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 080197 > Feb > 97 > PCM - Wire Harness Connector Repair Package > Page 208 7. Then, insert the probe of special tool 6934 (Figure 3) into the back of the insulator cavity. 8. Grasp the wire and tool 6934 and slowly remove the wire and terminal from the insulator (Figure 4). Then, remove the strain relief and wire seal (Figure 1). 9. Inspect the initial and final locks of the insulator (Figure 1) for damage. Replace the insulator if there are any signs of damage. 10. Inspect all wire terminals for corrosion. If corrosion is evident, replace the terminal ends and the insulator. 11. To verify how secure the cavity of the terminal fits onto the PCM pins, insert and remove the wire end terminal onto the mating pin of the PGM. Then, rotate the terminal 90°, 180°, and 270° while inserting and removing the terminal from the pin. If any connection is loose, replace the wire end terminal. 12. Inspect and replace the PCM connector cover or connector plug if the locking tabs are damaged. Perform the following Repair Procedure if damage or wear is identified in any component of the insulator or terminals (including corrosion on the terminal). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 080197 > Feb > 97 > PCM - Wire Harness Connector Repair Package > Page 209 PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves replacing either the insulator or terminals of the PCM connectors. Insulator Replacement NOTE: THIS PROCEDURE ASSUMES THAT THE WIRE END TERMINALS WERE ALREADY REMOVED WHEN THE DIAGNOSIS WAS PERFORMED. 1. Utilizing the appropriate insulator (see Parts Required list), install the wire and terminal into the appropriate cavities of the insulator. Refer to the appropriate Service Manual, Group 8W-80, for proper terminal-to-cavity locations in the connector. Fully seat all terminals into the insulator. 2. Push in the two lock tabs on the side of the connector (Figure 5). 3. Install the connector into the proper cavity of the PCM. 4. Connect the battery negative cable (both batteries should be connected if the vehicle is equipped with a 5.9L Cummins Diesel). 5. Reset the clock and reprogram the radio stations to the presets recorded in step 1 of the Diagnosis. Wire End Terminal Replacement NOTE: THIS PROCEDURE ASSUMES THAT THE DAMAGED OR CORRODED WIRE END TERMINAL WAS ALREADY REMOVED WHEN THE DIAGNOSIS WAS PERFORMED. 1. The wire of the terminal end that needs repaired will need to be cut and discarded. Measure approximately three inches down the wire from the end of the terminal and cut the wire. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 080197 > Feb > 97 > PCM - Wire Harness Connector Repair Package > Page 210 2. Cut one of the wires with terminal ends from package P/N 04882087 in half. This action will allow for two repairs if necessary. 3. Remove approximately one inch of insulation from the wires that are being spliced together. 4. Place a piece of heat shrink tubing over one of the wires. Make sure the tubing will be long enough to cover and seal the entire repair. 5. Spread the strands of the wire apart on each part of the exposed wire (Example 1) (Figure 6). 6. Push the ends of the two wires together until the strands of wire are close to the insulation (Example 2) (Figure 6). 7. Twist the wires together (Example 3) (Figure 6). 8. Solder the connection together using rosin core type solder only. Do not use acid core solder. 9. Center the heat shrink tubing over the joint and heat the tubing using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 10. Secure the wires to the existing harness to prevent chafing or damage to the insulation. 11. Install the wire terminal end into the appropriate cavity of the insulator. Fully seat all terminals into the insulator. 12. Push in the single lock tab on the side of the connector (Figure 5). 13. Install the connector into the proper cavity of the PCM. 14. Connect the battery negative cable (both batteries should be connected if the vehicle is equipped with a 5.9L Cummins Diesel). 15. Reset the clock and reprogram the radio stations to the presets recorded in step 1 of the Diagnosis. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) 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 211 Powertrain Control Module: Specifications DESCRIPTION .................................................................................................................................... .............................................................. TORQUE Powertrain Control Module Mounting Screws ..................................................................................................................................... 3-5 Nm (30-40 in lb) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) 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 212 Powertrain Control Module: Locations Powertrain Control Module (PCM) The Powertrain Control Module (PCM) is mounted in the engine compartment. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 215 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 Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 216 Electrostatic Discharge Symbol All Electrostatic Discharge (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, especially 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. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 217 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 218 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 219 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 220 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 221 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 222 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 223 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 224 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. 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. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 225 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 226 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 227 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 228 Powertrain Control Module: Diagnostic Aids 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 in 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 and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 229 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. 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 every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. 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 fuse circuit. 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 the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 230 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools 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 - This instrument is 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 vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. 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 non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 231 PCM Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) 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 > Five Volt Sensor Supply-Primary Powertrain Control Module: Description and Operation Five Volt Sensor Supply-Primary Supplies the required 5 volt power source to the crankshaft position sensor, camshaft position sensor, Manifold Absolute Pressure (MAP) sensor and throttle position sensor. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) 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 > Five Volt Sensor Supply-Primary > Page 234 Powertrain Control Module: Description and Operation Five Volt Sensor Supply-Secondary Supplies the required 5 volt power source to the transmission pressure sensor and the vehicle speed sensor. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) 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 > Five Volt Sensor Supply-Primary > Page 235 Powertrain Control Module: Description and Operation Power Grounds The power ground is used to control ground circuits for the following powertrain control module (PCM) loads: Generator field winding - Fuel injectors - Ignition coil - Certain relays/solenoids Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) 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 > Five Volt Sensor Supply-Primary > Page 236 Powertrain Control Module: Description and Operation Sensor Return-PCM Input Sensor Return provides a low noise ground reference for all system sensors. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) 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 > Five Volt Sensor Supply-Primary > Page 237 Powertrain Control Module: Description and Operation Five Volt Sensor Supply-Primary Supplies the required 5 volt power source to the crankshaft position sensor, camshaft position sensor, Manifold Absolute Pressure (MAP) sensor and throttle position sensor. Five Volt Sensor Supply-Secondary Supplies the required 5 volt power source to the transmission pressure sensor and the vehicle speed sensor. Power Grounds The power ground is used to control ground circuits for the following powertrain control module (PCM) loads: Generator field winding - Fuel injectors - Ignition coil - Certain relays/solenoids Sensor Return-PCM Input Sensor Return provides a low noise ground reference for all system sensors. Signal Ground-PCM Input Signal ground provides a low noise ground to the data link connector. System Description Fig 1 Powertrain Control Module (PCM) SYSTEM DIAGNOSIS The Powertrain Control Module (PCM) can test many of its own input and output circuits. If the PCM senses a fault in a major system, it stores a Diagnostic Trouble Code (DTC) in its memory. Technicians can display stored DTC's with different methods. One way is using the DRB scan tool. Another way is using the malfunction indicator (check engine) lamp. On certain models the vehicle odometer can be used to display the numeric DTC. POWERTRAIN CONTROL MODULE (PCM) The powertrain control module (PCM) (Fig. 1) operates the fuel system. The PCM was formerly referred to as the SBEC or engine controller. The PCM is a pre-programmed, dual microprocessor digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, certain transmission features, speed control, air conditioning compressor clutch engagement and idle speed. The PCM can adapt its programming to meet changing operating conditions. The PCM receives input signals from various switches and sensors. Based on these inputs, the PCM regulates various engine and vehicle operations through different system components. These components are referred to as Powertrain Control Module (PCM) Outputs. The sensors and switches that provide inputs to the PCM are considered Powertrain Control Module (PCM) Inputs. The PCM adjusts ignition timing based upon inputs it receives from sensors that react to: engine rpm, manifold absolute pressure, engine coolant temperature, throttle position, transmission gear selection (automatic transmission), vehicle speed and the brake switch. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) 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 > Five Volt Sensor Supply-Primary > Page 238 The PCM adjusts idle speed based on inputs it receives from sensors that react to: throttle position, vehicle speed, transmission gear selection, engine coolant temperature and from inputs it receives from the air conditioning clutch switch and brake switch. Based on inputs that it receives, the PCM adjusts ignition coil dwell. The PCM also adjusts the generator charge rate through control of the generator field and provides speed control operation. PCM INPUTS: - A/C request (if equipped with factory A/C) - A/C select (if equipped with factory A/C) - Auto shutdown (ASD) sense - Battery temperature - Battery voltage - Brake switch - CCD bus (+) circuits - CCD bus (-) circuits - Camshaft position sensor signal - Crankshaft position sensor - Data link connection for DRB scan tool - Engine coolant temperature sensor - Fuel level - Generator (battery voltage) output - Ignition circuit sense (ignition switch in on/of/ crank/run position) - Intake manifold air temperature sensor - Leak detection pump (switch) sense (if equipped) - Manifold absolute pressure (MAP) sensor - Oil pressure - Output shaft speed sensor - Overdrive/override switch - Oxygen sensors - Park/neutral switch (auto. trans. only) - Power ground - Sensor return - Signal ground - Speed control multiplexed single wire input - Throttle position sensor - Transmission governor pressure sensor - Transmission temperature sensor - Vehicle speed sensor PCM OUTPUTS: - A/C clutch relay - Auto shutdown (ASD) relay - CCD bus (+) circuits - CCD bus (-) circuits - Data link connection for DRB scan tool - EGR valve control solenoid (if equipped) - EVAP canister purge solenoid - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel injectors - Fuel pump relay - Generator field driver (-) - Generator field driver (+) - Generator lamp (if equipped) - Idle air control (IAC) motor - Ignition coil - Leak detection pump - Malfunction indicator lamp (Check engine lamp) -- Driven through CCD circuits. - Overdrive indicator lamp (if equipped) - Speed control vacuum solenoid - Speed control vent solenoid - Tachometer (if equipped). Driven through CCD circuits. - Transmission convertor clutch circuit - Transmission 3-4 shift solenoid - Transmission relay Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) 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 > Five Volt Sensor Supply-Primary > Page 239 - Transmission temperature lamp (if equipped) - Transmission variable force solenoid The powertrain control module (PCM) contains a voltage convertor. This converts battery voltage to a regulated 5.0 volts. It is used to power the crankshaft position sensor, camshaft position sensor and vehicle speed sensor. The PCM also provides a five (5) volt supply for the manifold absolute pressure (MAP) sensor and throttle position sensor (TPS). SPEED CONTROL SYSTEM OPERATION The speed control electronic control circuitry is integrated into the Powertrain Control Module (PCM). The PCM is located in the engine compartment. The PCM speed control functions are monitored by the On-Board Diagnostics (OBD). All OBD-sensed systems are monitored by the PCM. Each monitored circuit is assigned a Diagnostic Trouble Code (DTC). The PCM will store a DTC in electronic memory for certain failures it detects. See Starting and Charging/Charging System/Testing and Inspection/Procedures/On-Board Diagnostic Test For Speed Control System for more information. The PCM cannot be repaired and must be replaced if faulty. CIRCUIT OPERATION Battery Feed Circuit A14 from the Power Distribution Center (PDC) supplies battery voltage to cavity A22 of the Powertrain Control Module (PCM). A 30 amp fuse in cavity 1 of the PDC protects circuit A14. Ignition Feed Circuit F18 provides an input to the Powertrain Control Module (PCM). This circuit is HOT in the START and RUN position and protected by a 10 amp fuse located in the junction block. Power for the fuse is supplied by circuit A21 from the ignition switch. Transmission Control The Powertrain Control Module (PCM) controls operation of the converter clutch, overdrive clutch, and governor pressure solenoid. The control module determines transmission shift points based on input signals from the transmission thermistor, transmission output shaft speed sensor, crankshaft position sensor, vehicle speed sensor, throttle position sensor, and battery temperature sensor. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) 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 > Testing and Inspection > Initial Inspection and Diagnostic Overview Powertrain Control Module: Initial Inspection and Diagnostic Overview Battery Feed - Check the 20 amp fuse located in cavity 1 of the PDC Ignition Feed - Check the 10 amp fuse located in the junction block Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) 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 > Testing and Inspection > Page 242 Powertrain Control Module: Service and Repair Powertrain Control Module (PCM) REMOVAL 1. Disconnect the negative battery cable at battery. 2. Carefully unplug the three 32-way connectors from PCM. 3. Remove three Powertrain Control Module (PCM) mounting bolts and remove PCM from vehicle. INSTALLATION 1. Install PCM and mounting bolts to vehicle. 2. Tighten bolts to 3-5 Nm (30-40 in lb). 3. Check pin connectors in the PCM and the three 32-way connectors for corrosion or damage. Repair as necessary 4. Install three 32-way connectors. 5. Install battery cable. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates Automatic Shut Down (ASD) Relay: Technical Service Bulletins Engine Controls/Emissions/A/T Manual Updates NUMBER: 26-06-98 GROUP: Miscellaneous DATE: June, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 2.5L, 3.9L, 5.2L, 5.9L 8.0L SFI/CNG/Diesel Diagnostic Manual - Publication Number 81-699-96041 DESCRIPTION OF CHANGES Revision to the diagnostic trouble codes Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 247 56 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 248 57 Revisions to the Throttle Position Sensor test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 249 162 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 250 166 Revisions to the Evap. Purge Flow Monitor tests Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 251 374 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 252 375 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 253 377 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 254 379 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 255 379A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 256 379B Revision to the EGR system Failure tests Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 257 432 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 258 433 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 259 434 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 260 435 Revision to the torque convertor clutch - no drop at lock up test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 261 465 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 262 467 Revision to the no temp rise seen at intake heater test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 263 514 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 264 515 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 265 516 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 266 517 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 267 518 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 268 519 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 269 520 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 270 521 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 271 521A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 272 521B Revision to the 12 volt supply relay test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 273 571 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Page 274 Automatic Shut Down (ASD) Relay: Locations Power Distribution Center Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Page 275 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Page 276 Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Page 277 Automatic Shut Down (ASD) Relay: Description and Operation CIRCUIT OPERATION Automatic Shut Down (ASD) Relay Circuit A16 from the Power Distribution Center (PDC) supplies battery voltage to the contact side of the Automatic Shut Down (ASD) relay. In the START or RUN position, the ignition switch connects circuit F18 from the 10 amp fuse in the junction block to the coil side of the ASD relay. The Powertrain Control Module (PCM) provides the ground path for the coil side of the relay on circuit K51. Circuit K51 connects to cavity C3 of the PCM. When the ASD relay energizes, it connects circuit A16 and circuit A142. Circuit A142 splices to supply voltage to the fuel injectors, ignition coil, and heated oxygen sensors. Circuit A142 also splices to cavity C12 of the PCM. This input tells the PCM the ASD relay has energized. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Relay Tests Automatic Shut Down (ASD) Relay: Testing and Inspection Relay Tests Fig 91 ASD And Fuel Pump Relay Terminals ASD and Fuel Pump Relay Test The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relay. The terminals on the bottom of each relay are numbered (Fig. 91). RELAY OPERATION Terminal 30: Connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. Terminal 85: The PCM grounds the coil side of the relay through this terminal. Terminal 86: Supplies voltage to the coil side of the relay. Terminal 87A: 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. Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TESTING 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 between 70 - 80 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. CAUTION: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter should now show continuity between relay terminals 87 and 30. - The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. - If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Relay Tests > Page 280 Automatic Shut Down (ASD) Relay: Testing and Inspection Helpful Information - Check the 30 amp fuse located in the PDC - Check the 10 amp fuse located in the junction block Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Page 281 Automatic Shut Down (ASD) Relay: Service and Repair Power Distribution Center NOTE: The Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). The PDC is located in the engine compartment. Refer to label on PDC cover for relay location. REMOVAL 1. Remove the PDC cover. 2. Remove the relay by lifting straight up. INSTALLATION 1. Check condition of relay terminals at PDC for corrosion or damage. - Also check the heights of relay terminal pins at PDC. Pin height should be same for all pins. - Repair as necessary before installing relay. 2. Push the relay into the connector. 3. Install the relay cover. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Description and Operation Fuel Pump Control Unit: Description and Operation CIRCUIT OPERATION The in-tank fuel pump module contains the fuel pump motor and fuel level sensor. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Power Distribution Center Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) 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 289 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) 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 290 Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) 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 291 Fuel Pump Relay: Description and Operation CIRCUIT OPERATION Circuit A14 from the Power Distribution Center (PDC) supplies battery voltage to the contact side of the fuel pump relay. In the START or RUN position, the ignition switch connects circuit F18 from the 10 amp fuse in the junction block to the coil side of the fuel pump relay. The Powertrain Control Module (PCM) provides the ground path for the coil side of the relay on circuit K151. Circuit K151 connects to cavity C19 of the PCM. When the fuel pump relay energizes, it connects circuit A14 and circuit A61. Circuit A61 supplies voltage to the fuel pump module. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Helpful Information Fuel Pump Relay: Testing and Inspection Helpful Information - Check the 20 amp fuse located in the PDC Check the 10 amp fuse located in the junction block Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Helpful Information > Page 294 Fuel Pump Relay: Testing and Inspection Relay Tests Fig 91 ASD And Fuel Pump Relay Terminals ASD and Fuel Pump Relay Test The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relay. The terminals on the bottom of each relay are numbered (Fig. 91). RELAY OPERATION Terminal 30: Connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. Terminal 85: The PCM grounds the coil side of the relay through this terminal. Terminal 86: Supplies voltage to the coil side of the relay. Terminal 87A: 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. Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TESTING 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 between 70 - 80 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. CAUTION: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter should now show continuity between relay terminals 87 and 30. - The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. - If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Page 295 Fuel Pump Relay: Service and Repair Fig 67 Power Distribution Center (PDC) Location The fuel pump relay is located in the Power Distribution Center (PDC) (Fig. 67). 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 Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates Automatic Shut Down (ASD) Relay: Technical Service Bulletins Engine Controls/Emissions/A/T Manual Updates NUMBER: 26-06-98 GROUP: Miscellaneous DATE: June, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 2.5L, 3.9L, 5.2L, 5.9L 8.0L SFI/CNG/Diesel Diagnostic Manual - Publication Number 81-699-96041 DESCRIPTION OF CHANGES Revision to the diagnostic trouble codes Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 300 56 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 301 57 Revisions to the Throttle Position Sensor test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 302 162 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 303 166 Revisions to the Evap. Purge Flow Monitor tests Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 304 374 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 305 375 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 306 377 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 307 379 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 308 379A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 309 379B Revision to the EGR system Failure tests Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 310 432 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 311 433 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 312 434 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 313 435 Revision to the torque convertor clutch - no drop at lock up test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 314 465 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 315 467 Revision to the no temp rise seen at intake heater test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 316 514 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 317 515 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 318 516 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 319 517 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 320 518 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 321 519 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 322 520 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 323 521 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 324 521A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 325 521B Revision to the 12 volt supply relay test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 326 571 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Page 327 Automatic Shut Down (ASD) Relay: Locations Power Distribution Center Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Page 328 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Page 329 Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Page 330 Automatic Shut Down (ASD) Relay: Description and Operation CIRCUIT OPERATION Automatic Shut Down (ASD) Relay Circuit A16 from the Power Distribution Center (PDC) supplies battery voltage to the contact side of the Automatic Shut Down (ASD) relay. In the START or RUN position, the ignition switch connects circuit F18 from the 10 amp fuse in the junction block to the coil side of the ASD relay. The Powertrain Control Module (PCM) provides the ground path for the coil side of the relay on circuit K51. Circuit K51 connects to cavity C3 of the PCM. When the ASD relay energizes, it connects circuit A16 and circuit A142. Circuit A142 splices to supply voltage to the fuel injectors, ignition coil, and heated oxygen sensors. Circuit A142 also splices to cavity C12 of the PCM. This input tells the PCM the ASD relay has energized. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Relay Tests Automatic Shut Down (ASD) Relay: Testing and Inspection Relay Tests Fig 91 ASD And Fuel Pump Relay Terminals ASD and Fuel Pump Relay Test The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relay. The terminals on the bottom of each relay are numbered (Fig. 91). RELAY OPERATION Terminal 30: Connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. Terminal 85: The PCM grounds the coil side of the relay through this terminal. Terminal 86: Supplies voltage to the coil side of the relay. Terminal 87A: 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. Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TESTING 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 between 70 - 80 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. CAUTION: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter should now show continuity between relay terminals 87 and 30. - The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. - If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Relay Tests > Page 333 Automatic Shut Down (ASD) Relay: Testing and Inspection Helpful Information - Check the 30 amp fuse located in the PDC - Check the 10 amp fuse located in the junction block Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Page 334 Automatic Shut Down (ASD) Relay: Service and Repair Power Distribution Center NOTE: The Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). The PDC is located in the engine compartment. Refer to label on PDC cover for relay location. REMOVAL 1. Remove the PDC cover. 2. Remove the relay by lifting straight up. INSTALLATION 1. Check condition of relay terminals at PDC for corrosion or damage. - Also check the heights of relay terminal pins at PDC. Pin height should be same for all pins. - Repair as necessary before installing relay. 2. Push the relay into the connector. 3. Install the relay cover. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module Technical Service Bulletin # 731 Date: 970701 Recall - Airbag Control Module No. 731 July, 1997 To: All Dealers Subject: Safety Recall # 731 -- Airbag Control Module Models: ^ 1997 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Belvidere Assembly Plant ("D" in the 11th VIN Position) Through September 3, 1996 (MDH 090317) ^ 1997 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Toluca Assembly Plant ("T" in the 11th VIN Position) Through September 9, 1996 (MDH 090906) ^ 1997 Model Year Dodge Dakota (AN) Vehicles Built Through September 5, 1996 (MDH 090521) ^ 1997 Model Year Jeep Wrangler (TJ) Vehicles Built Through September 3, 1996 (MDH 090319) ^ 1997 Model Year Jeep Grand Cherokee (ZJ) Vehicles Built Through September 3, 1996 (MDH 090312) ^ 1996 Model Year Dodge Viper GTS Coupe (SR) Vehicles Built Through September 30, 1996 (MDH 093014) The airbags on the above listed vehicles, may inadvertently deploy during a three (3) second period after the ignition key has been turned to the off position, which could injure a vehicle occupant. To correct this condition, the airbag control module (ACM) must be replaced. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory, and should perform this recall on vehicles in for service as determined by using DIAL System Function 70. Details of this service action are explained in the following sections. Service Procedure Videotape No videotape of the service procedure for this recall will be provided. Dealer Notification & Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53, 70 and VIP All involved vehicles will be entered to DIAL System Functions 53, 70 and VIP at the time of recall implementation for dealer inquiry as needed. Parts Important: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 344 Each involved dealer, to whom vehicles in the recall were invoiced (or the current dealer at the same street address), will receive enough of each ACM Package to service about 25% of those vehicles. Each package contains one (1) ACM. Refer to the table above for the appropriate package application: Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for the service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Service Procedure For Neon (PL) Vehicles: 1. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. For Manual Transmission Equipped Vehicles: Remove the shifter knob fastener and remove the shifter knob. 3. Remove the front two (2) center console attaching screws located near the cup holders (Figure 1). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 345 4. Remove the two (2) screws at the bottom of the storage bin (Figure 2). 5. Remove the bolt access covers and the two lower console bracket bolts on each side of the console bin. 6. Raise the park brake hand lever as high as possible. 7. Remove the center console assembly. WARNING: The auto adjusting feature of the park brake lever assembly contains a clock spring loaded to approximately 20 lbs. DO NOT release the auto adjuster lock out device before installing the cables into the equalizer. Keep hands out of auto adjuster sector and pawl area. Failure to observe caution in handling this mechanism could lead to serious injury. 8. Lower the park brake handle. 9. Grasp the park brake lever output cable by hand and pull upward until a 3/16" drill bit can be inserted into the handle and sector gear mechanism (Figure 3). This will remove the tension from the park brake cables. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 346 10. Remove both rear park brake cables from the park brake cable equalizer (Figure 4). 11. Disconnect the brake warning light electrical connector from the park brake lever switch. 12. Remove the two park brake lever attaching nuts and remove the park brake lever assembly. 13. Disconnect the ACM wiring connector (Figure 5): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 14. Remove the remaining three (3) nuts that secure the ACM mounting bracket to the floor, disconnect the two (2) park brake lever switch wire harness clips from the ACM bracket and then remove the ACM and bracket assembly. 15. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 16. Loosely install the three (3) ACM attaching nuts. 17. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 347 18. Install the park brake lever assembly. 19. Tighten the four (4) ACM nuts and the remaining park brake lever nut to 115 in-lbs (12.5 N.m). 20. Connect the park brake lever switch electrical connector and attach the wiring clips to the ACM bracket. 21. Install both rear park brake cables into the equalizer. 22. Pull the park brake lever handle all the way up. 23. Firmly grasp the park brake lever locking pin (drill bit) and quickly remove it from the mechanism. 24. Cycle the park brake lever once to position the park brake cables. 25. Make sure that the park brake lever is fully raised and then install the center console assembly. 26. Install the front two (2) center console attaching screws located near the cup holders (Figure 1). 27. Install the two (2) screws at the bottom of the storage bin (Figure 2). 28. Install the two (2) outer lower console bracket bolts on each side of the storage bin and then install the bolt covers. 29. For Manual Transmission Equipped Vehicles: Install the shifter knob and fastener. 30. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 31. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 32. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. Service Procedure For Dakota (AN) Vehicles: 1. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Pull back the floor carpet from the area around the center instrument panel support. 3. Remove the two (2) front center support bracket screws (Figure 6). 4. Remove the two (2) left side and one (1) right side support bracket screws (Figure 6). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 348 5. Remove the support bracket. 6. Remove the ground eyelet screw from the left side of the ACM bracket. 7. Disconnect the ACM wiring connector (Figure 7): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 8. Remove the three (3) screws that secure the ACM mounting bracket to the floor pan transmission tunnel (Figure 8). 9. Remove the ACM and bracket assembly. 10. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 11. Tighten the three (3) ACM to floorpan transmission tunnel attaching screws to 105 in-lbs (11.8 N.m). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 349 12. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. 13. Install the ground eyelet screw to the left side of the ACM bracket. 14. Install the center instrument panel support bracket. 15. Install the two (2) left side and one (1) right side support bracket screws (Figure 6). Tighten the bracket screws to 105 in-lbs (11.8 N.m). 16. Install the two (2) front center support bracket screws (Figure 6). Tighten the bracket screws to 105 in-lbs (11.8 N.m). 17. Reinstall the floor carpet around the center instrument panel support. 18. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 19. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 20. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. Service Procedure For Wrangler (TJ) Vehicles: 1. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Pull back the floor carpet from the area under the heater-A/C housing floor duct and forward of the center floor console. 3. For vehicles equipped with ABS: Remove the ABS acceleration sensor from its mounting bracket and set aside (Figure 9). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 350 4. Remove the four (4) screws that secure the ACM mounting bracket to the floor pan transmission tunnel (Figure 10). 5. Disconnect the ACM wiring connector (Figure 11): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 6. Slide the ACM and bracket assembly out from under the heater-A/C housing floor duct and remove it from the vehicle. 7. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 8. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. 9. Tighten the four (4) ACM to floorpan transmission tunnel attaching screws to 95 in-lbs (10.7 N.m) (Figure 10). 10. For vehicles equipped with ABS: Reinstall the ABS acceleration sensor (Figure 9). Tighten the sensor mounting bolts to 40 in-lbs (4.5 N.m). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 351 11. Reinstall the floor carpet under the heater-A/C floor duct. 12. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 13. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 14. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. Service Procedure For Grand Cherokee (ZJ) Vehicles: 1. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Remove the transmission shift lever handle by pulling straight up firmly and quickly. 3. Pry up the transmission shift indicator bezel with a trim stick (Figure 12). 4. Lift the bezel far enough to remove the lamp socket from the bezel and then remove the transmission shift indicator bezel from the console. 5. Pry up the transfer case shift indicator bezel with a trim stick (Figure 12). 6. Lift the bezel far enough to remove the lamp socket from the bezel and then remove the transfer case bezel from the console. 7. Remove the console attaching screws and then remove the console (Figure 12). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 352 8. Disconnect the ACM wiring connector (Figure 13): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 9. Remove the four (4) screws that secure the ACM mounting bracket to the floor transmission tunnel (Figure 14). 10. Remove the ACM and bracket assembly. 11. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 12. Tighten the four (4) ACM attaching screws to 95 in-lbs (10.7 N.m). 13. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. 14. Install the console and secure it with the attaching screws (Figure 12). 15. Install the lamp socket into the transfer case shift bezel and then install the bezel into the console (Figure 12). 16. Install the lamp socket into the transmission shift indicator bezel and then install the bezel into the console (Figure 12). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 353 17. Install the transmission shift lever handle. 18. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 19. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 20. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. Service Procedure For Viper GTS Coupe (SR) Vehicles: 1. Remove the left rear wheel and tire assembly. 2. Remove the left rear wheel well inner splash shield. 3. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 4. Remove the instrument panel center bezel and then disconnect the rear window defogger switch, the power window switches and the lighter (Figure 15). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 354 5. Remove the right and left knee blockers (Figure 16). 6. Remove the headlamp switch knob by inserting a paper clip in the hole under the knob and pushing gently to release the lock clip (Figure 16). 7. Remove the tilt steering handle. 8. Remove the upper steering column shroud. 9. Remove the instrument panel bezel (Figure 16). NOTE: Be careful not to break the headlamp switch lock tab when removing the I/P bezel. 10. Remove the two (2) radio mounting screws. 11. Remove the radio and disconnect the wire connector, coaxial cable and antenna cable. 12. Remove the radio from the vehicle. 13. Remove the HVAC control module. Only disconnect the vacuum and electrical connectors. Do not disconnect the cable. Set the control module aside. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 355 14. Reach through the radio opening and disconnect the ACM wiring connector (Figure 17): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 15. Remove the three (3) nuts that secure the ACM mounting bracket to the floor pan transmission tunnel (Figure 18). 16. Slide the ACM and bracket assembly out through the radio opening. 17. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 18. Tighten the three (3) ACM to floorpan transmission tunnel attaching screws to 95 in-lbs (10.7 N.m). 19. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. 20. Connect the HVAC control head electrical and vacuum connectors. Install the HVAC control module. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 356 21. Connect the radio wire connector, coaxial cable and antenna cable. 22. Install the radio into the instrument panel and tighten the two (2) mounting screws. 23. Install the instrument panel bezel (Figure 16). NOTE: Be careful when installing the I/P bezel. Do not break the headlamp switch lock tab. 24. Install the headlamp switch knob (Figure 16). 25. Install the upper steering column cover. 26. Install the tilt steering handle. 27. Install the right and left knee blockers (Figure 16). 28. Connect the rear window defogger switch, the power window switches and the lighter and then install the instrument panel center bezel (Figure 15). 29. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 30. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 31. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. 32. Install the left rear wheel well inner splash shield. 33. Install the left rear wheel and tire assembly. Completion Reporting and Reimbursement / Parts Return Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. Parts Return Initially, a small number of ACM and bracket assemblies are required to be returned to the Warranty Material Return Center. When an adequate number of returned parts have been accumulated, Parts Return Documents will no longer be generated and parts are to be discarded. Note: See the Warranty Administration Manual, Recall Claim Processing Section for complete recall claim processing and material return instructions. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 357 CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Dealer Service Instructions IMPORTANT Safety Recall # 731 -- Airbag Control Module ^ Effective immediately, this recall (# 731) cancels and supercedes Recall # 683 -- Airbag Control Module for 1997 Jeep Wrangler (TJ) vehicles. ^ This service requirement applies only to: ^ 1997 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Belvidere Assembly Plant ("D" in the 11th VIN Position) Through September 3, 1996 (MDH 090317) ^ 1997 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Toluca Assembly Plant ("T" in the 11th VIN Position) Through September 9, 1996 (MDH 090906) ^ 1997 Model Year Dodge Dakota (AN) Vehicles Built Through September 5, 1996 (MDH 090521) ^ 1997 Model Year Jeep Wrangler (TJ) Vehicles Built Through September 3, 1996 (MDH 090319) ^ 1997 Model Year Jeep Grand Cherokee (ZJ) Vehicles Built Through September 3, 1996 (MDH 090312) ^ 1996 Model Year Dodge Viper GTS Coupe (SR) Vehicles Built Through September 30, 1996 (MDH 093014) ^ The airbags on the above listed vehicles, may inadvertently deploy during a three (3) second period after the ignition key has been turned to the off position. To correct this condition, the airbag control module (ACM) must be replaced. Parts Packages: ^ Each involved dealer, to whom vehicles in the recall were invoiced, will receive enough ACM Packages to service about 25% of those vehicles. Owner Letter SAFETY RECALL TO REPLACE YOUR VEHICLE'S AIRBAG CONTROL MODULE Dear Chrysler Vehicle Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Chrysler Corporation has determined that a defect which relates to motor vehicle safety exists in some 1997 Plymouth and Dodge Neon; Dodge Dakota; Jeep Grand Cherokee and Wrangler; and 1996 Dodge Viper GTS Coupe vehicles. The problem is... The airbags on your vehicle (identified on the enclosed form), may inadvertently deploy during a three (3) second period after the ignition key has been turned to the off position, which could injure a vehicle occupant. What Chrysler and your dealer will do... Chrysler will repair your (vehicle) free of charge (parts and labor). To do this, your dealer will replace the airbag control module. The work will take about one hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do to ensure your safety... ^ Simply contact your dealer right away to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to the dealer. If you need help... Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 358 If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-853-1403. A representative will assist you in getting your vehicle repaired. If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590, or call the Toll Free Auto Safety Hotline at 1-800-424-9393. (Washington, D.C. area residents may call 366-0123.) We're sorry for any inconvenience, but we are sincerely concerned about your safety. Thanks for your attention to this important matter. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module Technical Service Bulletin # 731 Date: 970701 Recall - Airbag Control Module No. 731 July, 1997 To: All Dealers Subject: Safety Recall # 731 -- Airbag Control Module Models: ^ 1997 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Belvidere Assembly Plant ("D" in the 11th VIN Position) Through September 3, 1996 (MDH 090317) ^ 1997 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Toluca Assembly Plant ("T" in the 11th VIN Position) Through September 9, 1996 (MDH 090906) ^ 1997 Model Year Dodge Dakota (AN) Vehicles Built Through September 5, 1996 (MDH 090521) ^ 1997 Model Year Jeep Wrangler (TJ) Vehicles Built Through September 3, 1996 (MDH 090319) ^ 1997 Model Year Jeep Grand Cherokee (ZJ) Vehicles Built Through September 3, 1996 (MDH 090312) ^ 1996 Model Year Dodge Viper GTS Coupe (SR) Vehicles Built Through September 30, 1996 (MDH 093014) The airbags on the above listed vehicles, may inadvertently deploy during a three (3) second period after the ignition key has been turned to the off position, which could injure a vehicle occupant. To correct this condition, the airbag control module (ACM) must be replaced. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory, and should perform this recall on vehicles in for service as determined by using DIAL System Function 70. Details of this service action are explained in the following sections. Service Procedure Videotape No videotape of the service procedure for this recall will be provided. Dealer Notification & Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53, 70 and VIP All involved vehicles will be entered to DIAL System Functions 53, 70 and VIP at the time of recall implementation for dealer inquiry as needed. Parts Important: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 364 Each involved dealer, to whom vehicles in the recall were invoiced (or the current dealer at the same street address), will receive enough of each ACM Package to service about 25% of those vehicles. Each package contains one (1) ACM. Refer to the table above for the appropriate package application: Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for the service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Service Procedure For Neon (PL) Vehicles: 1. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. For Manual Transmission Equipped Vehicles: Remove the shifter knob fastener and remove the shifter knob. 3. Remove the front two (2) center console attaching screws located near the cup holders (Figure 1). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 365 4. Remove the two (2) screws at the bottom of the storage bin (Figure 2). 5. Remove the bolt access covers and the two lower console bracket bolts on each side of the console bin. 6. Raise the park brake hand lever as high as possible. 7. Remove the center console assembly. WARNING: The auto adjusting feature of the park brake lever assembly contains a clock spring loaded to approximately 20 lbs. DO NOT release the auto adjuster lock out device before installing the cables into the equalizer. Keep hands out of auto adjuster sector and pawl area. Failure to observe caution in handling this mechanism could lead to serious injury. 8. Lower the park brake handle. 9. Grasp the park brake lever output cable by hand and pull upward until a 3/16" drill bit can be inserted into the handle and sector gear mechanism (Figure 3). This will remove the tension from the park brake cables. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 366 10. Remove both rear park brake cables from the park brake cable equalizer (Figure 4). 11. Disconnect the brake warning light electrical connector from the park brake lever switch. 12. Remove the two park brake lever attaching nuts and remove the park brake lever assembly. 13. Disconnect the ACM wiring connector (Figure 5): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 14. Remove the remaining three (3) nuts that secure the ACM mounting bracket to the floor, disconnect the two (2) park brake lever switch wire harness clips from the ACM bracket and then remove the ACM and bracket assembly. 15. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 16. Loosely install the three (3) ACM attaching nuts. 17. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 367 18. Install the park brake lever assembly. 19. Tighten the four (4) ACM nuts and the remaining park brake lever nut to 115 in-lbs (12.5 N.m). 20. Connect the park brake lever switch electrical connector and attach the wiring clips to the ACM bracket. 21. Install both rear park brake cables into the equalizer. 22. Pull the park brake lever handle all the way up. 23. Firmly grasp the park brake lever locking pin (drill bit) and quickly remove it from the mechanism. 24. Cycle the park brake lever once to position the park brake cables. 25. Make sure that the park brake lever is fully raised and then install the center console assembly. 26. Install the front two (2) center console attaching screws located near the cup holders (Figure 1). 27. Install the two (2) screws at the bottom of the storage bin (Figure 2). 28. Install the two (2) outer lower console bracket bolts on each side of the storage bin and then install the bolt covers. 29. For Manual Transmission Equipped Vehicles: Install the shifter knob and fastener. 30. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 31. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 32. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. Service Procedure For Dakota (AN) Vehicles: 1. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Pull back the floor carpet from the area around the center instrument panel support. 3. Remove the two (2) front center support bracket screws (Figure 6). 4. Remove the two (2) left side and one (1) right side support bracket screws (Figure 6). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 368 5. Remove the support bracket. 6. Remove the ground eyelet screw from the left side of the ACM bracket. 7. Disconnect the ACM wiring connector (Figure 7): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 8. Remove the three (3) screws that secure the ACM mounting bracket to the floor pan transmission tunnel (Figure 8). 9. Remove the ACM and bracket assembly. 10. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 11. Tighten the three (3) ACM to floorpan transmission tunnel attaching screws to 105 in-lbs (11.8 N.m). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 369 12. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. 13. Install the ground eyelet screw to the left side of the ACM bracket. 14. Install the center instrument panel support bracket. 15. Install the two (2) left side and one (1) right side support bracket screws (Figure 6). Tighten the bracket screws to 105 in-lbs (11.8 N.m). 16. Install the two (2) front center support bracket screws (Figure 6). Tighten the bracket screws to 105 in-lbs (11.8 N.m). 17. Reinstall the floor carpet around the center instrument panel support. 18. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 19. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 20. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. Service Procedure For Wrangler (TJ) Vehicles: 1. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Pull back the floor carpet from the area under the heater-A/C housing floor duct and forward of the center floor console. 3. For vehicles equipped with ABS: Remove the ABS acceleration sensor from its mounting bracket and set aside (Figure 9). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 370 4. Remove the four (4) screws that secure the ACM mounting bracket to the floor pan transmission tunnel (Figure 10). 5. Disconnect the ACM wiring connector (Figure 11): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 6. Slide the ACM and bracket assembly out from under the heater-A/C housing floor duct and remove it from the vehicle. 7. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 8. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. 9. Tighten the four (4) ACM to floorpan transmission tunnel attaching screws to 95 in-lbs (10.7 N.m) (Figure 10). 10. For vehicles equipped with ABS: Reinstall the ABS acceleration sensor (Figure 9). Tighten the sensor mounting bolts to 40 in-lbs (4.5 N.m). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 371 11. Reinstall the floor carpet under the heater-A/C floor duct. 12. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 13. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 14. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. Service Procedure For Grand Cherokee (ZJ) Vehicles: 1. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Remove the transmission shift lever handle by pulling straight up firmly and quickly. 3. Pry up the transmission shift indicator bezel with a trim stick (Figure 12). 4. Lift the bezel far enough to remove the lamp socket from the bezel and then remove the transmission shift indicator bezel from the console. 5. Pry up the transfer case shift indicator bezel with a trim stick (Figure 12). 6. Lift the bezel far enough to remove the lamp socket from the bezel and then remove the transfer case bezel from the console. 7. Remove the console attaching screws and then remove the console (Figure 12). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 372 8. Disconnect the ACM wiring connector (Figure 13): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 9. Remove the four (4) screws that secure the ACM mounting bracket to the floor transmission tunnel (Figure 14). 10. Remove the ACM and bracket assembly. 11. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 12. Tighten the four (4) ACM attaching screws to 95 in-lbs (10.7 N.m). 13. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. 14. Install the console and secure it with the attaching screws (Figure 12). 15. Install the lamp socket into the transfer case shift bezel and then install the bezel into the console (Figure 12). 16. Install the lamp socket into the transmission shift indicator bezel and then install the bezel into the console (Figure 12). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 373 17. Install the transmission shift lever handle. 18. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 19. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 20. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. Service Procedure For Viper GTS Coupe (SR) Vehicles: 1. Remove the left rear wheel and tire assembly. 2. Remove the left rear wheel well inner splash shield. 3. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 4. Remove the instrument panel center bezel and then disconnect the rear window defogger switch, the power window switches and the lighter (Figure 15). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 374 5. Remove the right and left knee blockers (Figure 16). 6. Remove the headlamp switch knob by inserting a paper clip in the hole under the knob and pushing gently to release the lock clip (Figure 16). 7. Remove the tilt steering handle. 8. Remove the upper steering column shroud. 9. Remove the instrument panel bezel (Figure 16). NOTE: Be careful not to break the headlamp switch lock tab when removing the I/P bezel. 10. Remove the two (2) radio mounting screws. 11. Remove the radio and disconnect the wire connector, coaxial cable and antenna cable. 12. Remove the radio from the vehicle. 13. Remove the HVAC control module. Only disconnect the vacuum and electrical connectors. Do not disconnect the cable. Set the control module aside. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 375 14. Reach through the radio opening and disconnect the ACM wiring connector (Figure 17): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 15. Remove the three (3) nuts that secure the ACM mounting bracket to the floor pan transmission tunnel (Figure 18). 16. Slide the ACM and bracket assembly out through the radio opening. 17. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 18. Tighten the three (3) ACM to floorpan transmission tunnel attaching screws to 95 in-lbs (10.7 N.m). 19. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. 20. Connect the HVAC control head electrical and vacuum connectors. Install the HVAC control module. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 376 21. Connect the radio wire connector, coaxial cable and antenna cable. 22. Install the radio into the instrument panel and tighten the two (2) mounting screws. 23. Install the instrument panel bezel (Figure 16). NOTE: Be careful when installing the I/P bezel. Do not break the headlamp switch lock tab. 24. Install the headlamp switch knob (Figure 16). 25. Install the upper steering column cover. 26. Install the tilt steering handle. 27. Install the right and left knee blockers (Figure 16). 28. Connect the rear window defogger switch, the power window switches and the lighter and then install the instrument panel center bezel (Figure 15). 29. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 30. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 31. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. 32. Install the left rear wheel well inner splash shield. 33. Install the left rear wheel and tire assembly. Completion Reporting and Reimbursement / Parts Return Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. Parts Return Initially, a small number of ACM and bracket assemblies are required to be returned to the Warranty Material Return Center. When an adequate number of returned parts have been accumulated, Parts Return Documents will no longer be generated and parts are to be discarded. Note: See the Warranty Administration Manual, Recall Claim Processing Section for complete recall claim processing and material return instructions. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 377 CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Dealer Service Instructions IMPORTANT Safety Recall # 731 -- Airbag Control Module ^ Effective immediately, this recall (# 731) cancels and supercedes Recall # 683 -- Airbag Control Module for 1997 Jeep Wrangler (TJ) vehicles. ^ This service requirement applies only to: ^ 1997 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Belvidere Assembly Plant ("D" in the 11th VIN Position) Through September 3, 1996 (MDH 090317) ^ 1997 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Toluca Assembly Plant ("T" in the 11th VIN Position) Through September 9, 1996 (MDH 090906) ^ 1997 Model Year Dodge Dakota (AN) Vehicles Built Through September 5, 1996 (MDH 090521) ^ 1997 Model Year Jeep Wrangler (TJ) Vehicles Built Through September 3, 1996 (MDH 090319) ^ 1997 Model Year Jeep Grand Cherokee (ZJ) Vehicles Built Through September 3, 1996 (MDH 090312) ^ 1996 Model Year Dodge Viper GTS Coupe (SR) Vehicles Built Through September 30, 1996 (MDH 093014) ^ The airbags on the above listed vehicles, may inadvertently deploy during a three (3) second period after the ignition key has been turned to the off position. To correct this condition, the airbag control module (ACM) must be replaced. Parts Packages: ^ Each involved dealer, to whom vehicles in the recall were invoiced, will receive enough ACM Packages to service about 25% of those vehicles. Owner Letter SAFETY RECALL TO REPLACE YOUR VEHICLE'S AIRBAG CONTROL MODULE Dear Chrysler Vehicle Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Chrysler Corporation has determined that a defect which relates to motor vehicle safety exists in some 1997 Plymouth and Dodge Neon; Dodge Dakota; Jeep Grand Cherokee and Wrangler; and 1996 Dodge Viper GTS Coupe vehicles. The problem is... The airbags on your vehicle (identified on the enclosed form), may inadvertently deploy during a three (3) second period after the ignition key has been turned to the off position, which could injure a vehicle occupant. What Chrysler and your dealer will do... Chrysler will repair your (vehicle) free of charge (parts and labor). To do this, your dealer will replace the airbag control module. The work will take about one hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do to ensure your safety... ^ Simply contact your dealer right away to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to the dealer. If you need help... Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 378 If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-853-1403. A representative will assist you in getting your vehicle repaired. If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590, or call the Toll Free Auto Safety Hotline at 1-800-424-9393. (Washington, D.C. area residents may call 366-0123.) We're sorry for any inconvenience, but we are sincerely concerned about your safety. Thanks for your attention to this important matter. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 379 Module Locations Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions Air Bag Control Module: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 382 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 Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 383 Electrostatic Discharge Symbol All Electrostatic Discharge (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, especially 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. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 384 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 385 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 386 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 387 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 388 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 389 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 390 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 391 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. 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. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 392 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 393 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 394 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 395 Air Bag Control Module: Diagnostic Aids 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 in 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 and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 396 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. 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 every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. 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 fuse circuit. 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 the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 397 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools 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 - This instrument is 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 vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. 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 non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 398 ABCM Connector Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 399 Airbag System Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Page 400 Air Bag Control Module: Description and Operation DESCRIPTION The Airbag Control Module (ACM) contains the impact sensor, and a microprocessor that monitors the impact sensor and the airbag system electrical circuits to determine the system readiness. The ACM contains On-Board Diagnostics (OBD), and will send an airbag lamp-on message to the instrument cluster on the Chrysler Collision Detection (CCD) data bus to light the airbag indicator lamp in the instrument cluster when a monitored airbag system fault occurs. OPERATION The ACM also contains an energy-storage capacitor. This capacitor stores enough electrical energy to deploy the airbags for up to one second following a battery disconnect or failure during an impact. The purpose of the capacitor is to provide airbag system protection in a severe secondary impact, if the initial impact has damaged or disconnected the battery, but was not severe enough to deploy the airbags. The ACM cannot be repaired and, if damaged or faulty, it must be replaced. CIRCUIT OPERATION Two circuits provide battery voltage to the Airbag Control Module (ACM); F14 and F24. Circuits F14 and F24 are connected to separate bus bars in the junction block. Different circuits from the Power Distribution Center (PDC) and the ignition switch supply battery voltage to the junction block bus bars. Circuit F24 supplies battery voltage to the ACM only when the ignition switch is in the RUN position. Circuit F14 circuit powers the ACM when the ignition switch is in either the START or RUN position. The ACM is case grounded and has an external dedicated ground, circuit Z2. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Testing and Inspection > Helpful Information Air Bag Control Module: Testing and Inspection Helpful Information - Check the 10 Amp fuses in the junction block Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Testing and Inspection > Helpful Information > Page 403 Air Bag Control Module: Testing and Inspection Module Testing Refer to Powertrain Management/Computers and Control Systems/Body Control Module/Testing and Inspection. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Testing and Inspection > Page 404 Air Bag Control Module: Service and Repair WARNING: ^ The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components you must first disconnect and isolate the battery negative (ground) cable. Then wait two minutes for the system capacitor to discharge before further system service. This is the only sure way to disable the airbag system. Failure to do this could result in accidental air bag 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. 1. Disconnect and isolate the battery negative cable. if the airbag has not been deployed, wait two minutes for the system capacitor to discharge before further service. 2. Remove the instrument panel center support bracket. 3. Remove the screw that secures the instrument panel wire harness ground eyelet to the left side of the floor pan transmission tunnel. 4. Unplug the Airbag Control Module (ACM) wire harness connector. To unplug the connector, first pull the two white locks out about 3 mm (0.125 in.) from each side of the connector. Then squeeze the two connector latch tabs between the thumb and fore-finger, while pulling the connector out from the ACM. NOTE: Always remove and replace the airbag control module and its mounting bracket as a unit. Replacement modules include a replacement mounting bracket. Do not transfer the module to another mounting bracket. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Testing and Inspection > Page 405 5. Remove the three screws that secure the ACM mounting bracket to the floor pan transmission tunnel. 6. Remove the ACM and mounting bracket as a unit. 7. When installing the ACM, position the unit with the arrow on the ACM housing pointing forward. 8. Attach the ACM to the floor pan transmission tunnel with the four mounting screws. Tighten the mounting screws to 11.8 N.m (105 in. lbs.). 9. Plug in the wire harness connector to the ACM. Be certain that the connector latches are fully engaged and that the connector locks are pushed in. 10. Reverse the remaining removal procedures to complete the installation. 11. Do not connect the battery negative cable at this time. See Testing and Inspection/Procedures for the proper procedures. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Power Distribution Center Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 410 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 411 Starter Relay: Description and Operation SYSTEM OPERATION The starter relay is a International Standards Organization (ISO) micro-relay The terminal designations and functions are the same as a conventional ISO relay. However, the micro-relay terminal orientation (or footprint) is different, the current capacity is lower, and the relay case dimensions are smaller than on the conventional ISO relay. The starter relay is a electro mechanical device that switches current to the pull-in coil of the starter solenoid when the ignition switch is turned to the Start position. The starter relay is located in the Power Distribution Center (PDC), in the engine compartment. Refer to the PDC label for relay identification and location. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 412 Starter Relay: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Power Distribution Center 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC for starter relay identification and location. 4. Unplug the starter relay from the PDC. 5. Install the starter relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 6. Install the PDC cover. 7. Connect the battery negative cable. 8. Test the relay operation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: Customer Interest TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 423 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 424 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: All Technical Service Bulletins TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 430 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 431 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 432 Control Module: Description and Operation This vehicle does not have a Transmission Control Module. Transmission control is accomplished through the Engine Control Module or Powertrain Control Module. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Torque Converter Clutch Relay > Component Information > Locations Torque Converter Clutch Relay: Locations Power Distribution Center Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Torque Converter Clutch Relay > Component Information > Locations > Page 436 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Power Distribution Center Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) 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 440 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) 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 441 Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) 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 442 Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) 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 443 Transmission Control System Relay: Description and Operation CIRCUIT OPERATION Four Speed Automatic Transmission The electronic transmission relay powers the overdrive solenoid, torque convertor clutch solenoid, and governor pressure solenoid. All three solenoids are molded together. Power for the coil side of the relay is supplied on circuit T4. This circuit is controlled by the Powertrain Control Module (PCM), and is the feed for the generator. Ground for the coil side of the relay is controlled by the PCM on circuit T3. This circuit connects to cavity E30 of the PCM connector. When the PCM grounds the relay, the relay contacts connect circuit A14 to circuit T8. Circuit T8 powers the solenoids. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) 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 444 Transmission Control System Relay: Testing and Inspection - Check the 20 Amp fuse in cavity 3 of the PDC Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 449 Wiper Relay: Description and Operation SYSTEM OPERATION The intermittent wipe relay is a International Standards Organization (ISO) micro-relay The terminal designations and functions are the same as a conventional ISO relay. However, the micro-relay terminal orientation (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than on the conventional ISO relay The intermittent wipe relay is a electromechanical device that switches current to the windshield wiper motor or wiper motor park switch when the relay is energized or de-energized by the Central Timer Module (CTM) in response to the proper inputs from the windshield wiper (multi-function) switch. The intermittent wipe relay is located in the Power Distribution Center (PDC), in the engine compartment. Refer to the PDC label for relay identification and location. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 450 Wiper Relay: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Intermittent Wiper Relay Relay Test The intermittent wipe relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the PDC label for intermittent wipe relay identification and location. Remove the intermittent wipe relay from the PDC as described to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2. If not OK, replace the faulty relay. 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 3. If not OK, replace the faulty relay 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, see the Relay Circuit Test. If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to the wiper (multi-function) switch. There should be continuity between the cavity for relay terminal 30 and the two fused ignition switch output circuit cavities of the multi-function switch wire harness connector at all times. If OK, go to Step 2. If not OK, repair the open circuit(s) to the multi-function switch as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position. There should be continuity between the cavity for relay terminal 87A and the wiper park switch sense circuit cavities of the wiper motor wire harness connector and the 14-way Central Timer Module (CTM) wire harness connector at all times. If OK, go to Step 3. If not OK, repair the open circuit(s) to the wiper motor and CTM as required. 3. The relay normally open terminal (87) is connected to the common feed terminal (30) in the energized position. There should be battery voltage at the cavity for relay terminal 87 with the ignition switch in the On or Accessory positions. If OK, go to Step 4. If not OK, repair the open circuit to the ignition switch as required. 4. The coil battery terminal (86) is connected to the electromagnet in the relay. There should be battery voltage at the cavity for relay terminal 86 with the ignition switch in the On or Accessory positions. If OK, go to Step 5. If not OK, repair the open circuit to the ignition switch as required. 5. The coil ground terminal (85) is connected to the electromagnet in the relay. It is grounded by the CTM to energize the relay and cycle the wiper motor. Check for continuity between the cavity for relay terminal 85 and the intermittent wiper relay control circuit cavity of the 14-way CTM wire harness connector. There should be continuity. If OK, replace the faulty base version CTM; or, use a DRB scan tool and the proper Diagnostic Procedures for diagnosis of the high-line version CTM. If not OK, repair the open circuit to the CTM as required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 451 Wiper Relay: Service and Repair REMOVAL and INSTALLATION 1. Disconnect and isolate the battery negative cable. Power Distribution Center 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC cover for intermittent wipe relay identification and location. 4. Unplug the intermittent wipe relay from the PDC. 5. Install the intermittent wipe relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 6. Install the PDC cover. 7. Connect the battery negative cable. 8. Test the relay operation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Description and Operation Door Sensor/Switch (For Alarm): Description and Operation SYSTEM OPERATION Door Jamb Switch The door jamb switches are mounted to the door hinge pillars. The switches close a path to ground for the Central Timer Module (CTM) when a door is opened, and open when a door is closed. The door jamb switches cannot be repaired and, if faulty or damaged, they must be replaced. CIRCUIT OPERATION Door Ajar Switches The Vehicle Theft Security System (VTSS) uses the door ajar switches to provide an input to the Central Timer Module (CTM). These switches are normally OPEN with the doors closed. When a door is opened the switch CLOSES completing a path to ground. Circuit G16 is used to monitor the doors. Disarm Switches Circuit G69 connects from the Central Timer Module (CTM) to the disarm switches located in the vehicle doors. These switches are normally OPEN. When the switch CLOSES a ground path is completed through the switch to circuit Z1. When the CTM senses a ground path on this circuit is turns the system OFF. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Description and Operation > Page 457 Door Sensor/Switch (For Alarm): Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Grasp the body of the door jamb switch with a pair of pliers and move the switch gently back-and-forth while pulling it out of the door hinge pillar mounting hole. Door Jamb Switch Remove/Install 3. Pull the switch out from the pillar far enough to access the wire harness connector. 4. Unplug the wire harness connector from the switch. 5. Reverse the removal procedures to install. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Description and Operation Hood Sensor/Switch (For Alarm): Description and Operation CIRCUIT OPERATION Circuit G71 connects from the Central Timer Module to the hood switch. The hood switch is normally OPEN when the hood is CLOSED. When the hood is OPENED the switch CLOSES completing a path to ground on circuit Z1. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Description and Operation Lock Cylinder Switch: Description and Operation SYSTEM OPERATION The door lock cylinder switches are mounted to the back of the key lock cylinder inside each door. They are normally-open momentary switches that close to ground only when the lock cylinder is rotated to the unlock position. The door lock cylinder switches cannot be repaired and, if faulty or damaged, they must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Description and Operation > Page 464 Lock Cylinder Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel and the door outside latch handle. Door Lock Cylinder Switch Remove/Install - Typical 3. Pull the door outside latch handle out from the outside of the door far enough to access the door lock cylinder switch. 4. Unplug the door lock cylinder switch from the back of the lock cylinder. 5. Unplug the door lock cylinder switch wire harness connector. 6. Disengage the two retainers that secure the door lock cylinder switch wire harness to the door inner panel. 7. Remove the door lock cylinder switch from the door. 8. Reverse the removal procedures to install. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Description and Operation Hood Sensor/Switch (For Alarm): Description and Operation CIRCUIT OPERATION Circuit G71 connects from the Central Timer Module to the hood switch. The hood switch is normally OPEN when the hood is CLOSED. When the hood is OPENED the switch CLOSES completing a path to ground on circuit Z1. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Description and Operation Power Door Lock Switch: Description and Operation SYSTEM OPERATION The power locks are controlled by a two-way switch mounted in a bezel on the trim panel of each front door. The switch controls the battery feeds to the lock and unlock sense inputs of the high-line Central Timer Module (CTM). The power lock switches cannot be repaired and, if faulty or damaged, the entire switch must be replaced. CIRCUIT OPERATION The door lock switches have two circuits that connect from the switches to the CTM. When the operator selects UNLOCK, from either switch, circuit F35 is connected to circuit P36. When the operator selects the LOCK, from either switch, voltage is passed through the CLOSED contacts in the switch to circuit P35. The CTM then process this request and supplies power and ground to the appropriate circuits. When the LOCK function is selected power is supplied on circuit P33 to all the motors. Ground is supplied on circuit P34. For the UNLOCK function the circuits are reversed. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Description and Operation > Page 473 Power Door Lock Switch: Testing and Inspection 1. Check the fuse in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the Power Distribution Center (PDC) as required. 3. Disconnect and isolate the battery negative cable. Remove the power lock switch from the door trim panel as described. Carefully separate the wire harness connector from the switch body. 4. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the power lock switch wire harness connector. If OK, go to Step 5. If not OK, repair the open circuit to the junction block as required. Power Lock Switch Continuity 5. Test the power lock switch continuity. See the Power Lock Switch Continuity chart to determine if the continuity is correct in the Off, Lock and Unlock switch positions. If OK, repair the power lock switch sense circuit(s) from the power lock switch wire harness connector to the Central Timer Module (CTM) as required. If not OK, replace the faulty switch. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Description and Operation > Page 474 Power Door Lock Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Power Windows And Lock Switches Remove/Install 2. Using a wide flat-bladed tool such as a trim stick, gently pry the upper edge of the power lock and power window switch bezel to release the snap-clip retainer that secures the bezel to the door trim panel. 3. Pull the switch bezel away from the door trim panel far enough to access the wire harness connectors. 4. Gently pry the locking tabs of the wire harness connectors away from the switches and carefully unplug the switches. 5. Using a wide flat-bladed tool such as a trim stick, gently pry the sides of the switch cavity on the back of the switch bezel to release the power lock switch from the bezel. 6. Reverse the removal procedures to install. When installing the switch bezel to the door trim panel, insert the rear of the bezel into the trim panel opening, then push down on the front of the bezel until the retaining tab snaps into place. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Description and Operation Power Mirror Switch: Description and Operation SYSTEM OPERATION Both the right and left power outside mirrors are controlled by a single multi-function switch unit mounted on the driver side door trim panel. The switch knob is rotated clockwise (right mirror control), or counterclockwise (left mirror control) to select the mirror to be adjusted. The switch knob is then moved in a joystick fashion to control movement of the selected mirror up, down, right, or left. The power mirror switch cannot be repaired and, if faulty or damaged, it must be replaced. The power switch knob is available for service replacement. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Description and Operation > Page 478 Power Mirror Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Power Mirror Switch Knob Remove/Install 2. Pull the power mirror switch control knob rearward to remove it from the switch stem. Power Mirror Switch Nut 3. Remove the nut that secures the power mirror switch to the door trim panel. Inside Door Latch Release Handle Pocket Screw Remove/Install Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Description and Operation > Page 479 4. Pull the inside door latch release handle to the open position and remove the screw in the release handle pocket that secures the door trim panel to the inside door handle bracket. Window Regulator Crank Handle Remove - Typical 5. If the vehicle is so equipped, remove the manual window regulator crank handle with a removal tool. 6. If the vehicle is so equipped, remove the power window and lock switches as follows: Power Window And Lock Switches Remove/Install a. Using a wide flat-bladed tool such as a trim stick, gently pry the upper edge of the switch bezel to release the snap-clip retainer that secures the bezel to the door trim panel. b. Pull the switch bezel away from the door trim panel far enough to access the wire harness connectors. c. Gently pry the locking tabs of the wire harness connectors away from the switches and carefully unplug the switches. Door Trim Panel Remove/Install 7. Remove the four screws that secure the door trim panel to the inner door. 8. To disengage the stepped retainers that secure the door trim panel to the inner door, gently pull the lower edge of the trim panel away from the Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Description and Operation > Page 480 door while lifting the panel upwards. 9. Pull the door trim panel away from the inner door far enough to access the power mirror switch wire harness connector. Door Trim Panel Wire Harness Connectors 10. Unplug the power mirror switch wire harness connector. 11. Remove the power mirror switch from the back of the door trim panel. 12. When installing the power window and lock switch bezel to the door trim panel, insert the rear of the bezel into the trim panel opening, then push down on the front of the bezel until the retaining tab snaps into place. 13. Reverse the remaining removal procedures to complete the installation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > 4WD Switch > Component Information > Description and Operation 4WD Switch: Description and Operation CIRCUIT OPERATION Circuit F12 from fuse 11 in the junction block supplies voltage for the four-wheel drive indicator lamp. The ground path for the lamp is provided when the switch closes. Circuit G107 connects the lamp to the four-wheel drive switch. The switch connects to ground circuit Z1. From circuit G107, the Controller Antilock Brakes (CAB) senses when the four-wheel drive switch closes. Circuit Gl07 connects to the CAB, for wheel drive switch and the four-wheel drive indicator lamp. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Description and Operation Brake Fluid Pressure Sensor/Switch: Description and Operation CIRCUIT OPERATION Circuit G9 from the Controller, Antilock Brakes (CAB) supplies ground for the brake warning lamp. The lamp can also be grounded when either the ignition switch is in the START position, the park brake switch closes or the brake warning lamp switch in the hydraulic combination valve closes. Circuit G14 connects the brake warning lamp switch to the lamp. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Description and Operation Parking Brake Warning Switch: Description and Operation CIRCUIT OPERATION On circuit G11, the Controller, Antilock Brakes (CAB) senses when the park brake switch closes. Circuit G11 also connects to the park brake lamp in the instrument cluster and through a diode to circuit G9. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions Wheel Speed Sensor: Technical Service Bulletins ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions NUMBER: 26-10-99I GROUP: Miscellaneous DATE: October, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1993-1997 Kelsey Hayes EBC-5H, EBC 310 ABS Diagnostic Manual - Publication Number 81-699-96026 DESCRIPTION OF CHANGES Revisions to the ABS test procedures for wheel speed sensors Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 495 39 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 496 43 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 497 45 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 498 47 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 499 51 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 500 55 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 501 57 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 502 59 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 503 63 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 504 67 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 505 69 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 506 71 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 507 173 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 508 177 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 509 179 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 510 181 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 511 187 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 512 191 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 513 193 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 514 195 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 515 201 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 516 205 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 517 207 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 518 209 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 519 256 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Electrical Specifications Wheel Speed Sensor: Electrical Specifications Sensor Coil Resistance 1000 to 2500 ohms Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Electrical Specifications > Page 522 Wheel Speed Sensor: Mechanical Specifications Front Sensor Mounting Bolt 160-220 in.lb Rear Sensor Mounting Bolt 170-230 in.lb Wheel Speed Sensor (WSS) Clearance 0.005-0.050 in WSS Attaching Bolt 170-230 in.lb Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) 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 Tone Wheels Toothed Tone Wheel Ring For Front Wheel Speed Sensor Rear Tone Wheel Location FRONT The toothed tone wheel ring for the front speed sensor is located on the hub/bearing. It is not a serviceable component. To replace the ring, the hub/bearing assembly must be replaced. Refer Steering and Suspension for the service procedure. REAR The toothed exciter (tone wheel) ring is press-fitted onto the differential carrier next to the final drive ring gear in the differential case. If the ring is damaged, the differential assembly must be serviced as outlined in Transmission and Drivetrain. Front Wheel Speed Sensor (WSS) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 525 RWAL Wheel Speed Sensor Rear Wheel Speed Sensor (WSS) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 526 Wheel Speed Sensor: Connector Locations Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 527 Wheel Speed Sensor: Diagrams Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Circuit Operation Wheel Speed Sensor: Description and Operation Circuit Operation CIRCUIT OPERATION The all wheel Antilock Brake System (ABS) uses three wheel speed sensors; a single sensor for both rear wheels and individual sensors for the front wheels. The single sensor used for the rear wheels mounts on the top of the rear axle differential housing. Each sensor converts wheel speed into an electrical signal that is transmitted to the Controller Antilock Brakes (CAB). A pair of twisted wires connect to each sensor and provide signals to the CAB. Circuits B6 and B7 provide signals to the CAB from the right front wheel speed sensor. Circuit B6, which provides the LOW signal, connects to cavity 4 of the CAB. Circuit B7 connects to cavity 9 of the CAB and provides the HIGH signal. Circuits B8 and B9 provide signals to the CAB from the left front wheel speed sensor. Circuit B8, which provides the LOW signal, connects to cavity 3 of the CAB. Circuit B9 connects to cavity 8 and provides the HIGH signal. Circuit B114 connects to cavity 10 of the CAB and provides the rear wheel speed sensor LOW input. While circuit B113 provides the HIGH input to cavity 5 of the CAB. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Circuit Operation > Page 530 Wheel Speed Sensor: Description and Operation Four Wheel Antilock Brakes Front Wheel Speed Sensor (WSS) Rear Wheel Speed Sensor (WSS) The Anti-Lock Brake System (ABS) uses three wheel speed sensors. A sensor is mounted to each front steering knuckles. The third sensor is mounted on top of the rear axle differential housing. The sensor is a magnet coil that is mounted over a tone wheel front/exciter ring rear with an air gap between them. The sensors measure the wheel speed by monitoring the rotation of the front tone wheels and rear exciter ring. As the teeth of the wheels and ring move through the magnetic field of the sensor, an AC voltage signal is generated. This signal frequency increases or decreases proportionally to the speed of the wheel. The Controller Anti-Lock Brake (CAB) monitors these signals for changes in wheel deceleration. If the CAB detects that a wheel or wheels are suddenly decelerating at a predetermined rate, the CAB will activate the ABS. Each wheel speed sensor's coil will have approximately 1000 to 2500 ohms of resistance. The CAB will disable anti-lock control, complete the anti-lock warning light circuit, and store trouble codes if it detects one of the following problems 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 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Circuit Operation > Page 531 Wheel Speed Sensor: Description and Operation Rear Wheel Antilock Brakes RWAL Wheel Speed Sensor The rear Wheel Speed Sensor (WSS) is mounted in the rear differential housing. The WSS consists of a magnet surrounded by windings from a single strand of wire. The sensor sends a small AC signal to the Controller Anti-Lock Brake (CAB). This signal is generated by magnetic induction. The magnetic induction is created when a toothed ring (exciter ring or tone wheel) passes the stationary magnetic WSS. Toothed Exciter Ring The toothed ring is press-fitted onto the differential carrier next to the final drive ring gear. When the ring gear is rotated, the exciter ring passes the tip of the WSS. As the exciter ring passes the tip of the WSS, the magnetic lines of force of the sensor are cut, causing the magnetic field to be moved across the sensor's windings. This, in turn causes current to flow through the WSS circuit. Wheel Speed Sensor (WSS) Operation 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 sine wave) is Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Circuit Operation > Page 532 interpreted by the CAB. It then compares the frequency of the sine wave 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 rotates, the stronger the signal will be. - Distance between the exciter ring teeth and WSS; the closer the WSS is to the exciter ring, the stronger the signal will be. The 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 to 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 left of the steering column and attached to the lower portion of the instrument panel. Data Link Connector (DLC) The rolls test terminal is spliced to the WSS circuit. The vehicle is then driven on a set of rollers and the WSS output is monitored for proper operation. CIRCUIT OPERATION The rear wheel speed sensor is mounted on the top of the rear axle differential. The sensor converts wheel speed into an electrical signal that is transmitted to the Controller, Antilock Brakes (CAB). Circuits B113 and B114, a pair of twisted wires, connect to the sensor and provide signals to the CAB. Circuit B113 connects to cavity 14 of the CAB. Circuit B114 connects to cavity 13 of the CAB. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Circuit Operation > Page 533 Wheel Speed Sensor: Description and Operation Tone Wheels Toothed Tone Wheel Ring For Front Wheel Speed Sensor Rear Tone Wheel Location FRONT The toothed tone wheel ring for the front speed sensor is located on the hub/bearing. It is not a serviceable component. To replace the ring, the hub/bearing assembly must be replaced. Refer Steering and Suspension for the service procedure. REAR The toothed exciter (tone wheel) ring is press-fitted onto the differential carrier next to the final drive ring gear in the differential case. If the ring is damaged, the differential assembly must be serviced as outlined in Transmission and Drivetrain. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Page 534 Wheel Speed Sensor: Testing and Inspection RWAL Speed Sensor Air Gap 1. Remove sensor from differential. 2. Measure and record the distance from the underside of the sensor flange to the end of the sensor pole piece. This distance represents dimension B. 3. Measure and record the distance between the sensor mounting surface of differential case and teeth at top of the exciter ring. This distance represents dimension A. 4. Subtract dimension B from dimension A to determine the Rear Wheel Anti-Lock (RWAL) speed sensor air gap. The gap should be a minimum of 0.127 mm (0.005 inch) and a maximum of 1.27 mm (0.050 inch). 5. If air gap is not within stated limits, proceed as follows: a. Dimension B distance should be 27.18-27.43 mm (1.070-1.080 inch). If the RWAL speed sensor is not within these limits, replace the RWAL speed sensor. b. Dimension A distance should be 27.56-28.45 mm (1.085-1.120 inch). If dimension A is not within the specification, replace the exciter ring or repair the differential. c. If dimension A and dimension B exceeds their specifications, replace both the RWAL speed sensor and exciter ring. Also, repair the differential if necessary. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Page 535 Wheel Speed Sensor: Adjustments The Wheel Speed Sensor (WSS) is not adjustable. A clearance specification of 0.005 to 0.050 inch has been established for manufacturing tolerances. If the clearance is not within these specifications, the WSS or other components may be damaged. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement Front Front Wheel Speed Sensor Mounting CAUTION: Special bolts are used to attach the front sensor. The bolts have a special shoulder, thread length and surface treatment. If the original bolts must be replaced, use only a factory replacement part. Do not use substitute bolts under any circumstances. REMOVAL 1. Raise and support vehicle. 2. Remove bolt attaching sensor to the steering knuckle. 3. Remove clamps securing sensor wire to control arm and inner fender panel. 4. In engine compartment, disconnect sensor wire from harness and remove sensor. INSTALLATION 1. Position sensor in the knuckle and install sensor attaching bolts. Tighten bolts to 18-25 Nm (160-220 inch lbs.). 2. Secure sensor wire retaining clamps to control arm and fender panel. 3. In engine compartment, connect sensor wire to harness connector. Make sure wire is routed away from hot or rotating underhood components. 4. Turn steering wheel back and forth to verify that wire is clear of steering and suspension components. 5. Remove supports and lower vehicle. Rear Rear Speed Sensor Mounting REMOVAL Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 538 1. Raise vehicle on hoist. 2. Remove bolt securing sensor and shield to differential housing. 3. Remove sensor and shield from differential housing. 4. Disconnect sensor wire harness and remove sensor. INSTALLATION 1. Connect harness to sensor. Be sure seal is securely in place between sensor and wiring connector. 2. Install O-ring on sensor (if removed). 3. Insert sensor in differential housing. 4. Install sensor shield. 5. Install and torque sensor attaching bolt to 19-29 N.m (170-230 in. lbs.). 6. Lower vehicle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 539 Wheel Speed Sensor: Service and Repair Tone Wheel Replacement Rear Tone Wheel The toothed exciter ring is press-fitted onto the differential carrier next to the final drive ring gear in the differential case. If the ring is damaged, refer to Transmission and Drivetrain for service procedures. With Four Wheel Antilock Brakes Toothed Tone Wheel Ring For Front Wheel Speed Sensor Rear Tone Wheel Location FRONT The toothed tone wheel ring for the front speed sensor is located on the hub/bearing. It is not a serviceable component. To replace the ring, the hub/bearing assembly must be replaced. Refer Steering and Suspension for the service procedure. REAR The toothed exciter (tone wheel) ring is press-fitted onto the differential carrier next to the final drive ring gear in the differential case. If the ring is damaged, the differential assembly must be serviced as outlined in Transmission and Drivetrain. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications DESCRIPTION .................................................................................................................................... .............................................................. TORQUE Engine Coolant Temperature Sensor ........................................................................................................................................................... 11 Nm (96 in lb) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 545 Fig 6 Engine Coolant Temperature Sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 546 ECT Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 547 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig 6 Engine Coolant Temperature Sensor DESCRIPTION The engine coolant temperature sensor is installed in the intake manifold next to the thermostat housing. OPERATION The sensor provides an input voltage to the powertrain control module (PCM) relating coolant temperature. The PCM uses this input along with inputs from other sensors to determine injector pulse width and ignition timing. As coolant temperature varies, the coolant temperature sensor resistance will change. This change in resistance results in a different input voltage to the PCM. 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. CIRCUIT OPERATION The engine coolant temperature (ECT) sensor provides an input to the Powertrain Control Module (PCM) on circuit K2. From circuit K2, the engine coolant temperature sensor draws up to 5 Volts from the PCM. The sensor is a variable resistor. As coolant temperature changes, the resistance in the sensor changes, causing a change in current draw. The K2 circuit connects to cavity A16 of the PCM. The PCM provides a ground for the engine coolant temperature sensor signal (circuit K2) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Testing Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Component Testing Fig 57 Engine Coolant Temperature Sensor - Typical Sensor Resistance Chart (OHMS) To perform a complete test of the engine coolant temperature sensor and its circuitry, refer to Powertrain Management/Computers and Controls/Testing and Inspection/Procedures/Diagnostic Charts. To test the sensor only, refer to the following: 1. Disconnect wire harness connector from coolant temperature sensor (Fig. 57). 2. Engines with air conditioning: - When removing the connector from sensor, do not pull directly on wiring harness. - Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). - Place the hook part of tool under the connector for removal. - The connector is snapped onto the sensor. - It is not equipped with a lock type tab. 3. Test the resistance of the sensor with a high input impedance (digital) volt-ohmmeter. - The resistance (as measured across the sensor terminals) should be as shown in the Coolant Temperature Sensor/Intake Air Temperature Sensor resistance chart. - Replace the sensor if it is not within the range of resistance specified in the chart. 4. Test continuity of the wire harness between the PCM wire harness connector and the coolant sensor connector terminals. - Diagrams/Electrical/Connector Views for terminal/cavity locations. - Repair the wire harness if an open circuit is indicated. 5. After tests are completed, connect electrical connector to sensor. - The sensor connector is symmetrical (not indexed). - It can be installed to the sensor in either direction. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Testing > Page 550 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Crankshaft position sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Page 551 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig. 66 Engine Coolant Temperature Sensor WARNING: Hot, pressurized coolant can cause injury by scalding. cooling system must be partially drained before removing the coolant temperature sensor. REMOVAL 1. Partially drain cooling system. 2. Remove air cleaner assembly 3. Disconnect electrical connector from sensor. 4. Engines with air conditioning: - When removing the connector from sensor, do not pull directly on wiring harness. - Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). - Place the hook part of tool under the connector for removal. - The connector is snapped onto the sensor. - It is not equipped with a lock type tab. 5. Remove sensor from intake manifold. INSTALLATION 1. Install sensor. 2. Tighten to 11 Nm (8 ft lb) torque. 3. Connect electrical connector to sensor. - The sensor connector is symmetrical (not indexed). - It can be installed to the sensor in either direction. 4. Install air cleaner assembly 5. Replace any lost engine coolant. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation Brake Switch (Cruise Control): Description and Operation SYSTEM OPERATION Vehicles equipped with the speed control option use a dual function stop lamp switch. The switch is mounted in the same location as the conventional stop lamp switch, on the brake pedal mounting bracket under the instrument panel. The PCM monitors the state of the dual function stop lamp switch. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations Cruise Control Switch: Locations Speed Control Switches Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 559 Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 560 Cruise Control Switch: Description and Operation SYSTEM OPERATION Two separate speed control switch modules are mounted on the steering wheel to the left and right side of the driver's airbag module. Within the two switch modules, five momentary contact switches, supporting seven different speed control functions are used. The outputs from these switches are filtered into one input. The Powertrain Control Module (PCM) determines which output has been applied through resistive multiplexing. The input circuit voltage is measured by the PCM to determine which switch function has been selected. A speed control indicator lamp, located on the instrument panel cluster is energized by the PCM via the CCD Bus. This occurs when speed control system power has been turned ON, and the engine is running. The two switch modules are labeled: ON/OFF, SET, RESUME/ACCEL, CANCEL and COAST. 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 individual switch fails, the switch module must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 561 Cruise Control Switch: Testing and Inspection For complete speed control system diagnosis, refer to the appropriate Powertrain Diagnostic Procedures service and the DRB scan tool in Powertrain Management/Computers and Control Systems. To test the speed control switch only, refer to the following: WARNING: BEFORE ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL AND STEERING COLUMN COMPONENTS, YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. WAIT 2 MINUTES FOR SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. FAILURE TO DO SO COULD RESULT IN ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect negative battery cable. Wait 2 minutes for airbag system capacitor to discharge. 2. Remove speed control switch module from steering wheel. Refer to the removal/installation for procedures. Speed Control Switch Continuity (Typical Switch Shown) 3. Check speed control switch module continuity as shown in chart. If OK, reinstall switch. If not OK, replace switch module assembly The individual switches and the indicator lamp can not be serviced separately. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 562 Cruise Control Switch: Service and Repair REMOVAL WARNING: BEFORE BEGINNING ANY AIRBAG SYSTEM COMPONENT REMOVAL OR INSTALLATION, REMOVE AND ISOLATE THE NEGATIVE (-) CABLE FROM THE BATTERY. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. THEN WAIT TWO MINUTES FOR SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE INJURY. 1. Disconnect and isolate negative battery cable. 2. Remove airbag module. Refer to Air Bags And Seat Belts/Air Bags for procedures. Speed Control Switches 3. Remove switch-to-steering wheel mounting screws. 4. Remove switch. 5. Remove electrical connector at switch. INSTALLATION 1. Install electrical connector to switch. 2. Install switch and mounting screws. 3. Tighten screws to 1.5 N.m (14 in. lbs.) torque. 4. Install airbag module. Refer to Air Bags And Seat Belts/Air Bags for procedures. 5. Connect negative battery cable. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Description and Operation Vehicle Speed Sensor/Transducer - Cruise Control: Description and Operation SYSTEM OPERATION The Vehicle Speed Sensor (VSS) is a pulse generator mounted to an adapter near the transmission output shaft. The sensor is driven through the adapter by a speedometer pinion gear. The VSS pulse signal to the speedometer/odometer is monitored by the PCM speed control circuitry to determine vehicle speed and to maintain speed control set speed. Refer to the appropriate Powertrain Diagnostic Procedures in Powertrain Management/Computer and Control Systems for diagnosis and testing of this component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Description and Operation Oil Pressure Sensor: Description and Operation Sends a signal from the oil pressure sending unit to the Powertrain Control Module (PCM) relating to engine oil pressure. CIRCUIT OPERATION The engine oil pressure sensor is a variable resistor. As engine oil pressure changes the resistance on circuit G60 changes. The G60 circuit connects to cavity B23 of the Powertrain Control Module (PCM) connector. Ground for the sensor is supplied on circuit K4. This circuit connects to cavity A4 of the PCM connector. This circuit is the ground circuit for many of the components in the fuel/ignition system. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Description and Operation Ambient Temperature Sensor / Switch HVAC: Description and Operation CIRCUIT OPERATION The ambient temperature sensor is a variable resistor. Circuit G31 supplies voltage from the overhead console to the sensor. Circuit G32 is the signal return from the sensor to the overhead console. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Description and Operation > Page 574 Ambient Temperature Sensor / Switch HVAC: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Ambient Temperature Sensor Remove/Install 2. Locate the ambient temperature sensor, on the radiator yoke behind the grille. 3. Unplug the sensor wire harness connector. 4. Remove the screw that secures the ambient temperature sensor to the radiator yoke. 5. Remove the ambient temperature sensor. 6. Reverse the removal procedures to install. Tighten the ambient temperature sensor mounting screw to 5.6 N.m (50 in lbs.). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Description and Operation Blower Motor Switch: Description and Operation The heater-only or heater-A/C blower motor is controlled by a rotary switch mounted in the heater-A/C control panel. The switch allows for the selection of four blower motor speeds and an Off position, but will only operate with the ignition switch in the On position, and the heater-A/C mode control switch in any position except Off. The blower motor switch is connected in series with the blower motor ground path through the heater-A/C mode control switch. The blower motor switch directs this ground path to the blower motor through the blower motor resistor wires, or directly to the blower motor, as required to achieve the selected blower motor speed. The blower motor switch cannot be repaired and, if faulty or damaged, it must be replaced. The switch is serviced only as a part of the heater-only or heater-A/C control assembly. The blower motor switch knob is serviced separately. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Description and Operation > Page 578 Blower Motor Switch: Testing and Inspection The blower motor switch is only serviced as a part of the heater-only or heater-A/C control assembly. 1. Turn the ignition switch to the Off position. Remove the heater-A/C control from the instrument panel. Check for continuity between the ground circuit cavity of the control wire harness connector and a good ground. There should be continuity. If OK, go to Step 2. If not OK, repair the open circuit to ground as required. 2. With the heater-A/C control wire harness connector unplugged, place the mode control switch knob in any position except the Off position. Check for continuity between the ground circuit terminal and each of the blower motor driver circuit terminals of the control as you move the blower switch to each of the four speed positions. There should be continuity at each driver circuit terminal in only one blower motor switch speed position. If OK, test and repair the blower driver circuits between the control connector and the blower motor resistor as required. If not OK, replace the faulty heater-A/C control unit. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations High Pressure Sensor / Switch: Locations Fig 25 High Pressure Cut-off Switch -- Typical HIGH PRESSURE CUT-OFF SWITCH The high pressure cut-off switch is located on the discharge line near the compressor. Fig 29 Low Pressure Cycling Clutch Switch Removal/Installation LOW PRESSURE CYCLING CLUTCH SWITCH The low pressure cycling clutch switch is mounted on the accumulator. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 583 High Pressure Sensor / Switch: Description and Operation Fig 25 High Pressure Cut-off Switch -- Typical HIGH PRESSURE CUT-OFF SWITCH The high pressure cut-off switch is located on the discharge line near the compressor. This switch is connected in series between the low pressure clutch cycling switch and the Powertrain Control Module (PCM). This switch prevents compressor operation when the discharge line pressure approaches high levels. When the discharge line pressure rises above 3100 to 3375 kPa (450 to 490 psi) the switch contacts open and interrupt the A/C request signal circuit to the PCM. The PCM responds by de-energizing the compressor clutch relay, which will cause the compressor clutch to disengage. The switch will close again when the pressure drops to 1860 to 2275 kPa (270 to 330 psi). The high pressure cut-off switch is a factory-calibrated unit. The switch cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Fig 29 Low Pressure Cycling Clutch Switch Removal/Installation LOW PRESSURE CYCLING CLUTCH SWITCH The low pressure cycling clutch switch is mounted on top of the accumulator. The switch is connected in series with the high pressure cut-off switch in the A/C request signal circuit, between the heater-A/C mode control switch and the Powertrain Control Module (PCM). The switch contacts open and close causing the PCM to turn the compressor clutch on and off. This regulates the system pressure and controls evaporator temperature. Controlling evaporator temperature prevents condensate water on the evaporator fins from freezing and obstructing air conditioning system air flow. The switch contacts are normally open when the suction pressure is approximately 172 kPa (25 psi) or lower. The switch will close when the suction pressure rises to approximately 296 kPa (43 psi) or above. Lower ambient temperatures, below approximately -1~C (30~F) during cold weather, will also open the switch contacts. This is due to the pressure/temperature relationship of the refrigerant in the system. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 584 The low pressure cycling clutch switch is a factory-calibrated unit. This switch cannot be adjusted or repaired. If faulty or damaged, the switch must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 585 High Pressure Sensor / Switch: Testing and Inspection Fig 25 High Pressure Cut-off Switch -- Typical HIGH PRESSURE CUT-OFF SWITCH 1. Verify that the refrigerant system is properly charged. 2. Unplug the high pressure switch wire harness connector and test for continuity between the switch terminals. There should be continuity If OK, refer to the wiring diagrams and repair the circuits as required. If not OK, replace the faulty switch. Fig 29 Low Pressure Cycling Clutch Switch Removal/Installation NOTE: Verify that the refrigerant system has the correct refrigerant charge. LOW PRESSURE CYCLING CLUTCH SWITCH 1. Unplug the low pressure cycling clutch switch wire harness connector from the switch on the accumulator, and install a jumper wire between the two connector cavities. 2. Connect a manifold gauge set to the refrigerant system service ports. 3. Place the heater-A/C mode control switch knob in any A/C position and start the engine. 4. Check the continuity between the two terminals of the low pressure switch. There should be continuity with a suction pressure reading of 296 kPa (43 psi) or above, and no continuity with a suction pressure reading of 172 kPa (25 psi) or below. If OK, test and repair the compressor clutch control circuit as required. If not OK, replace the faulty switch. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 586 High Pressure Sensor / Switch: Service and Repair Fig 25 High Pressure Cut-off Switch -- Typical HIGH PRESSURE CUT-OFF SWITCH Removal 1. Disconnect and isolate the battery negative cable. 2. Unplug the wire harness connector from the switch. 3. Unscrew the switch from the discharge line fitting. Installation 1. Install and tighten the switch. 2. Unplug the wire harness connector into the switch. 3. Connect the battery negative cable. Fig 29 Low Pressure Cycling Clutch Switch Removal/Installation LOW PRESSURE CYCLING CLUTCH SWITCH 1. Disconnect and isolate the battery negative cable. 2. Unplug the wire harness connector from the low pressure cycling clutch switch near the top of the accumulator. 3. Unscrew the switch from the fitting on the accumulator. 4. Reverse the removal procedures to install. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations Low Pressure Sensor / Switch: Locations Fig 25 High Pressure Cut-off Switch -- Typical HIGH PRESSURE CUT-OFF SWITCH The high pressure cut-off switch is located on the discharge line near the compressor. Fig 29 Low Pressure Cycling Clutch Switch Removal/Installation LOW PRESSURE CYCLING CLUTCH SWITCH The low pressure cycling clutch switch is mounted on the accumulator. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 590 Low Pressure Sensor / Switch: Description and Operation Fig 25 High Pressure Cut-off Switch -- Typical HIGH PRESSURE CUT-OFF SWITCH The high pressure cut-off switch is located on the discharge line near the compressor. This switch is connected in series between the low pressure clutch cycling switch and the Powertrain Control Module (PCM). This switch prevents compressor operation when the discharge line pressure approaches high levels. When the discharge line pressure rises above 3100 to 3375 kPa (450 to 490 psi) the switch contacts open and interrupt the A/C request signal circuit to the PCM. The PCM responds by de-energizing the compressor clutch relay, which will cause the compressor clutch to disengage. The switch will close again when the pressure drops to 1860 to 2275 kPa (270 to 330 psi). The high pressure cut-off switch is a factory-calibrated unit. The switch cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Fig 29 Low Pressure Cycling Clutch Switch Removal/Installation LOW PRESSURE CYCLING CLUTCH SWITCH The low pressure cycling clutch switch is mounted on top of the accumulator. The switch is connected in series with the high pressure cut-off switch in the A/C request signal circuit, between the heater-A/C mode control switch and the Powertrain Control Module (PCM). The switch contacts open and close causing the PCM to turn the compressor clutch on and off. This regulates the system pressure and controls evaporator temperature. Controlling evaporator temperature prevents condensate water on the evaporator fins from freezing and obstructing air conditioning system air flow. The switch contacts are normally open when the suction pressure is approximately 172 kPa (25 psi) or lower. The switch will close when the suction pressure rises to approximately 296 kPa (43 psi) or above. Lower ambient temperatures, below approximately -1~C (30~F) during cold weather, will also open the switch contacts. This is due to the pressure/temperature relationship of the refrigerant in the system. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 591 The low pressure cycling clutch switch is a factory-calibrated unit. This switch cannot be adjusted or repaired. If faulty or damaged, the switch must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 592 Low Pressure Sensor / Switch: Testing and Inspection Fig 25 High Pressure Cut-off Switch -- Typical HIGH PRESSURE CUT-OFF SWITCH 1. Verify that the refrigerant system is properly charged. 2. Unplug the high pressure switch wire harness connector and test for continuity between the switch terminals. There should be continuity If OK, refer to the wiring diagrams and repair the circuits as required. If not OK, replace the faulty switch. Fig 29 Low Pressure Cycling Clutch Switch Removal/Installation NOTE: Verify that the refrigerant system has the correct refrigerant charge. LOW PRESSURE CYCLING CLUTCH SWITCH 1. Unplug the low pressure cycling clutch switch wire harness connector from the switch on the accumulator, and install a jumper wire between the two connector cavities. 2. Connect a manifold gauge set to the refrigerant system service ports. 3. Place the heater-A/C mode control switch knob in any A/C position and start the engine. 4. Check the continuity between the two terminals of the low pressure switch. There should be continuity with a suction pressure reading of 296 kPa (43 psi) or above, and no continuity with a suction pressure reading of 172 kPa (25 psi) or below. If OK, test and repair the compressor clutch control circuit as required. If not OK, replace the faulty switch. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 593 Low Pressure Sensor / Switch: Service and Repair Fig 25 High Pressure Cut-off Switch -- Typical HIGH PRESSURE CUT-OFF SWITCH Removal 1. Disconnect and isolate the battery negative cable. 2. Unplug the wire harness connector from the switch. 3. Unscrew the switch from the discharge line fitting. Installation 1. Install and tighten the switch. 2. Unplug the wire harness connector into the switch. 3. Connect the battery negative cable. Fig 29 Low Pressure Cycling Clutch Switch Removal/Installation LOW PRESSURE CYCLING CLUTCH SWITCH 1. Disconnect and isolate the battery negative cable. 2. Unplug the wire harness connector from the low pressure cycling clutch switch near the top of the accumulator. 3. Unscrew the switch from the fitting on the accumulator. 4. Reverse the removal procedures to install. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation Fuel Gauge Sender: Description and Operation Fig 31 Fuel Gauge Sending Unit Location - Typical Module Fig 32 Fuel Gauge Sending Unit Lock Tab/Tracks 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). The resistor track is used to send electrical signals to the Powertrain Control Module (PCM) for fuel gauge operation and for OBD II emission requirements. For fuel gauge operation: As fuel level increases, the float and arm move up. This decreases the sending unit resistance, causing the fuel gauge to read full. As fuel level decreases, the float and arm move down. This increases the sending unit resistance causing the fuel gauge to read empty. After this fuel level signal is sent to the PCM, the PCM will transmit the data across the CCD bus circuits to the instrument panel. Here it is translated into the appropriate fuel gauge level reading. For OBD II emission requirements: The voltage signal is sent from the resistor track to the PCM to indicate fuel level. The purpose of this feature is to prevent a false setting of misfire and fuel system monitor trouble codes. This is if the fuel level in the tank is less than approximately 15 percent of its rated capacity. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Page 598 Fuel Gauge Sender: Testing and Inspection The fuel gauge sending unit contains a variable resistor (track). As the float moves up or down, electrical resistance will change. 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 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 Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Page 599 Fuel Gauge Sender: Service and Repair Fig 31 Fuel Gauge Sending Unit Location - Typical Module Fig 32 Fuel Gauge Sending Unit Lock Tab/Tracks The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module. The fuel pump module is located inside of fuel tank. REMOVAL 1. Remove fuel tank. Refer to Fuel Tank Removal/ Installation. 2. Remove fuel pump module. Refer to Fuel Pump Module Removal/Installation. 3. Unplug 6-way electrical connector. 4. Disconnect 2 sending unit wires at 6-way connector. The locking collar of connector must be removed before wires can be released from connector. Note location of wires within 6-way connector. 5. The sending unit is retained to pump module with a small lock tab and notch. Carefully push lock tab to the side and away from notch while sliding sending unit downward on tracks for removal. Note wire routing while removing unit from module. INSTALLATION 1. Position sending unit into tracks. Note wire routing. 2. Push unit on tracks until lock tab snaps into notch. 3. Connect 2 sending unit wires into 6-way connector and install locking collar. 4. Connect 6-way electrical connector to module. 5. Carefully connect lower section of pump module to upper section (3 tabs lock upper section to lower section). 6. Install fuel pump module. Refer to Fuel Pump Module Removal/Installation. 7. Install fuel tank. Refer to Fuel Tank Removal/ Installation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Description and Operation Parking Brake Warning Switch: Description and Operation CIRCUIT OPERATION On circuit G11, the Controller, Antilock Brakes (CAB) senses when the park brake switch closes. Circuit G11 also connects to the park brake lamp in the instrument cluster and through a diode to circuit G9. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Specifications Backup Lamp Switch: Specifications Mounting .............................................................................................................................................. .................................................... 37 Nm (27 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Specifications > Page 607 Transmission Connectors Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Component Locations Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Component Locations > Page 612 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 613 Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 614 Brake Light Switch: Description and Operation OPERATION The brake light switch is mounted on a bracket on the brake pedal support. The switch is self adjusting. An initial adjustment is only necessary when the switch has been replaced, or removed for service access to other components. The primary function of the switch is to turn on the stop lamps during braking. The switch is also used to send signals to components that must know when the brakes are applied, such as the Powertrain Control Module (PCM), which uses the signal to cancel speed control. The Controller Anti-Lock Brake (CAB) uses the brake switch signal to monitor brake pedal application. When the switch contacts open (brakes applied), the CAB receives the brake applied signal. The CAB then monitors the Anti-Lock Brake System (ABS) to anticipate the need for an ABS stop. CIRCUIT OPERATION Circuit K29 provides an input to the Powertrain Control Module (PCM). This circuit connects to cavity C24 of the PCM connector. On circuit K29 the Controller Antilock Brakes (CAB) senses when the brake pedal has been pressed. Circuit K29 also connects to the Powertrain Control Module (PCM) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 615 Brake Light Switch: Testing and Inspection The brake light switch has a 12 volt feed circuit from the fuse block. Verity fuse is OK, then check the feed from the fuse block to the switch. If the switch is receiving a 12 volt supply, depress the brake pedal and check for voltage to the brake light circuit. If no voltage is present, the switch must be replaced. If the switch does not have 12 volts from the fuse block, check for continuity between the fuse block and switch and repair as necessary. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 616 Brake Light Switch: Adjustments 1. Push and hold brake pedal in applied position. 2. Push switch forward until fully seated against bracket. 3. Release brake pedal. 4. Lightly pull brake pedal rearward until master cylinder push rod bottoms against master cylinder internal stop. This action will set switch plunger at proper stroke length. CAUTION: Do not use excessive force to move the pedal rearward and do not overextend the pedal and push rod. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 617 Brake Light Switch: Service and Repair Stop Lamp Switch & Bracket REMOVAL 1. Disconnect switch harness. 2. Press and hold brake pedal in applied position. 3. Rotate switch counterclockwise about 30 degrees to align switch lock tab with notch in bracket. 4. Pull switch rearward out of mounting bracket and release brake pedal. INSTALLATION 1. Pull switch plunger all the way out to fully extended position. 2. Push switch plunger inward four detent positions (clicks). This is required preset position for switch installation. Plunger will extend approximately 0.55 inch out of housing at this setting. 3. Connect harness wires to switch. 4. Press and hold brake pedal down. 5. Install switch. Align tab on switch with notch in switch bracket. Then insert switch in bracket and turn it clockwise about 30 degrees to lock it in place. 6. Release brake pedal, then lightly pull pedal fully rearward. Pedal will adjust switch plunger to correct position as pedal is moved to rear. CAUTION: Do not use excessive force to move the pedal rearward for switch adjustment. Excessive force will damage the switch. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Service and Repair Combination Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is so equipped, remove the tilt steering column lever. Steering Column Shrouds Remove/Install - Typical 3. Remove both the upper and lower shrouds from the steering column. 4. Remove the lower fixed column shroud. Multifunction Switch 5. Move the upper fixed column shroud to gain access to the rear of the multi-function switch. 6. Remove the multi-function switch tamper proof mounting screws (a Snap On tamper proof torx bit TTXR20B2 or equivalent is required). 7. Gently pull the switch away from the column. Loosen the wire harness connector screw. The screw will remain in the wire harness connector. 8. Unplug the wire harness connector from the multi-function switch. 9. Reverse the removal procedures to install. Tighten the fasteners as follows: - Multi-function switch wire harness connector screw - 2 N.m (17 in. lbs.) - Multi-function switch retaining screws - 2 N.m (17 in. lhs.). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Service and Repair Fog/Driving Lamp Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the cluster bezel as described. Lamp Switch Remove/Install 3. Squeeze the latch tabs on the back of the switch and remove the switch from the receptacle on the rear of the cluster bezel. 4. Reverse the removal procedures to install. Be certain that the switch latches are fully engaged in the cluster bezel receptacle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Service and Repair Glove Box Lamp Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Open the glove box. Glove Box Lamp And Switch Remove/Install 3. Reach inside and above the glove box opening and unlatch and unplug the glove box lamp and switch wire harness connector. 4. From inside and above the glove box opening, squeeze the retaining tabs on the glove box lamp and switch housing together and push the unit out through the instrument panel mounting hole. 5. Reverse the removal procedures to install. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Description and Operation Hazard Warning Switch: Description and Operation SYSTEM OPERATION Multi-Function Switch Turn Signal Switch And Hazard Warning Switch The turn signal and hazard warning switches are integral to the multi-function switch assembly. The multi-function switch assembly is mounted to the left side of the steering column. This switch contains circuitry for the following functions: Turn signals - Hazard warning - Headlamp beam selection - Headlamp optical horn - Windshield wipers - Windshield washers. The information contained addresses only the multi-function switch functions for the turn signal and hazard warning circuits. However, the multi-function switch cannot be repaired. If any function of the switch is faulty, or if the switch is damaged, the entire switch assembly must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Description and Operation > Page 630 Hazard Warning Switch: Testing and Inspection Perform the diagnosis of the hazard warning and/or turn signal systems as described before testing the multi-function switch. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Unplug the multi-function switch wire harness connector as described. Multi-Function Switch Continuity 2. Using an ohmmeter, perform the switch continuity checks at the switch terminals as shown in the Multi-Function Switch Continuity chart. 3. If the switch fails any of the continuity checks, replace the faulty switch. If the switch is OK, repair the lighting circuits as required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Description and Operation > Page 631 Hazard Warning Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is so equipped, remove the tilt steering column lever. Steering Column Shrouds Remove/Install - Typical 3. Remove both the upper and lower shrouds from the steering column. 4. Remove the lower fixed column shroud. Multifunction Switch 5. Move the upper fixed column shroud to gain access to the rear of the multi-function switch. 6. Remove the multi-function switch tamper proof mounting screws (a Snap On tamper proof torx bit TTXR20B2 or equivalent is required). 7. Gently pull the switch away from the column. Loosen the wire harness connector screw. The screw will remain in the wire harness connector. 8. Unplug the wire harness connector from the multi-function switch. 9. Reverse the removal procedures to install. Tighten the fasteners as follows: - Multi-function switch wire harness connector screw - 2 N.m (17 in. lbs.) - Multi-function switch retaining screws - 2 N.m (17 in. lhs.). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation Headlamp Switch: Description and Operation CIRCUIT OPERATION In Off Or Parking Lamp Position Circuit A3 from fuse 2 in the Power Distribution Center (PDC) supplies battery voltage to the headlamp switch. The headlamp switch has an internal circuit breaker. In the OFF and PARK positions, the headlamp switch feeds circuit L25 which connects to the multi-function switch. Circuit L25 powers the high-beam circuit when the operator flashes the headlamps with the turn signal stalk of the multi-function switch. The multi-function switch connects circuit L25 to circuit L3. Circuit L3 feeds the high beam of the headlamps. In On Position When the headlamp switch is in the ON position, the A3 circuit from the Power Distribution Center (PDC) connects to circuit L2. Circuit L2 connects to the multi-function switch and feeds the L4 circuit. The L4 circuit powers the low beam of the headlamps. When the operator selects high beam operation with the turn signal stalk of the multi-function switch, circuit L2 connects to the L3 circuit. Circuit L3 powers high beam operation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Page 635 Headlamp Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the cluster bezel as described. WARNING: IF THE HEADLAMP SWITCH WAS TURNED ON, WAIT FIVE MINUTES TO ALLOW THE CERAMIC DIMMER RESISTOR TO COOL. IF THE RESISTOR IS NOT ALLOWED TO COOL, IT CAN BURN YOUR FINGERS. Headlamp Switch And Bezel Remove/Install 3. Remove the three screws that secure the head- lamp switch bezel to the instrument panel. 4. Pull the headlamp switch and bezel out from the instrument panel far enough to unplug the two wire harness connectors. 5. Pull the headlamp switch control knob out to its On position stop. 6. Depress the headlamp switch knob and shaft release button on the top of the switch housing, and pull the switch knob and shaft out of the switch. 7. Remove the push nut retainer that secures the headlamp switch bezel to the switch mounting bracket. 8. Reverse the removal procedures to install. Tighten the headlamp switch mounting screws to 2.2 N.m (20 in. lbs.). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Description and Operation Horn Switch: Description and Operation SYSTEM OPERATION A center-blow, resistive membrane type horn switch is installed on the back side of the driver side airbag module trim cover in the center of the steering wheel. When the center area of the airbag trim cover is depressed, the horn switch completes a circuit to ground for the coil side of the horn relay The steering wheel and steering column must be properly grounded for the horn switch to function. The horn switch is only serviced as a part of the airbag module trim cover. If the horn switch should fail, or if the airbag is deployed, the airbag module trim cover and horn switch unit must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Description and Operation > Page 639 Horn Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Remove the steering column opening cover and knee blocker. Check for continuity between the metal steering column jacket and a good ground. There should be continuity. If OK, go to Step 2. If not OK, refer to Steering and check for proper installation of the steering column mounting nuts. 2. Remove the driver side airbag module. Unplug the horn switch wire harness connectors. Remove the horn relay from the Power Distribution Center (PDC). Check for continuity between the steering column half of the horn switch feed wire harness connector and a good ground. There should be no continuity If OK, go to Step 3. If not OK, repair the short circuit as required. 3. Check for continuity between the steering column half of the horn switch feed wire harness connector and the horn relay control circuit cavity for the horn relay in the PDC. There should be continuity If OK, go to Step 4. If not OK, repair the open circuit as required. 4. Check for continuity between the horn switch feed wire and the horn switch ground wire on the airbag module. There should be no continuity If OK, go to Step 5. If not OK, replace the faulty horn switch. 5. Depress the center of the airbag module cover and check for continuity between the horn switch feed wire and the horn switch ground wire on the airbag module. There should be continuity If not OK, replace the faulty horn switch. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Description and Operation > Page 640 Horn Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH A DRIVER SIDE AIRBAG, THE HORN SWITCH IS INTEGRAL TO THE AIRBAG MODULE TRIM COVER. SERVICE OF THIS COMPONENT SHOULD BE PERFORMED ONLY BY CHRYSLER-TRAINED AND AUTHORIZED DEALER SERVICE TECHNICIANS. FAILURE TO TAKE THE PROPER PRECAUTIONS OR TO FOLLOW THE PROPER PROCEDURES COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS FOR THE SERVICE PROCEDURES. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Description and Operation Turn Signal Switch: Description and Operation SYSTEM OPERATION Multi-Function Switch Turn Signal Switch And Hazard Warning Switch The turn signal and hazard warning switches are integral to the multi-function switch assembly. The multi-function switch assembly is mounted to the left side of the steering column. This switch contains circuitry for the following functions: Turn signals - Hazard warning - Headlamp beam selection - Headlamp optical horn - Windshield wipers - Windshield washers. The information contained addresses only the multi-function switch functions for the turn signal and hazard warning circuits. However, the multi-function switch cannot be repaired. If any function of the switch is faulty, or if the switch is damaged, the entire switch assembly must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Description and Operation > Page 644 Turn Signal Switch: Testing and Inspection Perform the diagnosis of the hazard warning and/or turn signal systems as described before testing the multi-function switch. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Unplug the multi-function switch wire harness connector as described. Multi-Function Switch Continuity 2. Using an ohmmeter, perform the switch continuity checks at the switch terminals as shown in the Multi-Function Switch Continuity chart. 3. If the switch fails any of the continuity checks, replace the faulty switch. If the switch is OK, repair the lighting circuits as required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations > Page 650 MAP Connector Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Battery Temp. Sensor Location Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) 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 654 Battery Temp. Sensor Connector Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) 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 655 Battery Temperature Sensor: Service Precautions WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN . Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) 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 656 Battery Temperature Sensor: Description and Operation SYSTEM OPERATION The battery temperature sensor 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. CIRCUIT OPERATION The Powertrain Control Module (PCM) determines battery temperature on circuit K118. Circuit K118 connects the PCM to the battery temperature sensor. Circuit K4 provides ground for the sensor. Circuit K118 connects to cavity C15 of the PCM. Circuit K4 connects to cavity A4. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Testing Battery Temperature Sensor: Testing and Inspection Testing To perform a complete test of this sensor and its circuitry, refer to the appropriate Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Charts Procedures. To test the sensor only, refer to the following: Battery Temperature Sensor 1. The sensor is located under the battery and is attached to the battery tray. A two-wire pigtail harness is attached directly to the sensor. The opposite end of this harness connects the sensor to the engine wiring harness. 2. Disconnect the two-wire pigtail harness from the engine harness. 3. Attach ohmmeter leads to the wire terminals of the pigtail harness. 4. At room temperature of 25 °C (75 - 80 °F), an ohmmeter reading of 9,000 (9K) to 11,000 (11K) ohms should be observed. 5. If reading is above or below the specification, replace the sensor. 6. Refer to the Removal and Installation for procedures. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Page 659 Battery Temperature Sensor: Service and Repair Battery Temperature Sensor The battery temperature sensor is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray. The sensor is located under the battery on drivers side of vehicle. REMOVAL 1. Remove battery. 2. Disconnect sensor pigtail harness from engine wire harness. 3. Pry sensor straight up from battery tray mounting hole. INSTALLATION 1. Feed pigtail harness through mounting hole in top of battery tray and press sensor into top of tray (snaps in). 2. Connect pigtail harness. 3. Install battery. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Component Locations Camshaft Position Sensor: Component Locations Camshaft Position Sensor The Camshaft Position (CMP) Sensor is mounted in the distributor housing. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 664 Distributor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 665 CPS Connector Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 666 Camshaft Position Sensor: Description and Operation LOCATION The camshaft position sensor is located in the distributor on all engines. DESCRIPTION The sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft. The pulse ring rotates 180 degrees through the sync signal generator. Its signal is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. OPERATION When the leading edge of the pulse ring (shutter) enters the sync signal generator, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a sync signal of approximately 5 volts. When the trailing edge of the pulse ring (shutter) leaves the sync signal generator, the change of the magnetic field causes the sync signal voltage to switch low to 0 volts. CIRCUIT OPERATION The camshaft position sensor is located internal to the distributor on all engine applications. The Powertrain Control Module (PCM) supplies 5 Volts to the camshaft position sensor on circuit K6. Circuit K6 connects to cavity A17 of the PCM. The PCM receives the camshaft position sensor signal on circuit K44. Circuit K44 connects to cavity A18 of the PCM. The PCM provides a ground for the camshaft position sensor (circuit K44) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 667 Camshaft Position Sensor: Testing and Inspection Circuit K6 splices to supply 5 Volts to the crankshaft position sensor, manifold absolute pressure sensor, and throttle position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Crankshaft position sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 668 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor NOTE: Distributor removal is not necessary to remove camshaft position sensor. REMOVAL 1. Remove air cleaner assembly 2. Disconnect negative cable from battery 3. Remove distributor cap from distributor (two screws). 4. Disconnect camshaft position sensor wiring harness from main engine wiring harness. 5. Remove distributor rotor from distributor shaft. 6. Lift the camshaft position sensor assembly from the distributor housing. INSTALLATION 1. Install camshaft position sensor to distributor. Align sensor into notch on distributor housing. 2. Connect wiring harness. 3. Install rotor 4. Install distributor cap. Tighten mounting screws. 5. Install air cleaner assembly. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications DESCRIPTION .................................................................................................................................... .............................................................. TORQUE Engine Coolant Temperature Sensor ........................................................................................................................................................... 11 Nm (96 in lb) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 672 Fig 6 Engine Coolant Temperature Sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 673 ECT Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 674 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig 6 Engine Coolant Temperature Sensor DESCRIPTION The engine coolant temperature sensor is installed in the intake manifold next to the thermostat housing. OPERATION The sensor provides an input voltage to the powertrain control module (PCM) relating coolant temperature. The PCM uses this input along with inputs from other sensors to determine injector pulse width and ignition timing. As coolant temperature varies, the coolant temperature sensor resistance will change. This change in resistance results in a different input voltage to the PCM. 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. CIRCUIT OPERATION The engine coolant temperature (ECT) sensor provides an input to the Powertrain Control Module (PCM) on circuit K2. From circuit K2, the engine coolant temperature sensor draws up to 5 Volts from the PCM. The sensor is a variable resistor. As coolant temperature changes, the resistance in the sensor changes, causing a change in current draw. The K2 circuit connects to cavity A16 of the PCM. The PCM provides a ground for the engine coolant temperature sensor signal (circuit K2) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Testing Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Component Testing Fig 57 Engine Coolant Temperature Sensor - Typical Sensor Resistance Chart (OHMS) To perform a complete test of the engine coolant temperature sensor and its circuitry, refer to Powertrain Management/Computers and Controls/Testing and Inspection/Procedures/Diagnostic Charts. To test the sensor only, refer to the following: 1. Disconnect wire harness connector from coolant temperature sensor (Fig. 57). 2. Engines with air conditioning: - When removing the connector from sensor, do not pull directly on wiring harness. - Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). - Place the hook part of tool under the connector for removal. - The connector is snapped onto the sensor. - It is not equipped with a lock type tab. 3. Test the resistance of the sensor with a high input impedance (digital) volt-ohmmeter. - The resistance (as measured across the sensor terminals) should be as shown in the Coolant Temperature Sensor/Intake Air Temperature Sensor resistance chart. - Replace the sensor if it is not within the range of resistance specified in the chart. 4. Test continuity of the wire harness between the PCM wire harness connector and the coolant sensor connector terminals. - Diagrams/Electrical/Connector Views for terminal/cavity locations. - Repair the wire harness if an open circuit is indicated. 5. After tests are completed, connect electrical connector to sensor. - The sensor connector is symmetrical (not indexed). - It can be installed to the sensor in either direction. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Testing > Page 677 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Crankshaft position sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Page 678 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig. 66 Engine Coolant Temperature Sensor WARNING: Hot, pressurized coolant can cause injury by scalding. cooling system must be partially drained before removing the coolant temperature sensor. REMOVAL 1. Partially drain cooling system. 2. Remove air cleaner assembly 3. Disconnect electrical connector from sensor. 4. Engines with air conditioning: - When removing the connector from sensor, do not pull directly on wiring harness. - Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). - Place the hook part of tool under the connector for removal. - The connector is snapped onto the sensor. - It is not equipped with a lock type tab. 5. Remove sensor from intake manifold. INSTALLATION 1. Install sensor. 2. Tighten to 11 Nm (8 ft lb) torque. 3. Connect electrical connector to sensor. - The sensor connector is symmetrical (not indexed). - It can be installed to the sensor in either direction. 4. Install air cleaner assembly 5. Replace any lost engine coolant. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications DESCRIPTION .................................................................................................................................... .............................................................. TORQUE Crankshaft Position Sensor ................................................................................................................. .......................................................... 8 Nm (70 in lb) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 682 Crankshaft Position Sensor: Locations Crankshaft Position Sensor The sensor is located on the top of cylinder block near the rear of right cylinder head. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 683 CKP Connector Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 684 Crankshaft Position Sensor: Description and Operation Fig. 4 Sensor Operation DESCRIPTION The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. The flywheel/drive plate has groups of notches at its outer edge. there are three sets of double notches and three sets of single notches. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. OPERATION Engine speed and crankshaft position are provided through the 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. CIRCUIT OPERATION The Powertrain Control Module (PCM) supplies 5 Volts to the crankshaft position sensor on circuit K6. Circuit K6 connects to cavity A17 of the PCM. The PCM receives the crankshaft position sensor signal on circuit K24. Circuit K24 connects to cavity A8 of the PCM. The PCM provides a ground for the crankshaft position sensor (circuit K24) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector. NOTE: The engine will not operate if the PCM does not receive a crankshaft position sensor input. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 685 Crankshaft Position Sensor: Testing and Inspection Circuit K6 splices to supply 5 Volts to the camshaft position sensor, manifold absolute pressure sensor, and throttle position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 686 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor NOTE: The sensor is bolted to the top of the cylinder block near the rear of right cylinder head. The sensor is accessed by removing the right front fender liner. REMOVAL 1. Remove right front tire and right front wheelhouse liner. 2. Disconnect crankshaft position sensor pigtail harness from main wiring harness. 3. Remove two sensor (recessed hex head) mounting bolts. 4. Remove sensor from engine. INSTALLATION 1. Position crankshaft position sensor to engine. 2. Install mounting bolts and tighten to 8 Nm (70 in lb) torque. 3. Connect main harness electrical connector to sensor. 4. Install right front tire and right front wheelhouse liner. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation The fuel level sensor (fuel gauge sending unit) sends a signal to the PCM to indicate fuel level. The purpose of this feature is to prevent a false setting of misfire and fuel system monitor trouble codes if the fuel level is less than approximately 15 percent of its rated capacity It is also used to send a signal for fuel gauge operation via the CCD bus circuits. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications Intake Air Temperature Sensor: Specifications DESCRIPTION .................................................................................................................................... .............................................................. TORQUE Intake Manifold Air Temp. Sensor ............................................................................................................................................................. 28 Nm (20 ft lb) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 693 Fig 59 Intake Manifold Air Temperature Sensor - Typical Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 694 IAT Connector Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 695 Intake Air Temperature Sensor: Description and Operation Fig 8 Intake Manifold Air Temperature Sensor PURPOSE The sensor provides an input voltage to the powertrain control module (PCM) indicating intake manifold air temperature. The input is used along with inputs from other sensors to determine injector pulse width. OPERATION As the temperature of the air-fuel stream in the manifold varies, the sensor resistance changes. This results in a different input voltage to the PCM. CIRCUIT OPERATION The intake air temperature sensor provides an input to the Powertrain Control Module (PCM) on circuit K21. Circuit K21 connects to cavity A15 of the PCM. From circuit K21, the intake air temperature sensor draws voltage from the PCM. The sensor is a variable resistor. As intake air temperature changes, the resistance in the sensor changes, causing a change in current draw. The PCM provides a ground for the intake air temperature sensor signal (circuit K21) through circuit K4. Circuit K4 connects to cavity A4 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Sensor Test Intake Air Temperature Sensor: Testing and Inspection Sensor Test Fig 59 Intake Manifold Air Temperature Sensor - Typical Sensor Resistance Chart (OHMS) To perform a complete test of the intake manifold air temperature sensor and its circuitry, refer to Powertrain Management/Computers and Controls/Testing and Inspection/Diagnostic Charts. To test the sensor only, refer to the following; 1. Disconnect the wire harness connector from the intake manifold air temperature sensor (Fig. 59). 2. Test the resistance of the sensor with an input impedance (digital) volt-ohmmeter. - The resistance (as measured across the sensor terminals) should be as shown in the Sensor Resistance Chart. - Replace the sensor if it is not within the range of resistance specified in the chart. 3. Test the resistance of the wire harness. - Do this between the PCM wire harness connector A-15 and the sensor connector terminal. - Also check between PCM connector A-4 to the sensor connector terminal. - Repair the wire harness as necessary if the resistance is greater than 1 ohm. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Sensor Test > Page 698 Intake Air Temperature Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Crankshaft position sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Page 699 Intake Air Temperature Sensor: Service and Repair Fig 88 Intake Manifold Air Temperature Sensor - Typical The intake manifold air temperature sensor is located in the front/side of the intake manifold (Fig. 88). REMOVAL 1. Remove air duct at throttle body. 2. Disconnect electrical connector at sensor (Fig. 88). 3. Remove sensor from intake manifold. INSTALLATION 1. Install sensor to intake manifold. Tighten to 28 Nm (20 ft lb) torque. 2. Install electrical connector. 3. Install air duct at throttle body. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications Manifold Pressure/Vacuum Sensor: Specifications DESCRIPTION .................................................................................................................................... .............................................................. TORQUE MAP Sensor Mounting Screws ............................................................................................................ ......................................................... 3 Nm (25 in lb) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 703 Manifold Pressure/Vacuum Sensor: Locations Fig 10 MAP And Throttle Position Sensor Location - Typical The MAP sensor is mounted into the right side of the intake manifold. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 704 Manifold Pressure/Vacuum Sensor: Description and Operation Fig 10 MAP And Throttle Position Sensor Location - Typical DESCRIPTION The Manifold Absolute Pressure (MAP) sensor reacts to absolute pressure in the intake manifold. It provides an input voltage to the powertrain control module (PCM). The MAP sensor is mounted into the right side of the intake manifold. OPERATION As engine load changes, manifold pressure varies. The change in manifold pressure causes MAP sensor voltage to change. The change in MAP sensor voltage results in a different input voltage to the PCM. The input voltage level supplies the PCM with information about ambient barometric pressure during engine start-up (cranking) and engine load while the engine is running. The PCM uses this input along with inputs from other sensors to adjust air-fuel mixture. CIRCUIT OPERATION From the Powertrain Control Module (PCM), circuit K6 supplies 5 Volts to the Manifold Absolute Pressure (MAP) sensor Circuit K6 connects to cavity A17 of the PCM. Circuit K1 delivers the MAP signal to the PCM. Circuit K1 connects to cavity A27 of the PCM. The PCM provides a ground for the MAP sensor signal (circuit K1) through circuit K4. Circuit K4 connects to cavity A4 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Helpful Information Manifold Pressure/Vacuum Sensor: Testing and Inspection Helpful Information Circuit K6 splices to supply 5 Volts to the Throttle Position Sensor (TPS), camshaft position sensor, and crankshaft position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Crankshaft position sensor - Intake air temperature sensor - Throttle position sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Helpful Information > Page 707 Manifold Pressure/Vacuum Sensor: Testing and Inspection Component Test Fig 49 MAP Sensor - Typical NOTE: To perform a complete test of MAP sensor (Fig. 49) and its circuitry, refer to Powertrain Management/Computers and Controls/Testing and Inspection/Diagnostic Charts. To test the MAP sensor only, refer to the following: Fig 50 Rubber L-Shaped Fitting - MAP Sensor-to-Throttle Body 1. Inspect the rubber L-shaped fitting from the MAP sensor to the throttle body (Fig. 50). Repair as necessary. CAUTION: When testing the MAP sensor, be sure that the harness wires are not damaged by the test meter probes. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Helpful Information > Page 708 Fig 51 MAP Sensor Connector Terminals - Typical 2. Test the MAP sensor output voltage at the MAP sensor connector between terminals A and B (Fig. 51). With the ignition switch ON and the engine OFF output voltage should be 4-to-5 volts. The voltage should drop to 1.5-to-2.1 volts with a hot, neutral idle speed condition. 3. Test powertrain control module (PCM) cavity A-27 for the same voltage described above to verify the wire harness condition. Repair as necessary 4. Test MAP sensor supply voltage at sensor connector between terminals A and C (Fig. 51) with the ignition ON. - The voltage should be approximately 5 volts (+/- 0.5V). - Five volts (+/- 0.5V) should also be at cavity A-17 of the PCM wire harness connector. - Repair or replace the wire harness as necessary. 5. Test the MAP sensor ground circuit at sensor connector terminal A (Fig. 51) and PCM connector A-4. - Repair the wire harness if necessary Refer to Diagrams/Electrical/Connector Views for cavity locations. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Page 709 Manifold Pressure/Vacuum Sensor: Service and Repair Fig 77 MAP Sensor Location Fig 78 MAP Sensor L-Shaped Rubber Fitting The MAP sensor is located on the front of the throttle body (Fig. 77). An L-shaped rubber fitting is used to connect the MAP sensor to throttle body (Fig. 78). REMOVAL 1. Remove air duct at throttle body 2. Remove two MAP sensor mounting bolts (screws) (Fig. 77). 3. While removing MAP sensor, slide the vacuum rubber L-shaped fitting (Fig. 78) from the throttle body 4. Remove rubber L-shaped fitting from MAP sensor. INSTALLATION 1. Install rubber L-shaped fitting to MAP sensor. 2. Position sensor to throttle body while guiding rubber fitting over throttle body vacuum nipple. 3. Install MAP sensor mounting bolts (screws). Tighten screws to 3 Nm (25 in lb) torque 4. Install air duct at throttle body. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Description and Operation Oil Pressure Sensor: Description and Operation Sends a signal from the oil pressure sending unit to the Powertrain Control Module (PCM) relating to engine oil pressure. CIRCUIT OPERATION The engine oil pressure sensor is a variable resistor. As engine oil pressure changes the resistance on circuit G60 changes. The G60 circuit connects to cavity B23 of the Powertrain Control Module (PCM) connector. Ground for the sensor is supplied on circuit K4. This circuit connects to cavity A4 of the PCM connector. This circuit is the ground circuit for many of the components in the fuel/ignition system. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Oxygen Sensor .................................................................................................................................... ......................................................... 30 Nm (22 ft lb) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) 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 Bank Locations Oxygen Sensor: Locations Oxygen Sensor Bank Locations Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) 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 Bank Locations > Page 718 Oxygen Sensor: Locations Oxygen Sensor Location Fig 82 Upstream Oxygen Sensor Locations Fig 83 Downstream Oxygen Sensor Location The upstream and downstream Oxygen (02S) sensors are located at the inlet and outlet ends of the catalytic converter. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) 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 Bank Locations > Page 719 Oxygen Sensor Configuration Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 720 Oxygen Sensor: Diagrams Pinout Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 721 Oxygen Sensor: Application and ID Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 722 Oxygen Sensor: Description and Operation OXYGEN SENSOR (O2S)-PCM INPUT Two heated O2S sensors are used. The sensors produce voltages from 0 to 1 volt, depending upon the oxygen content of the exhaust gas in the exhaust manifold. When a large amount of oxygen is present (caused by a lean air/fuel mixture), the sensors produces a low voltage. When there is a lesser amount present (rich air/fuel mixture) it produces a higher voltage. By monitoring the oxygen content and converting it to electrical voltage, the sensors act as a rich-lean switch. In Closed Loop operation, the PCM monitors the O2S sensor input (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. The oxygen sensors are equipped with a heating element that keeps the sensors at proper operating temperature during all operating modes. 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. The Automatic Shutdown (ASD) relay supplies battery voltage to both the upstream and downstream heated oxygen sensors. The oxygen sensors are equipped with a heating element. The heating elements reduce the time required for the sensors to reach operating temperature. UPSTREAM HEATED OXYGEN SENSOR The upstream O2S sensor is located near the inlet end of the catalytic converter. It 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 the air/fuel ratio by adjusting injector pulse width. DOWNSTREAM HEATED OXYGEN SENSOR The downstream heated oxygen sensor is located near the outlet end of the catalytic converter The downstream heated oxygen sensor input is used to detect catalytic convertor deterioration. As the convertor deteriorates, the input from the downstream sensor begins to match the upstream sensor input except for a slight time delay By comparing the downstream heated oxygen sensor input to the input from the upstream sensor, the PCM calculates catalytic convertor efficiency. When the catalytic converter efficiency drops below emission standards, the PCM stores a diagnostic trouble code and illuminates the Malfunction Indicator Lamp (MIL). For more information, refer to Emission Control Systems. CIRCUIT OPERATION When the Automatic Shut Down (ASD) relay contacts CLOSE, they connect circuits A16 and A142. Circuit A142 splices to supply voltage to the heated oxygen sensors. Circuit K141 delivers the signal from the center heated oxygen sensor to the PCM. Circuit K141 connects to cavity A24 of the Powertrain Control Module (PCM). Circuit K341 delivers the signal from the rear sensor and connects to cavity A25 of the PCM. Circuit K241 delivers the signal from the right heated oxygen sensor to the PCM. Circuit K241 connects to cavity A26 of the Powertrain Control Module (PCM). Circuit K441 delivers the signal from the left sensor and connects to cavity A25 of the PCM. The PCM provides a ground for the heated oxygen sensor signals (circuits K141 and K341) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector. Circuit Z1 provides a ground for the heater circuit in the sensors. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Helpful Information Oxygen Sensor: Testing and Inspection Helpful Information Circuit A142 splices to supply voltage to the fuel injectors and ignition coil. Circuit K4 splices to supply ground for the signals from the following: - Camshaft position sensor - Crankshaft position sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Helpful Information > Page 725 Oxygen Sensor: Testing and Inspection Sensor Heating Element Test Fig 82 Upstream Oxygen Sensor Locations Fig 83 Downstream Oxygen Sensor Location The upstream O2S sensor is located in the exhaust downpipe. The downstream sensor is located near outlet end of catalytic converter. Refer to (Fig. 82) or (Fig. 83). WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. REMOVAL 1. Raise and support the vehicle. 2. Disconnect the wire connector from the O2S sensor. CAUTION: When disconnecting the sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove the O2S sensor. Snap-On oxygen sensor wrench (number YA 8875) may be used for removal and installation. NOTE: Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to the threads of a new oxygen sensor. INSTALLATION 1. Install the 02S sensor. Tighten to 30 Nm (22 ft lb) torque. 2. Connect the O2S sensor wire connector. 3. Lower the vehicle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Page 726 Oxygen Sensor: Service and Repair Fig 82 Upstream Oxygen Sensor Locations Fig 83 Downstream Oxygen Sensor Location NOTE: The upstream and downstream Oxygen (02S) sensors are located at the inlet and outlet ends of the catalytic converter. REMOVAL WARNING: The exhaust manifold, exhaust pipes and catalytic converter become very hot during engine operation. Allow engine to cool before removing oxygen sensor. 1. Raise and support the vehicle. 2. Disconnect the wire connector from the 02S sensor. CAUTION: When disconnecting the sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove the O2S sensor. Snap-On oxygen sensor wrench (number YA 8875) may be used for removal and installation. INSTALLATION Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to the threads of a new oxygen sensor. 1. Install the 02S sensor. Tighten to 30 Nm (22 ft lb) torque. 2. Connect the 02S sensor wire connector. 3. Lower the vehicle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Power Steering - Pressure Switch Torque Revisions Power Steering Pressure Switch: Technical Service Bulletins Power Steering - Pressure Switch Torque Revisions NUMBER: 26-10-96B GROUP: Miscellaneous DATE: October, 1996 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 Dakota - Publication Number 81-270-7146 DESCRIPTION OF CHANGES Revised power steering pressure switch torque (124-195 In. Lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Power Steering - Pressure Switch Torque Revisions > Page 731 14-65 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Power Steering - Pressure Switch Torque Revisions > Page 732 14-66 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Page 733 Power Steering Pressure Switch: Specifications The content of this article reflects changes called for in TSB 26-10-96. Power Steering Pressure Switch ................................................................................................................................................ 14-22 Nm (124-195 in.lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates Throttle Position Sensor: Technical Service Bulletins Engine Controls/Emissions/A/T - Manual Updates NUMBER: 26-06-98 GROUP: Miscellaneous DATE: June, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 2.5L, 3.9L, 5.2L, 5.9L 8.0L SFI/CNG/Diesel Diagnostic Manual - Publication Number 81-699-96041 DESCRIPTION OF CHANGES Revision to the diagnostic trouble codes Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 738 56 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 739 57 Revisions to the Throttle Position Sensor test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 740 162 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 741 166 Revisions to the Evap. Purge Flow Monitor tests Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 742 374 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 743 375 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 744 377 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 745 379 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 746 379A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 747 379B Revision to the EGR system Failure tests Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 748 432 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 749 433 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 750 434 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 751 435 Revision to the torque convertor clutch - no drop at lock up test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 752 465 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 753 467 Revision to the no temp rise seen at intake heater test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 754 514 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 755 515 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 756 516 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 757 517 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 758 518 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 759 519 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 760 520 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 761 521 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 762 521A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 763 521B Revision to the 12 volt supply relay test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 764 571 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 765 Throttle Position Sensor: Technical Service Bulletins Fuel/Engine Controls - Injector Circuit/TPS Revisions NUMBER: 26-05-98F GROUP: Miscellaneous DATE: May, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 2.5L, 3.9L, 5.2L, 5.9L Truck Powertrain Diagnostic Manual - Publication Number 81-699-96041 DESCRIPTION OF CHANGES Revision to the injector connector diagram Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 766 224 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 767 225 Revision to the throttle position sensor test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 768 164 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 769 165 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 770 168 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 771 169 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 772 169A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 773 169B Revision to the TPS voltage test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 774 422 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 775 423 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 776 Throttle Position Sensor: Specifications DESCRIPTION .................................................................................................................................... .............................................................. TORQUE Throttle Position Sensor Mounting Screws ................................................................................................................................................... 7 Nm (60 in lb) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 777 Throttle Position Sensor: Locations Fig. 15 MAP And Throttle Position Sensor Location - Typical The TPS is mounted on the throttle body. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 778 Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 779 Throttle Position Sensor: Description and Operation DESCRIPTION The Throttle Position Sensor (TPS) is a variable resistor that provides the powertrain control module (PCM) with an input signal (voltage) that represents throttle blade position. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the resistance of the TPS changes. OPERATION 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 1 volt at minimum throttle opening (idle), to 4 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. This input signal is also used to determine overdrive and converter clutch shift schedule and to select the proper governor curve. Fig. 15 MAP And Throttle Position Sensor Location - Typical LOCATION The TPS is mounted on the throttle body. CIRCUIT OPERATION From the Powertrain Control Module (PCM), circuit K6 supplies 5 Volts to the Throttle Position Sensor (TPS). Circuit K6 connects to cavity A17 of the PCM. Circuit K22 delivers the TPS signal to the PCM. Circuit K22 connects to cavity A23 of the PCM. The PCM provides a ground for the TPS signal (circuit K22) through circuit K4. Circuit K4 connects to cavity A4 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Component Test Throttle Position Sensor: Testing and Inspection Component Test Fig 62 TPS To perform a complete test of the TPS and its circuitry, refer to Powertrain Management/Computers and Controls/Testing and Inspection/Diagnostic Charts. To test the TPS only, refer to the following: The TPS (Fig. 62) can be tested with a digital voltmeter. The center electrical terminal of the TPS is the output terminal. With the ignition key in the ON position, check the TPS output voltage at the center terminal wire of the connector. Check this at idle (throttle plate closed) and at wide open throttle (WOT). At idle, TPS output voltage should be greater than 0.350 millivolts but less than 900 millivolts. At wide open throttle, TPS output voltage must be less than 4.5 volts. The output voltage should increase gradually as the throttle plate is slowly opened from idle to WOT. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Component Test > Page 782 Throttle Position Sensor: Testing and Inspection Helpful Information Circuit K6 splices to supply 5 Volts to the manifold absolute pressure sensor, crankshaft position sensor and camshaft position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Crankshaft position sensor - Intake air temperature sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Page 783 Throttle Position Sensor: Service and Repair Fig 71 TPS Mounting Bolts Fig 72 Installation - Typical REMOVAL 1. Remove air duct at throttle body. 2. Disconnect TPS electrical connector. 3. Remove two TPS mounting bolts (Fig. 71). 4. Remove TPS from throttle body. NOTES: - The throttle shaft end of the throttle body slides into a socket in the TPS (Fig. 72). - The TPS must be installed so that it can be rotated a few degrees. - If the sensor will not rotate, install the sensor with the throttle shaft on the other side of the socket tangs. - The TPS will be under slight tension when rotated. INSTALLATION 1. Install the TPS and two retaining bolts. 2. Tighten bolts to 7 Nm (60 in lb) torque. 3. Manually operate the throttle control lever by hand to check for any binding of the TPS. 4. Connect TPS electrical connector to TPS. 5. Install air duct at throttle body. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 787 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. 4. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 5. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 6. Test continuity of new switch with 12V test lamp. 7. Connect switch wires and lower vehicle. 8. Top off transmission fluid level. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications Vehicle Speed Sensor: Specifications DESCRIPTION .................................................................................................................................... .............................................................. TORQUE Vehicle Speed Sensor Mounting Bolt ......................................................................................................................................................... 2.2 Nm (20 in lb) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 791 Vehicle Speed Sensor: Locations Fig 13 Vehicle Speed Sensor Location - 2WD - Typical Fig 14 Vehicle Speed Sensor Location - 4WD - Typical Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 794 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 Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 795 Electrostatic Discharge Symbol All Electrostatic Discharge (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, especially 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. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 796 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 797 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 798 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 799 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 800 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 801 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 802 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 803 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. 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. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 804 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 805 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 806 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 807 Vehicle Speed Sensor: Diagnostic Aids 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 in 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 and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 808 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. 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 every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. 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 fuse circuit. 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 the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 809 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools 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 - This instrument is 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 vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. 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 non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 810 Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Circuit Operation Vehicle Speed Sensor: Description and Operation Circuit Operation CIRCUIT OPERATION The Powertrain Control Module (PCM) supplies 5 Volts to the vehicle speed sensor on circuit K7. Circuit K7 connects B31 of the PCM. Circuit G7 from the vehicle speed sensor provides an input signal to the PCM. The G7 circuit connects to cavity B27 of the PCM. The PCM provides a ground for the vehicle speed sensor signal (circuit G7) through circuit K4. Circuit K4 connects to cavity A4 of the PCM. HELPFUL INFORMATION Circuit K4 also provides ground for the signals from the following: Heated oxygen sensors - Crankshaft position sensor - Camshaft position sensor - Engine coolant temperature sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Circuit Operation > Page 813 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor Operation Fig 13 Vehicle Speed Sensor Location - 2WD - Typical Fig 14 Vehicle Speed Sensor Location - 4WD - Typical DESCRIPTION The sensor input is used by the powertrain control module (PCM) to determine vehicle speed and distance traveled. OPERATION The speed sensor generates 8 pulses per sensor revolution. These signals, in conjunction with a closed throttle signal from the throttle position sensor, indicate a closed throttle deceleration to the PCM. When the vehicle is stopped at idle, a closed throttle signal is received by the PCM (but a speed sensor signal is not received). Under deceleration conditions, the PCM adjusts the idle air control (IAC) motor to maintain a desired Manifold Absolute Pressure (MAP) value. Under idle conditions, the PCM adjusts the IAC motor to maintain a desired engine speed. The vehicle speed sensor is located on the speedometer pinion gear adapter. The pinion gear adapter is located on the extension housing of the transmission (drivers side). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Component Test Vehicle Speed Sensor: Testing and Inspection Component Test To perform a complete test of the idle air control motor and circuits see Computers and System Diagnosis/Testing and Inspection/Diagnostic Charts. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Component Test > Page 816 Vehicle Speed Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Crankshaft position sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Intake air temperature sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Page 817 Vehicle Speed Sensor: Service and Repair Fig 91 Vehicle Speed Sensor Location - 2WD - Typical Fig 92 Vehicle Speed Sensor Location - 4WD - Typical The vehicle speed sensor is located on the speedometer pinion gear adapter (Fig. 91) or (Fig. 92). The pinion gear adapter is located on the extension housing of the transmission (drivers side). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Page 818 Fig 93 Sensor Removal/Installation REMOVAL 1. Raise and support vehicle. 2. Disconnect the electrical connector from the sensor. 3. Remove the sensor mounting bolt (Fig. 93). 4. Remove the sensor (pull straight out) from the speedometer pinion gear adapter (Fig. 93). - Do not remove the gear adapter from the transmission. INSTALLATION 1. Clean the inside of speedometer pinion gear adapter before installing speed sensor. 2. Install sensor into speedometer gear adapter and install mounting bolt. - Before tightening bolt, verify speed sensor is fully seated (mounted flush) to speedometer pinion gear adapter. 3. Tighten sensor mounting bolt to 2.2 Nm (20 in lb) torque. 4. Connect electrical connector to sensor. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates Purge Flow Sensor: Technical Service Bulletins Engine Controls/Emissions/A/T - Manual Updates NUMBER: 26-06-98 GROUP: Miscellaneous DATE: June, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 2.5L, 3.9L, 5.2L, 5.9L 8.0L SFI/CNG/Diesel Diagnostic Manual - Publication Number 81-699-96041 DESCRIPTION OF CHANGES Revision to the diagnostic trouble codes Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 824 56 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 825 57 Revisions to the Throttle Position Sensor test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 826 162 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 827 166 Revisions to the Evap. Purge Flow Monitor tests Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 828 374 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 829 375 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 830 377 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 831 379 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 832 379A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 833 379B Revision to the EGR system Failure tests Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 834 432 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 835 433 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 836 434 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 837 435 Revision to the torque convertor clutch - no drop at lock up test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 838 465 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 839 467 Revision to the no temp rise seen at intake heater test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 840 514 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 841 515 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 842 516 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 843 517 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 844 518 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 845 519 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 846 520 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 847 521 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 848 521A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 849 521B Revision to the 12 volt supply relay test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 850 571 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates Throttle Position Sensor: Technical Service Bulletins Engine Controls/Emissions/A/T - Manual Updates NUMBER: 26-06-98 GROUP: Miscellaneous DATE: June, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 2.5L, 3.9L, 5.2L, 5.9L 8.0L SFI/CNG/Diesel Diagnostic Manual - Publication Number 81-699-96041 DESCRIPTION OF CHANGES Revision to the diagnostic trouble codes Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 856 56 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 857 57 Revisions to the Throttle Position Sensor test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 858 162 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 859 166 Revisions to the Evap. Purge Flow Monitor tests Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 860 374 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 861 375 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 862 377 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 863 379 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 864 379A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 865 379B Revision to the EGR system Failure tests Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 866 432 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 867 433 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 868 434 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 869 435 Revision to the torque convertor clutch - no drop at lock up test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 870 465 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 871 467 Revision to the no temp rise seen at intake heater test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 872 514 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 873 515 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 874 516 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 875 517 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 876 518 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 877 519 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 878 520 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 879 521 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 880 521A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 881 521B Revision to the 12 volt supply relay test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 882 571 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 883 Throttle Position Sensor: Technical Service Bulletins Fuel/Engine Controls - Injector Circuit/TPS Revisions NUMBER: 26-05-98F GROUP: Miscellaneous DATE: May, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 2.5L, 3.9L, 5.2L, 5.9L Truck Powertrain Diagnostic Manual - Publication Number 81-699-96041 DESCRIPTION OF CHANGES Revision to the injector connector diagram Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 884 224 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 885 225 Revision to the throttle position sensor test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 886 164 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 887 165 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 888 168 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 889 169 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 890 169A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 891 169B Revision to the TPS voltage test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 892 422 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 893 423 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 894 Throttle Position Sensor: Specifications DESCRIPTION .................................................................................................................................... .............................................................. TORQUE Throttle Position Sensor Mounting Screws ................................................................................................................................................... 7 Nm (60 in lb) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 895 Throttle Position Sensor: Locations Fig. 15 MAP And Throttle Position Sensor Location - Typical The TPS is mounted on the throttle body. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 896 Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 897 Throttle Position Sensor: Description and Operation DESCRIPTION The Throttle Position Sensor (TPS) is a variable resistor that provides the powertrain control module (PCM) with an input signal (voltage) that represents throttle blade position. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the resistance of the TPS changes. OPERATION 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 1 volt at minimum throttle opening (idle), to 4 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. This input signal is also used to determine overdrive and converter clutch shift schedule and to select the proper governor curve. Fig. 15 MAP And Throttle Position Sensor Location - Typical LOCATION The TPS is mounted on the throttle body. CIRCUIT OPERATION From the Powertrain Control Module (PCM), circuit K6 supplies 5 Volts to the Throttle Position Sensor (TPS). Circuit K6 connects to cavity A17 of the PCM. Circuit K22 delivers the TPS signal to the PCM. Circuit K22 connects to cavity A23 of the PCM. The PCM provides a ground for the TPS signal (circuit K22) through circuit K4. Circuit K4 connects to cavity A4 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Component Test Throttle Position Sensor: Testing and Inspection Component Test Fig 62 TPS To perform a complete test of the TPS and its circuitry, refer to Powertrain Management/Computers and Controls/Testing and Inspection/Diagnostic Charts. To test the TPS only, refer to the following: The TPS (Fig. 62) can be tested with a digital voltmeter. The center electrical terminal of the TPS is the output terminal. With the ignition key in the ON position, check the TPS output voltage at the center terminal wire of the connector. Check this at idle (throttle plate closed) and at wide open throttle (WOT). At idle, TPS output voltage should be greater than 0.350 millivolts but less than 900 millivolts. At wide open throttle, TPS output voltage must be less than 4.5 volts. The output voltage should increase gradually as the throttle plate is slowly opened from idle to WOT. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Component Test > Page 900 Throttle Position Sensor: Testing and Inspection Helpful Information Circuit K6 splices to supply 5 Volts to the manifold absolute pressure sensor, crankshaft position sensor and camshaft position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Crankshaft position sensor - Intake air temperature sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Page 901 Throttle Position Sensor: Service and Repair Fig 71 TPS Mounting Bolts Fig 72 Installation - Typical REMOVAL 1. Remove air duct at throttle body. 2. Disconnect TPS electrical connector. 3. Remove two TPS mounting bolts (Fig. 71). 4. Remove TPS from throttle body. NOTES: - The throttle shaft end of the throttle body slides into a socket in the TPS (Fig. 72). - The TPS must be installed so that it can be rotated a few degrees. - If the sensor will not rotate, install the sensor with the throttle shaft on the other side of the socket tangs. - The TPS will be under slight tension when rotated. INSTALLATION 1. Install the TPS and two retaining bolts. 2. Tighten bolts to 7 Nm (60 in lb) torque. 3. Manually operate the throttle control lever by hand to check for any binding of the TPS. 4. Connect TPS electrical connector to TPS. 5. Install air duct at throttle body. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations Camshaft Position Sensor: Component Locations Camshaft Position Sensor The Camshaft Position (CMP) Sensor is mounted in the distributor housing. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 907 Distributor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 908 CPS Connector Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 909 Camshaft Position Sensor: Description and Operation LOCATION The camshaft position sensor is located in the distributor on all engines. DESCRIPTION The sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft. The pulse ring rotates 180 degrees through the sync signal generator. Its signal is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. OPERATION When the leading edge of the pulse ring (shutter) enters the sync signal generator, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a sync signal of approximately 5 volts. When the trailing edge of the pulse ring (shutter) leaves the sync signal generator, the change of the magnetic field causes the sync signal voltage to switch low to 0 volts. CIRCUIT OPERATION The camshaft position sensor is located internal to the distributor on all engine applications. The Powertrain Control Module (PCM) supplies 5 Volts to the camshaft position sensor on circuit K6. Circuit K6 connects to cavity A17 of the PCM. The PCM receives the camshaft position sensor signal on circuit K44. Circuit K44 connects to cavity A18 of the PCM. The PCM provides a ground for the camshaft position sensor (circuit K44) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 910 Camshaft Position Sensor: Testing and Inspection Circuit K6 splices to supply 5 Volts to the crankshaft position sensor, manifold absolute pressure sensor, and throttle position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Crankshaft position sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 911 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor NOTE: Distributor removal is not necessary to remove camshaft position sensor. REMOVAL 1. Remove air cleaner assembly 2. Disconnect negative cable from battery 3. Remove distributor cap from distributor (two screws). 4. Disconnect camshaft position sensor wiring harness from main engine wiring harness. 5. Remove distributor rotor from distributor shaft. 6. Lift the camshaft position sensor assembly from the distributor housing. INSTALLATION 1. Install camshaft position sensor to distributor. Align sensor into notch on distributor housing. 2. Connect wiring harness. 3. Install rotor 4. Install distributor cap. Tighten mounting screws. 5. Install air cleaner assembly. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications DESCRIPTION .................................................................................................................................... .............................................................. TORQUE Crankshaft Position Sensor ................................................................................................................. .......................................................... 8 Nm (70 in lb) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 915 Crankshaft Position Sensor: Locations Crankshaft Position Sensor The sensor is located on the top of cylinder block near the rear of right cylinder head. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 916 CKP Connector Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 917 Crankshaft Position Sensor: Description and Operation Fig. 4 Sensor Operation DESCRIPTION The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. The flywheel/drive plate has groups of notches at its outer edge. there are three sets of double notches and three sets of single notches. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. OPERATION Engine speed and crankshaft position are provided through the 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. CIRCUIT OPERATION The Powertrain Control Module (PCM) supplies 5 Volts to the crankshaft position sensor on circuit K6. Circuit K6 connects to cavity A17 of the PCM. The PCM receives the crankshaft position sensor signal on circuit K24. Circuit K24 connects to cavity A8 of the PCM. The PCM provides a ground for the crankshaft position sensor (circuit K24) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector. NOTE: The engine will not operate if the PCM does not receive a crankshaft position sensor input. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 918 Crankshaft Position Sensor: Testing and Inspection Circuit K6 splices to supply 5 Volts to the camshaft position sensor, manifold absolute pressure sensor, and throttle position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 919 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor NOTE: The sensor is bolted to the top of the cylinder block near the rear of right cylinder head. The sensor is accessed by removing the right front fender liner. REMOVAL 1. Remove right front tire and right front wheelhouse liner. 2. Disconnect crankshaft position sensor pigtail harness from main wiring harness. 3. Remove two sensor (recessed hex head) mounting bolts. 4. Remove sensor from engine. INSTALLATION 1. Position crankshaft position sensor to engine. 2. Install mounting bolts and tighten to 8 Nm (70 in lb) torque. 3. Connect main harness electrical connector to sensor. 4. Install right front tire and right front wheelhouse liner. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Description and Operation Ignition Switch: Description and Operation IGNITION SWITCH AND KEY LOCK CYLINDER The ignition switch is located on the steering column. The Key-In-Switch is located in the ignition switch module. For electrical diagnosis of the Key-In-Switch, refer to Chime/Buzzer Warning Systems. For removal/installation of either the key lock cylinder or ignition switch, refer to Ignition Switch and Key Cylinder Removal/Installation. On vehicles equipped with an automatic transmission, a cable connects an interlock device within the steering column assembly to the transmission floor shift lever. This interlock device is used to lock the transmission shifter in the PARK position when the key is in the LOCKED or ACCESSORY position. The interlock device is not serviceable. If repair is necessary, the steering column assembly must be replaced. Refer to procedures. The shifter interlock cable can be adjusted or replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Description and Operation > Page 923 Ignition Switch: Service and Repair Fig 46 Shroud Removal/Installation - Typical IGNITION SWITCH AND KEY CYLINDER The ignition key must be in the key cylinder for cylinder removal. KEY CYLINDER REMOVAL 1. Disconnect negative cable from battery. 2. If equipped with tilt column, remove tilt lever by turning it counterclockwise. 3. Remove upper and lower covers (shrouds) from steering column. 4. If equipped with automatic transmission, place shifter in PARK position. Fig 47 Retaining Pin 5. A retaining pin is located at side of key cylinder assembly. a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder from ignition switch. IGNITION SWITCH REMOVAL 1. Remove key lock cylinder. Refer to previous steps. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Description and Operation > Page 924 Fig 48 Switch Mounting Screws 2. Remove 3 ignition switch mounting screws. Use tamper proof torx bit (Snap-On SDMTR10 or equivalent) to remove screws. 3. Gently pull switch away from column. Release connector locks on 7-terminal wiring connector at ignition switch and remove connector. 4. Release connector lock on 4-terminal halo lamp wiring connector and remove connector. IGNITION SWITCH AND KEY CYLINDER INSTALLATION If installing ignition key lock cylinder only, proceed to following steps 2, 3 and 4. Also refer to following steps 12 through 18. If installing both switch and key cylinder, refer to steps 1 through 18. Fig 50 Flag In RUN Position Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Description and Operation > Page 925 Fig 51 Key Cylinder - Rear View 1. Rotate flag on rear of ignition switch until in RUN position. This step must be done to allow tang on key cylinder to fit into slots within ignition switch. Fig 52 Installing Key Cylinder Into Switch 2. With key into ignition key cylinder, rotate key clockwise until retaining pin can be depressed. 3. Install key cylinder into ignition switch by aligning retaining pin into retaining pin slot. Push key cylinder into switch until retaining pin engages. After pin engages, rotate key to OFF or LOCK position. 4. Check for proper retention of key cylinder by attempting to pull cylinder from switch. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Description and Operation > Page 926 Fig 53 Ignition Switch View From Column Fig 54 Park Lock Linkage - Automatic Transmission - Typical 5. Automatic Transmission Only: Before attaching ignition switch to steering column, the transmission shifter must be in PARK position. The park lock dowel pin on rear of ignition switch must also be properly indexed into the park lock linkag before installing switch. 6. The flag at rear of ignition switch must be properly indexed into steering column before installing switch. This flag is used to operate the steering wheel lock lever in steering column. This lever allows steering wheel position to be locked when key switch is in LOCK position. 7. Place ignition switch in LOCK position. The switch is in the LOCK position when column lock flag is parallel to ignition switch terminals. 8. Automatic Transmission Only: Apply a light coating of grease to park lock dowel pin and park lock slider linkage. Before installing switch, push the park lock slider linkage forward until it bottoms. Do a final positioning by pulling it rearward about one-quarter inch. 9. Apply a light coating of grease to both column lock flag and shaft at end of flag. 10. Place ignition switch into openings on steering column. a. Automatic Transmission Only: Be sure park lock dowel pin on rear of ignition switch enters slot in park lock slider linkage. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Description and Operation > Page 927 Fig 55 Steering Wheel Lock Lever b. Be sure flag on rear of switch is positioned above steering wheel lock lever. c. Align dowel pins on rear of switch into holes on side of steering column. d. Install 3 ignition switch mounting screws. Tighten screws to 3 Nm +/- 5 Nm (26 in lb +/- 4 in lb) torque. 11. Connect electrical connectors to ignition switch and halo lamp. Make sure that switch locking tabs are fully seated in wiring connectors. 12. Install steering column covers (shrouds). Tighten screws to 2 Nm (17 in lb) torque. 13. Install tilt column lever (if equipped). 14. Connect negative cable to battery. 15. Check for proper operation of halo light. 16. Automatic Transmission Only: Shifter should lock in PARK position when key is in LOCK position (if equipped with shift lock device). Shifter should unlock when key rotated to ON position. 17. Check for proper operation of ignition switch in ACCESSORY, LOCK, OFF, ON, RUN, and START positions. 18. Steering wheel should lock when key is in LOCK position. Rotate steering wheel to verify Steering wheel should unlock when key is rotated to ON position. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches Air Bag Deactivation Switch: Technical Service Bulletins Air Bag - On/Off Switches NUMBER: 08-025-01 GROUP: Electrical DATE: Nov. 23, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-037-99, DATED NOVEMBER 12, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1999 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-00004). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS, PARTS, AND 2001 MODEL YEAR PROCEDURES. NOTE: THIS BULLETIN DOES NOT APPLY TO DIAMLERCHRYSLER CANADA DEALERS. SUBJECT: Airbag On-Off Switches MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - **2001** (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) Lebaron Coupe/Convertible 1994 - **2001** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - **2001** (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - **2001** (DN) Durango 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus **2001** (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 1993 - **2001** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - **2001** (PL) Neon 1997 (PR) Prowler **2001 (PT) PT Cruiser** **2001** (RS) Town & Country/Caravan/Voyager Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 933 1996 - 1997 (SR) Viper **2001 - 2002 (ST) Sebring Coupe/Stratus Coupe** 1997 - 2001** (TJ) Wrangler 1999 - **2001** (WJ) Grand Cherokee 1997 - **2001** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. NOTE: **SOME 2001 MODEL YEAR PACKAGES (AN/AN84/DN/JR/LH/PL/PT/RS/TJ) REQUIRE OCCUPANT RESTRAINT CONTROLLER (ORC) CONFIGURATION USING THE DRB III(R) AS DETAILED IN EACH VEHICLE SPECIFIC PACKAGE.** DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. NOTE: FOR SOME 2000 MODEL YEAR APPLICATIONS (AB/AN/AN84/DN/JA/NS) **AND SOME 2001 CARRYOVER APPLICATIONS (AB/BR/WJ/XJ)**, A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05013528AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT IS ORANGE, AND MUST BE PRESENTED TO THE CUSTOMER IN PLACE OF THE YELLOW ONE, P/N 05013517AA, THAT WILL COME IN THE AIRBAG KIT. **FOR SOME 2001 MODEL YEAR APPLICATIONS (WITH J1850 BUS, AN/AN84/DN/JR/LH/PL(PT/RS/TJ) A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05016025AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT MUST BE PRESENTED TO THE CUSTOMER AFTER INSTALLATION.** Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 934 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 935 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 936 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 937 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 938 PARTS REQUIRED: NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have~ 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available in the "Forms Folder" under "TSB/Recall" tab of MDS2 and printed on your dealership letterhead. keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 939 Air Bag Deactivation Switch: Technical Service Bulletins Air Bag System - ON-OFF Switch Availibility NO: 08-17-98 Rev. C GROUP: Electrical DATE: Dec. 30, 1998 SUBJECT: Airbag On-Off Switches THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-17-98 Rev. B DATED SEPTEMBER 18, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL MODELS HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: **1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan** 1995 - **1999** (AB) Ram Van/Wagon **1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon** 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/Convertible 1994 -**1999** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan/Voyager **1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue** 1994 - **1999** (BR) Ram Pickup **1995 - 1996 (B7) Stealth** 1998 - **1999** (DN) Durango **1995 - 1999 (FJ) Avenger/Sebring/Talon** 1995 - **1999** (JA) Breeze/Cirrus/Stratus 1996 - **1999** (JX) Sebring Convertible 1993 -**1999** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - **1999** (NS) Town & Country/Caravan/ Voyager 1995 - **1999** (PL) Neon 1996 - 1997 (SR) Viper 1997 - **1999** (TJ) Wrangler 1997 - **1999** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. Other applicable passenger vehicles will be announced as soon as the switches are available. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 940 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 941 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 942 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 943 PARTS REQUIRED: Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 944 NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have. 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available on T.I.L. and printed on your dealership letterhead. Keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 945 POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation Impact Sensor: Description and Operation DESCRIPTION Airbag Control Module Remove/Install The impact sensor provides verification of the direction and severity of an impact. One impact sensor is used. It is located inside the Airbag Control Module (ACM), which is secured to a bracket on the floor pan transmission tunnel inside the vehicle. OPERATION The impact sensor is an accelerometer that senses the rate of deceleration. The microprocessor in the ACM monitors the impact sensor signal. A pre-programmed decision algorithm in the microprocessor determines when the deceleration rate indicates an impact is severe enough to require airbag system protection. When the programmed conditions are met, the ACM sends an electrical signal to deploy the airbag system components. The impact sensor is calibrated for the specific vehicle. The sensor is only serviced as a unit with the ACM. The sensor cannot be repaired or adjusted and, if faulty or damaged, the ACM unit must be replaced. CIRCUIT OPERATION The Airbag system uses a sensor internal to the Airbag Control Module (ACM) to detect impact. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations Battery Temp. Sensor Location Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 953 Battery Temp. Sensor Connector Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 954 Battery Temperature Sensor: Service Precautions WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN . Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 955 Battery Temperature Sensor: Description and Operation SYSTEM OPERATION The battery temperature sensor 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. CIRCUIT OPERATION The Powertrain Control Module (PCM) determines battery temperature on circuit K118. Circuit K118 connects the PCM to the battery temperature sensor. Circuit K4 provides ground for the sensor. Circuit K118 connects to cavity C15 of the PCM. Circuit K4 connects to cavity A4. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Testing and Inspection > Testing Battery Temperature Sensor: Testing and Inspection Testing To perform a complete test of this sensor and its circuitry, refer to the appropriate Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Charts Procedures. To test the sensor only, refer to the following: Battery Temperature Sensor 1. The sensor is located under the battery and is attached to the battery tray. A two-wire pigtail harness is attached directly to the sensor. The opposite end of this harness connects the sensor to the engine wiring harness. 2. Disconnect the two-wire pigtail harness from the engine harness. 3. Attach ohmmeter leads to the wire terminals of the pigtail harness. 4. At room temperature of 25 °C (75 - 80 °F), an ohmmeter reading of 9,000 (9K) to 11,000 (11K) ohms should be observed. 5. If reading is above or below the specification, replace the sensor. 6. Refer to the Removal and Installation for procedures. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Testing and Inspection > Page 958 Battery Temperature Sensor: Service and Repair Battery Temperature Sensor The battery temperature sensor is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray. The sensor is located under the battery on drivers side of vehicle. REMOVAL 1. Remove battery. 2. Disconnect sensor pigtail harness from engine wire harness. 3. Pry sensor straight up from battery tray mounting hole. INSTALLATION 1. Feed pigtail harness through mounting hole in top of battery tray and press sensor into top of tray (snaps in). 2. Connect pigtail harness. 3. Install battery. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Description and Operation Clutch Switch: Description and Operation A clutch pedal position switch has been added to the starter circuit. The switch, which is in circuit with the starter solenoid, requires that the clutch pedal be fully depressed in order to start the engine. The switch is located on the clutch master cylinder push rod. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Description and Operation Ignition Switch: Description and Operation IGNITION SWITCH AND KEY LOCK CYLINDER The ignition switch is located on the steering column. The Key-In-Switch is located in the ignition switch module. For electrical diagnosis of the Key-In-Switch, refer to Chime/Buzzer Warning Systems. For removal/installation of either the key lock cylinder or ignition switch, refer to Ignition Switch and Key Cylinder Removal/Installation. On vehicles equipped with an automatic transmission, a cable connects an interlock device within the steering column assembly to the transmission floor shift lever. This interlock device is used to lock the transmission shifter in the PARK position when the key is in the LOCKED or ACCESSORY position. The interlock device is not serviceable. If repair is necessary, the steering column assembly must be replaced. Refer to procedures. The shifter interlock cable can be adjusted or replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Description and Operation > Page 965 Ignition Switch: Service and Repair Fig 46 Shroud Removal/Installation - Typical IGNITION SWITCH AND KEY CYLINDER The ignition key must be in the key cylinder for cylinder removal. KEY CYLINDER REMOVAL 1. Disconnect negative cable from battery. 2. If equipped with tilt column, remove tilt lever by turning it counterclockwise. 3. Remove upper and lower covers (shrouds) from steering column. 4. If equipped with automatic transmission, place shifter in PARK position. Fig 47 Retaining Pin 5. A retaining pin is located at side of key cylinder assembly. a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder from ignition switch. IGNITION SWITCH REMOVAL 1. Remove key lock cylinder. Refer to previous steps. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Description and Operation > Page 966 Fig 48 Switch Mounting Screws 2. Remove 3 ignition switch mounting screws. Use tamper proof torx bit (Snap-On SDMTR10 or equivalent) to remove screws. 3. Gently pull switch away from column. Release connector locks on 7-terminal wiring connector at ignition switch and remove connector. 4. Release connector lock on 4-terminal halo lamp wiring connector and remove connector. IGNITION SWITCH AND KEY CYLINDER INSTALLATION If installing ignition key lock cylinder only, proceed to following steps 2, 3 and 4. Also refer to following steps 12 through 18. If installing both switch and key cylinder, refer to steps 1 through 18. Fig 50 Flag In RUN Position Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Description and Operation > Page 967 Fig 51 Key Cylinder - Rear View 1. Rotate flag on rear of ignition switch until in RUN position. This step must be done to allow tang on key cylinder to fit into slots within ignition switch. Fig 52 Installing Key Cylinder Into Switch 2. With key into ignition key cylinder, rotate key clockwise until retaining pin can be depressed. 3. Install key cylinder into ignition switch by aligning retaining pin into retaining pin slot. Push key cylinder into switch until retaining pin engages. After pin engages, rotate key to OFF or LOCK position. 4. Check for proper retention of key cylinder by attempting to pull cylinder from switch. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Description and Operation > Page 968 Fig 53 Ignition Switch View From Column Fig 54 Park Lock Linkage - Automatic Transmission - Typical 5. Automatic Transmission Only: Before attaching ignition switch to steering column, the transmission shifter must be in PARK position. The park lock dowel pin on rear of ignition switch must also be properly indexed into the park lock linkag before installing switch. 6. The flag at rear of ignition switch must be properly indexed into steering column before installing switch. This flag is used to operate the steering wheel lock lever in steering column. This lever allows steering wheel position to be locked when key switch is in LOCK position. 7. Place ignition switch in LOCK position. The switch is in the LOCK position when column lock flag is parallel to ignition switch terminals. 8. Automatic Transmission Only: Apply a light coating of grease to park lock dowel pin and park lock slider linkage. Before installing switch, push the park lock slider linkage forward until it bottoms. Do a final positioning by pulling it rearward about one-quarter inch. 9. Apply a light coating of grease to both column lock flag and shaft at end of flag. 10. Place ignition switch into openings on steering column. a. Automatic Transmission Only: Be sure park lock dowel pin on rear of ignition switch enters slot in park lock slider linkage. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Description and Operation > Page 969 Fig 55 Steering Wheel Lock Lever b. Be sure flag on rear of switch is positioned above steering wheel lock lever. c. Align dowel pins on rear of switch into holes on side of steering column. d. Install 3 ignition switch mounting screws. Tighten screws to 3 Nm +/- 5 Nm (26 in lb +/- 4 in lb) torque. 11. Connect electrical connectors to ignition switch and halo lamp. Make sure that switch locking tabs are fully seated in wiring connectors. 12. Install steering column covers (shrouds). Tighten screws to 2 Nm (17 in lb) torque. 13. Install tilt column lever (if equipped). 14. Connect negative cable to battery. 15. Check for proper operation of halo light. 16. Automatic Transmission Only: Shifter should lock in PARK position when key is in LOCK position (if equipped with shift lock device). Shifter should unlock when key rotated to ON position. 17. Check for proper operation of ignition switch in ACCESSORY, LOCK, OFF, ON, RUN, and START positions. 18. Steering wheel should lock when key is in LOCK position. Rotate steering wheel to verify Steering wheel should unlock when key is rotated to ON position. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Specifications Neutral Safety Switch: Specifications Mounting Bolts ..................................................................................................................................... .................................................... 34 Nm (25 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Specifications > Page 973 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Specifications > Page 974 Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Specifications > Page 975 Neutral Safety Switch: Description and Operation DESCRIPTION The park/neutral switch is located on the transmission housing and provides an input to the powertrain control module (PCM). This will indicate that the automatic transmission is in Park, Neutral or a drive gear selection. OPERATION This input is used to determine idle speed (varying with gear selection), fuel injector pulse width, ignition timing advance and vehicle speed control operation. CIRCUIT OPERATION Park/Neutral Position Switch When closed, the case-grounded Park/Neutral position switch provides a ground path on circuit T41 for the coil side of the engine starter motor relay Circuit A41 from the ignition switch provides battery voltage to the coil side of the relay. Circuit T41 splices to cavity A6 of the Powertrain Control Module (PCM). The Park/Neutral position switch provides an input to the PCM. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Specifications > Page 976 Neutral Safety Switch: Testing and Inspection NOTE: The center terminal of the park/neutral position switch is the starter-circuit terminal. It provides the ground for the starter solenoid circuit through the selector lever in PARK and NEUTRAL positions only. The outer terminals on the switch are for the backup lamp circuit. To test the switch, remove the wiring connector. Test for continuity between the center terminal and the transmission case. Continuity should exist only when the transmission is in PARK or NEUTRAL. Shift the transmission into REVERSE and test continuity at the switch outer terminals. Continuity should exist only when the transmission is in REVERSE. Continuity should not exist between the outer terminals and the case. Check gearshift linkage adjustment before replacing a switch that tests faulty. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Specifications > Page 977 Neutral Safety Switch: Service and Repair REPLACEMENT 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. 4. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 5. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 6. Test continuity of new switch with 12V test lamp. 7. Connect switch wires and lower vehicle. 8. Top off transmission fluid. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Power Steering - Pressure Switch Torque Revisions Power Steering Pressure Switch: Technical Service Bulletins Power Steering - Pressure Switch Torque Revisions NUMBER: 26-10-96B GROUP: Miscellaneous DATE: October, 1996 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 Dakota - Publication Number 81-270-7146 DESCRIPTION OF CHANGES Revised power steering pressure switch torque (124-195 In. Lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Power Steering - Pressure Switch Torque Revisions > Page 984 14-65 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Power Steering - Pressure Switch Torque Revisions > Page 985 14-66 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Page 986 Power Steering Pressure Switch: Specifications The content of this article reflects changes called for in TSB 26-10-96. Power Steering Pressure Switch ................................................................................................................................................ 14-22 Nm (124-195 in.lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) 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 > Technical Service Bulletins > Customer Interest for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm Fluid Pressure Sensor/Switch: Customer Interest A/T - Engine Bucking/Surging at 5,300 Rpm NO: 18-19-98 GROUP: Driveability DATE: Apr. 10, 1998 SUBJECT: Vehicle Bucking During Wide Open Throttle Acceleration MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE JAN 16, 1998 MDH (0116XX) EQUIPPED WITH GASOLINE ENGINES AND A 42/44/46 OR 47RE TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may experience bucking during wide open throttle (WOT) acceleration. The bucking occurs at approximately 5300 RPM. This condition may be caused by reaching the high RPM fuel shut off rev limit before the transmission can shift into the next higher gear and is most likely to occur with high electrical loads (high beams on, heated back lite, heated seats, radio, HVAC blower on MAX etc.). During high current demands, the generator may emit electrical noise that can affect the transmission governor pressure sensor output. If this occurs, the transmission may not shift properly to the next higher gear under (WOT) acceleration conditions and therefore reach the fuel shut off rev limiter. This may be seen most often between the 2-3 shift but can also be experienced between the 1-2 shift. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. NOTE: ONLY PERFORM THE FOLLOWING PROCEDURE SAFELY ON A HIGHWAY OR ROAD OBEYING ALL POSTED SPEED LIMITS AND LAWS. Attempt to duplicate the condition by switching on all accessory loads and driving the vehicle with WOT accelerations through a shift sequence to see if the engine will reach the fuel shut off rev limiter before the 2-3 or 1-2 shift is made. If the bucking condition is experienced at approximately 5300 RPM before making the appropriate upshifts, switch off all electrical loads and repeat the procedure. Repeat the procedure with the electrical loads on and off a second time. If the bucking occurs with the electrical loads on and does not occur with the loads off, perform the Repair Procedure. PARTS REQUIRED: 1 56041403AA Sensor, Governor Pressure REPAIR PROCEDURE: This bulletin involves installing a newly designed governor pressure sensor. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) 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 > Technical Service Bulletins > Customer Interest for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm > Page 997 1. Following the procedures in the applicable service manual, replace the governor pressure sensor with p/n 56041403AA (Figure 1). 2. Check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-96-06-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm Fluid Pressure Sensor/Switch: All Technical Service Bulletins A/T - Engine Bucking/Surging at 5,300 Rpm NO: 18-19-98 GROUP: Driveability DATE: Apr. 10, 1998 SUBJECT: Vehicle Bucking During Wide Open Throttle Acceleration MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE JAN 16, 1998 MDH (0116XX) EQUIPPED WITH GASOLINE ENGINES AND A 42/44/46 OR 47RE TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may experience bucking during wide open throttle (WOT) acceleration. The bucking occurs at approximately 5300 RPM. This condition may be caused by reaching the high RPM fuel shut off rev limit before the transmission can shift into the next higher gear and is most likely to occur with high electrical loads (high beams on, heated back lite, heated seats, radio, HVAC blower on MAX etc.). During high current demands, the generator may emit electrical noise that can affect the transmission governor pressure sensor output. If this occurs, the transmission may not shift properly to the next higher gear under (WOT) acceleration conditions and therefore reach the fuel shut off rev limiter. This may be seen most often between the 2-3 shift but can also be experienced between the 1-2 shift. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. NOTE: ONLY PERFORM THE FOLLOWING PROCEDURE SAFELY ON A HIGHWAY OR ROAD OBEYING ALL POSTED SPEED LIMITS AND LAWS. Attempt to duplicate the condition by switching on all accessory loads and driving the vehicle with WOT accelerations through a shift sequence to see if the engine will reach the fuel shut off rev limiter before the 2-3 or 1-2 shift is made. If the bucking condition is experienced at approximately 5300 RPM before making the appropriate upshifts, switch off all electrical loads and repeat the procedure. Repeat the procedure with the electrical loads on and off a second time. If the bucking occurs with the electrical loads on and does not occur with the loads off, perform the Repair Procedure. PARTS REQUIRED: 1 56041403AA Sensor, Governor Pressure REPAIR PROCEDURE: This bulletin involves installing a newly designed governor pressure sensor. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm > Page 1003 1. Following the procedures in the applicable service manual, replace the governor pressure sensor with p/n 56041403AA (Figure 1). 2. Check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-96-06-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) 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 > Technical Service Bulletins > Page 1004 Fluid Pressure Sensor/Switch: Description and Operation NOTE: This input is used with 4-speed electronic transmissions only DESCRIPTION The transmission governor pressure sensor provides a signal proportional to the transmission governor pressure. OPERATION It provides feedback for control of the variable force solenoid, which regulates transmission governor pressure. CIRCUIT OPERATION The governor pressure sensor supplies the transmission pressure input to the Powertrain Control Module on circuit T25. Circuit T25 connects to cavity B29 of the PCM. Circuit K7 from cavity B31 of the PCM supplies 5 Volts to the sensor. The PCM provides ground for the governor pressure sensor on circuit K4. Circuit K4 connects to cavity A4 of the PCM. The governor pressure sensor is part of the transmission solenoid assembly. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Description and Operation > Switch Operation Overdrive Switch: Description and Operation Switch Operation The overdrive OFF (control) switch is located on the gearshift lever. The switch is a momentary contact device that signals the Powertrain Control Module (PCM) to toggle current status of the overdrive function. 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 Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Description and Operation > Switch Operation > Page 1009 Overdrive Switch: Description and Operation Overdrive Override Switch-PCM Input PURPOSE On vehicles equipped with an automatic transmission and overdrive, the powertrain control module (PCM) regulates the 3-4 overdrive up-shift and downshift through the overdrive solenoid. OPERATION This solenoid is located in the transmission. An overdrive/override push-button switch is located at the end of transmission shift lever. This solenoid is located in the transmission. An overdrive/override push-button switch is located at the end of the transmission shift lever. The overdrive/override push-button switch is normally open (overdrive allowed) when the lamp is not illuminated. It momentarily closes (overdrive not allowed) when the operator presses the switch and the lamp is illuminated. Overdrive will revert to ON (lamp off) each time the ignition switch in turned on. The transmission downshifts if the operator presses the override switch while in overdrive. CIRCUIT OPERATION Automatic transmission equipped vehicles may have an overdrive switch. The operator disables or enables overdrive when the switch is depressed. The overdrive switch consists of a switch connected to the Powertrain Control Module (PCM), an illumination lamp and an overdrive ON/OFF indicator lamp. If overdrive is currently enabled, it is disabled when the operator depresses the overdrive switch. Conversely, if the operator already disabled over-drive, it is enabled when the switch is depressed. Circuit T6 from the overdrive switch connects to cavity C13 of the PCM and provides the overdrive signal. The PCM turns the overdrive ON/OFF indicator lamp ON or OFF by providing a ground for the lamp on circuit T18. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1013 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. 4. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 5. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 6. Test continuity of new switch with 12V test lamp. 7. Connect switch wires and lower vehicle. 8. Top off transmission fluid level. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) 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 Sensor Mounting ................................................................................................................................. ..................................................... 27 Nm (20 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) 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 1017 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) 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 1018 Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) 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 > Output Shaft Speed Sensor-PCM Input Transmission Speed Sensor: Description and Operation Output Shaft Speed Sensor-PCM Input This sensor generates a signal to the PCM relating to the speed of the transmission main drive shaft. NOTE: This input is used with 4-speed electronic transmissions only. CIRCUIT OPERATION Four Speed Automatic Transmission The output shaft speed sensor generates a signal indicating the speed of the transmission output shaft. Circuits T13 and T14 connect the sensor to the Powertrain Control Module (PCM). Circuit T13 connects to cavity B25 of the PCM. Circuit T14 connects to cavity B28. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) 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 > Output Shaft Speed Sensor-PCM Input > Page 1021 Transmission Speed Sensor: Description and Operation Sensor Operation The speed sensor is located in the overdrive gear case. The sensor is positioned over the park gear and monitors transmission output shaft rotating speed. Speed sensor signals are triggered by the park gear lugs as they rotate past the sensor pickup face. Input signals from the sensor are sent to the transmission control module for processing. The vehicle speed sensor also serves as a backup for the transmission speed sensor. Signals from this sensor are shared with the powertrain control module. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) 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 > Page 1022 Transmission Speed Sensor: Service and Repair Removal Transmission Speed Sensor Removal Installation 1. Remove transmission speed sensor and O-ring seal from overdrive case. Installation 1. Install transmission speed sensor and O-ring seal in overdrive case. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations Governor Pressure Sensor, Transmission Temperature Sensor, Governor Pressure Solenoid, Governor The transmission temperature sensor is located in the transmission solenoid assembly in the valve body. The governor pressure sender and the transmission fluid temperature thermistor are separate sensors in the same component. This component is attached to the governor body in the solenoid assembly of the valve body. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) 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 - Description and Operation Transmission Temperature Sensor/Switch: Description and Operation Transmission Temperature Sensor - Description and Operation Transmission fluid temperature readings are supplied to the transmission control module by the thermistor. The temperature readings are used to control engagement of the fourth gear overdrive clutch, the converter clutch, and governor pressure. Normal resistance value for the thermistor at room temperature is approximately 1000 ohms. The PCM prevents engagement of the converter clutch and overdrive clutch, when fluid temperature is below approximately 10 °C (50 °F). If fluid temperature exceeds 126 °C (260 °F), the PCM causes a 4-3 downshift and engage the converter clutch. Engagement is according to the third gear converter clutch engagement schedule. The overdrive OFF lamp in the instrument panel illuminates when the shift back to third occurs. The transmission will not allow fourth gear operation until fluid temperature decreases to approximately 110 °C (230 °F). The thermistor is part of the governor pressure sensor assembly and is immersed in transmission fluid at all times. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) 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 - Description and Operation > Page 1028 Transmission Temperature Sensor/Switch: Description and Operation Transmission Temperature Sensor - PCM Input NOTE: This input is used in the shift operation for 4-speed electronic transmissions only. The temperature data is used for: torque converter clutch operation, overdrive shift, low temperature shift compensation, wide open throttle shift strategy and governor pressure transducer calibration. CIRCUIT OPERATION The transmission temperature sensor is located in the transmission solenoid assembly. The sensor is a variable resistor, as transmission temperature changes the resistance in the sensor changes. Circuit T34 connects from the Powertrain Control Module (PCM) to the sensor. Ground for the sensor is supplied on circuit K4. This circuit is the ground circuit for many of the components used in the fuel/ignition system. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Description and Operation Power Window Switch: Description and Operation SYSTEM OPERATION The power windows are controlled by two-way momentary switches mounted in a bezel on the trim panel of each front door. A second power window switch on the left side allows the driver to control the passenger side window. The power windows will only operate when the ignition switch is in the On position. Both front door windows can be raised or lowered electrically by operating the power window switches. The switches control the battery and ground feeds to the power window motors. The power window switches cannot be repaired and, if faulty or damaged, they must be replaced. CIRCUIT OPERATION Driver Side Switch Circuit F21 supplies voltage to the right power window switch for raising and lowering the windows. When the drivers side switch is put in the DOWN position, the switch supplies voltage to circuit Q26. Circuit Q26 connects to the down side of the passenger side switch. Voltage passes through the passenger side switch to the window motor on circuit Q22. The ground path from the motor is on circuit Q12 back through the passenger side switch to circuit Q16, through the drivers side switch to ground on circuit Z1. When the drivers side switch is put in the UP position, the switch supplies voltage to circuit Q16. Circuit Q16 connects to the UP side of the passenger side switch. Voltage passes through the passenger's side switch to the window motor on circuit Q12. The ground path from the motor is on circuit Q22 back through the passenger's side switch to circuit Q26, through the drivers side switch to ground on circuit Z1. Passenger Side Switch Circuit F21 splices to supply voltage to the right window switch on the passenger side of the vehicle. When the passenger side switch is put in the DOWN position, the switch supplies voltage to the motor on circuit Q22. The ground path from the motor is on circuit Q12 back through the passenger side switch to circuit Q16, through the drivers side switch to ground on circuit Z1. In the UP position, the passenger side switch supplies voltage to the window motor on circuit Q12. The ground path from the motor is on circuit Q22 back through the passenger side switch to circuit Q26, through the drivers side switch to ground on circuit Z1. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Helpful Information Power Window Switch: Testing and Inspection Helpful Information - Check fuse E in the PDC. - Check the circuit breaker in cavity 20 of the junction block. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Helpful Information > Page 1035 Power Window Switch: Testing and Inspection Power Window Switch Test Before you proceed with this diagnosis, confirm proper circuit breaker operation. See the diagnosis for the Circuit Breaker. 1. Remove the switch from the trim panel as described. Carefully separate the wire harness connector from the switch body. Left Side Switch Continuity Right Side Switch Continuity 2. Check the switch continuity in each position, as shown in the charts. If OK, see the Power Window Motor diagnosis. If not OK, replace the faulty switch. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Page 1036 Power Window Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Power Window And Lock Switches Remove/Install 2. Using a wide flat-bladed tool such as a trim stick, gently pry the upper edge of the power lock and power window switch bezel to release the snap clip retainer that secures the bezel to the door trim panel. 3. Pull the switch bezel away from the door trim panel far enough to access the wire harness connectors. 4. Gently pry the locking tabs of the wire harness connectors away from the switches and carefully unplug the switches. 5. Using a wide flat-bladed tool such as a trim stick, gently pry the sides of the switch cavity on the back of the switch bezel to release the power window switch from the bezel. 6. Reverse the removal procedures to install. When installing the switch bezel to the door trim panel, insert the rear of the bezel into the trim panel opening, then push down on the front of the bezel until the retaining tab snaps into place. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Service and Repair Washer Fluid Level Switch: Service and Repair REMOVAL 1. Remove the washer reservoir as described. NOTE: The pivoting float of the washer fluid sensor must be in a horizontal position within the reservoir in order to be removed. With the reservoir empty and held in an upright position, the pivoting float will orient itself to the horizontal position when the sensor connector is pointed straight downwards. 2. Gently pry the washer fluid level sensor out of the rubber grommet seal. Care must be taken not to damage the reservoir. 3. Remove the rubber grommet seal from the reservoir and discard. 4. Reverse the removal procedures to install. Always use a new rubber grommet seal on the reservoir. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation Windshield Washer Switch: Description and Operation SYSTEM OPERATION Multi-Function Switch Wiper Switch And Washer Switch The windshield wiper and washer switches are contained in the multi-function switch assembly. The multi-function switch assembly is secured to the left side of the steering column. The multi-function switch contains circuitry for the following functions: Turn signals - Hazard warning - Headlamp beam selection - Headlamp optical horn - Windshield wipers - Windshield washers. The information contained addresses only the switch functions for the wiper and washer systems. However, the multi-function switch cannot be repaired. If any function of the multi-function switch is faulty, or if the switch is damaged, the entire switch assembly must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation > Page 1044 Windshield Washer Switch: Testing and Inspection Perform the diagnosis for the wiper system and/or washer system as described before testing the multi-function switch. WARNING: ON VEHICLES EQUIPPED WITH AN AIRBAG, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Unplug the multi-function switch wire harness connector as described. Multi-Function Switch Continuity 2. Using an ohmmeter, perform the switch continuity checks at the switch terminals as shown in the Multi-Function Switch Continuity chart. 3. If the switch fails any of the continuity checks, replace the faulty switch. If the switch is OK, repair the wiper system and/or washer system wire harness circuits as required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation > Page 1045 Windshield Washer Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is so equipped, remove the tilt steering column lever. Steering Column Shrouds Remove/Install - Typical 3. Remove both the upper and lower shrouds from the steering column. 4. Remove the lower fixed column shroud. Multi-Function Switch Connector - Typical 5. Move the upper fixed column shroud to gain access to the rear of the multi-function switch. 6. Remove the multi-function switch tamper proof mounting screws (a Snap On tamper proof torx bit TTXR20B2 or equivalent is required). 7. Gently pull the switch away from the column. Loosen the wire harness connector screw. The screw will remain in the wire harness connector. 8. Unplug the wire harness connector from the multi-function switch. 9. Reverse the removal procedures to install. Tighten the fasteners as follows: - Multi-function switch wire harness connector screw - 2 N.m (17 in. lbs.) - Multi-function switch retaining screws - 2 N.m (17 in. lbs.). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation Wiper Switch: Description and Operation SYSTEM OPERATION Multi-Function Switch Wiper Switch And Washer Switch The windshield wiper and washer switches are contained in the multi-function switch assembly. The multi-function switch assembly is secured to the left side of the steering column. The multi-function switch contains circuitry for the following functions: Turn signals - Hazard warning - Headlamp beam selection - Headlamp optical horn - Windshield wipers - Windshield washers. The information contained addresses only the switch functions for the wiper and washer systems. However, the multi-function switch cannot be repaired. If any function of the multi-function switch is faulty, or if the switch is damaged, the entire switch assembly must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 1049 Wiper Switch: Testing and Inspection Perform the diagnosis for the wiper system and/or washer system as described before testing the multi-function switch. WARNING: ON VEHICLES EQUIPPED WITH AN AIRBAG, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Unplug the multi-function switch wire harness connector as described. Multi-Function Switch Continuity 2. Using an ohmmeter, perform the switch continuity checks at the switch terminals as shown in the Multi-Function Switch Continuity chart. 3. If the switch fails any of the continuity checks, replace the faulty switch. If the switch is OK, repair the wiper system and/or washer system wire harness circuits as required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 1050 Wiper Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is so equipped, remove the tilt steering column lever. Steering Column Shrouds Remove/Install - Typical 3. Remove both the upper and lower shrouds from the steering column. 4. Remove the lower fixed column shroud. Multi-Function Switch Connector - Typical 5. Move the upper fixed column shroud to gain access to the rear of the multi-function switch. 6. Remove the multi-function switch tamper proof mounting screws (a Snap On tamper proof torx bit TTXR20B2 or equivalent is required). 7. Gently pull the switch away from the column. Loosen the wire harness connector screw. The screw will remain in the wire harness connector. 8. Unplug the wire harness connector from the multi-function switch. 9. Reverse the removal procedures to install. Tighten the fasteners as follows: - Multi-function switch wire harness connector screw - 2 N.m (17 in. lbs.) - Multi-function switch retaining screws - 2 N.m (17 in. lbs.). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications Alignment: Specifications CASTER: Preferred Setting ................................................................................................................................. ....................................................................... +3.9° Range ................................................................ ................................................................................................................ (+3.9° +/-0.70°) +3.2° to +4.6° Max RH/LH Difference ............................................................................................................... .............................................................................. 0.50° CAMBER: Preferred Setting ................................................................................................................................. ..................................................................... +0.38° Range ................................................................ ........................................................................................................... (+0.38° +/-0.50°) -0.12° to +0.88° Max RH/LH Difference ............................................................................................................. ................................................................................ 0.50° TOTAL TOE: Preferred Setting ................................................................................................................................. ..................................................................... +0.15° Range ................................................................ .......................................................................................................... (+0.15° +/-0.10°) +0.05° to +0.25° Max RH/LH Difference ............................................................................................................. ..................................................................................... 0° Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1055 Alignment: Description and Operation CAUTION: Do not attempt to modify any suspension or steering component by heating and bending. DESCRIPTION Wheel alignment involves the correct positioning of the wheels in relation to the vehicle. The positioning is accomplished through suspension and steering linkage adjustments. An alignment is considered essential for efficient steering, good directional stability and to minimize tire wear. The most important measurements of an alignment are caster, camber and toe. Caster - is the forward or rearward tilt of the steering knuckle from vertical. Tilting the top of the knuckle forward provides negative caster. Tilting the top of the knuckle rearward provides positive caster. Positive caster promotes directional stability. This angle enables the front wheels to return to a straight ahead position after turns. Camber - is the inward or outward tilt of the wheel relative to the center of the vehicle. Tilting the top of the wheel inward provides negative camber. Tilting the top of the wheel outward provides positive camber. Incorrect camber will cause wear on the inside or outside edge of the tire. Toe - is the difference between the leading inside edges and trailing inside edges of the front tires. Uneven wheel toe position cause's unstable steering, uneven tire wear and steering wheel off-center. The wheel toe position is the final front wheel alignment adjustment. Steering Axis Inclination Angle - is measured in degrees. It is the angle that the steering knuckles are tilted. The inclination angle has a fixed relationship with the camber angle. It will not change except when a spindle or ball stud is damaged or bent. The angle is not adjustable and the damaged component(s) must be replaced to correct the alignment. NOTE: Routine inspection of the front suspension and steering components is a good preventative maintenance practice. Inspection also helps to ensure safe operation of the vehicle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1056 Alignment: Testing and Inspection PRE-ALIGNMENT INSPECTION Before starting wheel alignment, the following inspection and necessary corrections must be completed. Refer to Suspension and Steering System Diagnosis Chart. See: Steering and Suspension/Testing and Inspection 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1057 Alignment: Service and Repair CAMBER AND CASTER ADJUSTMENT Camber and caster angle adjustments involve changing the position of the upper suspension arm pivot bar. Adjuster C-4576 can be used to make camber/caster adjustments. CASTER Move only the rear position of the pivot bar in or out. This will change the caster angle significantly and camber angle only slightly. To retain the camber while adjusting caster, move the rear pivot bar in or out. Move the forward pivot very slightly in the opposite direction. The caster angle should be adjusted as close as possible to the preferred specification. NOTE: For example, to increase a positive caster angle, move the rear position of the pivot bar inward (toward the engine). Move the front of pivot bar outward (away from the engine) slightly until the original camber angle is obtained. CAMBER Move only the forward position of the pivot bar in or out. This will change the camber angle significantly and caster angle only slightly. The camber angle should be adjusted as close as possible to the preferred specification. After adjustment is made tighten the pivot bar nuts to proper torque specification. TOE ADJUSTMENT The wheel toe position adjustment should be the final adjustment. 1. Start the engine and turn wheels both ways before straightening the wheels. Secure the steering wheel with the front wheels in the straight-ahead position. 2. Loosen the tie rod jam nuts. NOTE: Each front wheel should be adjusted for one-half of the total toe position specification. This will ensure the steering wheel will be centered when the wheels are positioned straight-ahead. 3. Adjust the wheel toe position by turning the tie rod as necessary. 4. Tighten the tie rod jam nut to 75 Nm (55 ft. lbs.). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1058 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Fuel Pressure Gauge Adapter - Usage Fuel Pressure: Technical Service Bulletins Fuel Pressure Gauge Adapter - Usage NO: 14-03-98 GROUP: Fuel DATE: May 1, 1998 SUBJECT: Fuel Pressure Gauge Adapter Usage MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) DISCUSSION: Currently, four different fuel pressure adapters are required, depending on application, to attach a fuel gauge for pressure testing. The matrix lists the adapter part numbers and their application. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Pressure, Vacuum and Temperature Specifications Fuel Pressure: Pressure, Vacuum and Temperature Specifications Fuel Pressure Engine at curb idle ............................................................................................................................... ........................................ 339 ± 34 kPa (49.2 ± 5 psi) Pressure Leakdown (fuel pump not engaged) ................................................................................................................. Not fall below 30 psi for 5 minutes Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Pressure, Vacuum and Temperature Specifications > Page 1066 Fuel Pressure: Capacity Specifications NOTE: Before performing this test, vent fuel pump pressure by performing the Fuel Pump Pressure Test. Use this test in conjunction with the Fuel Pressure Leak Down Test. 1. Release fuel system pressure. Refer to the Fuel Pressure Release Procedure. 2. Disconnect fuel supply line at fuel rail. Some engines may require air cleaner housing removal before line disconnection. 3. Connect appropriate Fuel Line Pressure Test Adapter Tool Hose (number 6631, 6923, 6541 or 6539) into disconnected fuel supply line. Insert other end of Adaptor Tool hose into a graduated container. 4. Remove fuel fill cap. 5. To activate fuel pump and pressurize system, obtain DRB scan tool and actuate ASD Fuel System Test. 6. A good fuel pump will deliver at least 1/4 liter of fuel in 7 seconds. Do not operate fuel pump for longer than 7 seconds with fuel line disconnected as fuel pump module reservoir may run empty. a. If capacity is lower than specification, but fuel pump can be heard operating through fuel fill cap opening, check for a kinked/damaged fuel supply line somewhere between fuel rail and fuel pump module. b. If line is not kinked/damaged, and fuel pressure is OK, but capacity is low, replace fuel filter/ fuel pressure regulator. The filter/regulator may be serviced separately on certain applications. Refer to Fuel Filter/Fuel Pressure Regulator Removal/Installation for additional information. c. If both fuel pressure and capacity are low, replace fuel pump module assembly Refer to Fuel Pump Module Removal/Installation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test Fuel Pressure: Testing and Inspection Fuel Pressure Leak Down Test Fig 11 Connecting Adapter Tool - Typical Fig 12 Connecting Adapter Tool - Typical NOTE: Use this test in conjunction with the Fuel Pump Pressure Test and Fuel Pump Capacity Test. Check Valve Operation: The electric fuel pump outlet contains a one-way check valve to prevent fuel flow back into the tank and to maintain fuel supply line pressure (engine warm) when pump is not operational. It is also used to keep the fuel supply line full of gasoline when pump is not operational. After the vehicle has cooled down, fuel pressure may drop to 0 psi (cold fluid contracts), but liquid gasoline will remain in fuel supply line between the check valve and fuel injectors. Fuel pressure that has dropped to 0 psi on a cooled down vehicle (engine off) is a normal condition. when the electric fuel pump is activated, fuel pressure should immediately rise to specification. Abnormally long periods of cranking to restart a hot engine that has been shut down for a short period of time may be caused by: ^ Fuel pressure bleeding past a fuel injector(s). ^ Fuel pressure bleeding past the check valve in the fuel pump module. Procedure 1. Disconnect the fuel inlet line at fuel rail. - On some engines, air cleaner housing removal may be necessary before fuel line disconnection. 2. Connect the appropriate Fuel Line Pressure Test Adapter Tool (number 6539, 6631, 6541 or 6923) between the disconnected fuel line and fuel rail (Fig. 11) or (Fig. 12). 3. Connect the 0-414 kPa (0-60 psi) fuel pressure test gauge (from Gauge Set 5069) to the test port on the appropriate Adaptor Tool. - The fittings on both tools must be in good condition and free from any small leaks before performing the proceeding test. 4. Start engine and bring to normal operating temperature. 5. Observe test gauge. Normal operating pressure should be 339 kPa +/- 34 kPa (49.2 psi +/- 5 psi). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 1069 6. Shut engine off. 7. Pressure should not fall below 30 psi for five minutes. 8. If pressure falls below 30 psi, it must be determined if a fuel injector, the check valve within the fuel pump module, or a fuel tube/line is leaking. 9. Again, start engine and bring to normal operating temperature. 10. Shut engine off. 11. Testing for fuel injector or fuel rail leakage: - Clamp off the rubber hose portion of Adaptor Tool between the fuel rail and the test port "T" on Adapter Tool. - If pressure now holds at or above 30 psi, a fuel injector or the fuel rail is leaking. 12. Testing for fuel pump check valve, filter/ regulator check valve or fuel tube/line leakage: - Clamp off the rubber hose portion of Adaptor Tool between the vehicle fuel line and test port "T" on Adapter Tool. - If pressure now holds at or above 30 psi, a leak may be found at a fuel tube/line. - If no leaks are found at fuel tubes or lines, one of the check valves in either the electric fuel pump or filter/ regulator may be leaking. NOTE: A quick loss of pressure usually indicates a defective check valve in the filter/regulator. A slow loss of pressure usually indicates a defective check valve in the electric fuel pump. The electric fuel pump is not serviced separately. Replace the fuel pump module assembly. The filter/regulator may be replaced separately on certain applications. Refer to Fuel Filter/Fuel Pressure Regulator Removal/Installation for additional information. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 1070 Fuel Pressure: Testing and Inspection Fuel Pressure Test - With Test Port Fig 8 Fuel Pressure Test Port - Typical WARNING: THE FUEL SYSTEM IS UNDER CONSTANT FUEL PRESSURE EVEN WITH THE ENGINE OFF. BEFORE DISCONNECTING FUEL LINE AT FUEL RAIL, THIS PRESSURE MUST BE RELEASED. REFER TO THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE. NOTE: Use this test in conjunction with the Fuel Pump Capacity Test and Fuel Pressure Leak Down Test found elsewhere. Check Valve Operation: The electric fuel pump outlet contains a one-way check valve to prevent fuel flow back into the tank and to maintain fuel supply line pressure (engine warm) when pump is not operational. - It is also used to keep the fuel supply line full of gasoline when pump is not operational. After the vehicle has cooled down, fuel pressure may drop to 0 psi (cold fluid contracts), but liquid gasoline will remain in fuel supply line between the check valve and fuel injectors. Fuel pressure that has dropped to 0 psi on a cooled down vehicle (engine off) is a normal condition. When the electric fuel pump is activated, fuel pressure should immediately rise to specification. NOTE: The fuel pressure test port is used on certain engines only. The test port is located on the fuel rail near the throttle position sensor (Fig. 8). A sealing cap is screwed onto the test port. All fuel systems are equipped with a fuel tank module mounted, combination fuel filter/fuel pressure regulator. The fuel pressure regulator is not controlled by engine vacuum. Procedure 1. Remove protective cap at fuel rail test port. Connect the 0-414 kPa (0-60 psi) fuel pressure gauge (from gauge set 5069) to test port pressure fitting on fuel rail. 2. Start and warm engine and note pressure gauge reading. Fuel pressure should be 339 kPa +/34 kPa (49.2 psi +/- 5 psi) at idle. 3. If engine runs but pressure is below 44.2 psi, check for a kinked fuel supply line somewhere between fuel rail and fuel pump module. If line is not kinked, replace fuel pump module assembly. Refer to Fuel Pump Module Removal/Installation. 4. If operating pressure is above 54.2 psi, electric fuel pump is OK, but fuel pressure regulator is defective. - Replace fuel filter/fuel pressure regulator. - Certain filter/regulators may be serviced separately and some require the replacement of the fuel pump module assembly Refer to Fuel Filter /Fuel Pressure Regulator Removal/Installation for more information. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 1071 Fuel Pressure: Testing and Inspection Fuel Pressure Test - Without Test Port Fig 10 Installing Adapter Tool And Pressure Gauge WARNING: THE FUEL SYSTEM IS UNDER CONSTANT FUEL PRESSURE EVEN WITH THE ENGINE OFF. BEFORE DISCONNECTING FUEL LINE AT FUEL RAIL, THIS PRESSURE MUST BE RELEASED. REFER TO THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE. NOTE: Use this test in conjunction with the Fuel Pump Capacity Test and Fuel Pressure Leak Down Test. Check Valve Operation: The electric fuel pump outlet contains a one-way check valve to prevent fuel flow back into the tank and to maintain fuel supply line pressure (engine warm) when pump is not operational. It is also used to keep the fuel supply line full of gasoline when pump is not operational. After the vehicle has cooled down, fuel pressure may drop to 0 psi (cold fluid contracts), but liquid gasoline will remain in fuel supply line between the check valve and fuel injectors. Fuel pressure that has dropped to 0 psi on a cooled down vehicle (engine off) is a normal condition. When the electric fuel pump is activated, fuel pressure should immediately rise to specification. All fuel systems are equipped with a fuel tank module mounted, combination fuel filter/fuel pressure regulator. The fuel pressure regulator is not controlled by engine vacuum. Procedure 1. Release fuel pressure. Refer to the Fuel System Pressure Release Procedure-Without Pressure Test Port. 2. Disconnect latch clip and fuel line at fuel rail. Refer to Quick-Connect Fittings for procedures. 3. Connect adapter tool number 6923 into the fuel rail (Fig. 10). Be sure adapter tool is fully seated into fuel rail. 4. Install latch clip to fuel rail. If latch clip can not be fully seated into fuel rail, check for adapter tool not fully seated to fuel rail. 5. Connect vehicle fuel line into adapter tool 6923 (Fig. 10). Be sure fuel line is fully seated into adapter tool 6923. 6. Remove protective cap at test port "T" on adapter tool number 6923. 7. Connect the 0-414 kPa (0-60 psi) fuel pressure gauge (from gauge set 5069) to the test port "T" (Fig. 10). 8. Start engine and note pressure gauge reading. Fuel pressure should be 339 kPa +/- 34 kPa (49.2 psi +/5 psi) at idle. 9. If engine runs but pressure is below 44.2 psi, check for a kinked fuel supply line somewhere between fuel rail and fuel pump module. If line is not kinked, replace fuel pump module assembly. Refer to Fuel Pump Module Removal/Installation. 10. If operating pressure is above 54.2 psi, electric fuel pump is OK, but fuel pressure regulator is defective. Replace fuel filter/fuel pressure regulator. Certain filter/regulators may be serviced separately and some require the replacement of the fuel pump module assembly. Refer to Fuel Filter/Fuel Pressure Regulator Removal/Installation for more information. 11. After performing pressure test, install fuel line into fuel rail. Install latch clip into fuel rail. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 1072 Fuel Pressure: Testing and Inspection Fuel Pump Capacity Test NOTE: Before performing this test, vent fuel pump pressure by performing the Fuel Pump Pressure Test. Use this test in conjunction with the Fuel Pressure Leak Down Test. 1. Release fuel system pressure. Refer to the Fuel Pressure Release Procedure. 2. Disconnect fuel supply line at fuel rail. Some engines may require air cleaner housing removal before line disconnection. 3. Connect appropriate Fuel Line Pressure Test Adapter Tool Hose (number 6631, 6923, 6541 or 6539) into disconnected fuel supply line. Insert other end of Adaptor Tool hose into a graduated container. 4. Remove fuel fill cap. 5. To activate fuel pump and pressurize system, obtain DRB scan tool and actuate ASD Fuel System Test. 6. A good fuel pump will deliver at least 1/4 liter of fuel in 7 seconds. Do not operate fuel pump for longer than 7 seconds with fuel line disconnected as fuel pump module reservoir may run empty. a. If capacity is lower than specification, but fuel pump can be heard operating through fuel fill cap opening, check for a kinked/damaged fuel supply line somewhere between fuel rail and fuel pump module. b. If line is not kinked/damaged, and fuel pressure is OK, but capacity is low, replace fuel filter/ fuel pressure regulator. The filter/regulator may be serviced separately on certain applications. Refer to Fuel Filter/Fuel Pressure Regulator Removal/Installation for additional information. c. If both fuel pressure and capacity are low, replace fuel pump module assembly Refer to Fuel Pump Module Removal/Installation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Minimum Air Flow Idle ......................................................................................................................... ......................................................... 500 to 900 rpm Note: Idle speed range achieved through Minimum Air Flow Idle Test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 1076 Idle Speed: Testing and Inspection The following test procedure has been developed to check throttle body calibrations for correct idle conditions. The procedure should be used to diagnose the throttle body for conditions that may cause idle problems. This procedure should be used only after normal diagnostic procedures have failed to produce results that indicate a throttle body related problem. Be sure to check for proper operation of the idle air control motor before performing this test. Fig. 73 Fixed Orifice Tool A special fixed orifice tool (number 6714) must be used for the following test. 1. Start the engine and bring to operating temperature. Be sure all accessories are off before performing this test. 2. Shut off the engine and remove the air cleaner element housing. Fig. 74 Install Orifice Tool 3. Disconnect the vacuum line at the PCV valve. 4. Install the 0.185 inch orifice tool (number 6714) into the disconnected vacuum line in place of the PCV valve. Fig. 75 Idle Purge Line Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 1077 5. Disconnect the idle purge vacuum line from fitting at throttle body This vacuum line is located on the front of throttle body next to the MAP sensor. Cap the fitting at throttle body after vacuum line has been removed. 6. Connect the DRB scan tool to the 16-way data link connector. This connector is located under the instrument panel to the left of the steering column. 7. Start the engine. 8. Using the DRB scan tool, scroll through the menus as follows: select-System, select-Engine, select-Fuel and Ignition, select-Actuator Tests, select Engine rpm and select-Minimum Air Flow. 9. The DRB scan tool will count down to stabilize the idle rpm and display the minimum air flow idle rpm. The idle rpm should be between 500 and 900 rpm. If the idle speed is outside of these specifications, replace the throttle body. 10. Disconnect the DRB scan tool from the vehicle. 11. Remove cap from idle purge fitting at throttle body and install vacuum line. 12. Remove orifice tool and connect vacuum line to PCV valve. 13. Install air cleaner element housing. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 1078 Idle Speed: Adjustments Idle speed is electronically controlled by the Powertrain Control Module (PCM) through the Idle Air Control (IAC) motor, and is not adjustable. CAUTION: This vehicle is equipped with a factory adjusted throttle plate position set screw. Never attempt to adjust idle speed using this screw, unless directed to do so in a service procedure. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > With Pressure Test Port Fuel Pressure Release: Service and Repair With Pressure Test Port WARNING: BECAUSE THE FUEL SYSTEM IS UNDER CONSTANT FUEL PRESSURE, IT MUST BE RELEASED BEFORE SERVICING ANY FUEL SYSTEM COMPONENT THIS DOES NOT APPLY TO THROTTLE BODY REMOVAL. NOTE: The fuel pressure test port is used on certain engines only. If equipped, the test port will be located on fuel rail. A sealing cap is screwed onto test port. - The fuel system is under constant fuel pressure (even with engine off). 1. Disconnect negative battery cable. 2. Remove fuel tank filler tube cap to release fuel tank pressure. 3. Remove protective cap from pressure test port on fuel rail. This is located on top of fuel rail. WARNING: DO NOT ALLOW FUEL TO SPILL ONTO ENGINE INTAKE OR EXHAUST MANIFOLDS. PLACE SHOP TOWELS UNDER AND AROUND PRESSURE PORT TO ABSORB FUEL WHEN PRESSURE IS RELEASED FROM FUEL RAIL. WARNING: WEAR PROPER EYE PROTECTION WHEN RELEASING FUEL SYSTEM PRESSURE. 4. Obtain fuel pressure gauge/hose assembly from fuel pressure gauge tool set 5069. Remove gauge from hose. 5. Place one end of hose (gauge end) into an approved gasoline container. 6. Place a shop towel under test port. 7. To release fuel pressure, screw other end of hose onto fuel pressure test port. 8. After fuel pressure has been released, remove hose from test port. 9. Install protective cap to fuel test port. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > With Pressure Test Port > Page 1084 Fuel Pressure Release: Service and Repair Without Pressure Test Port NOTE: Use the following procedure if the fuel rail is not equipped with a fuel pressure test port. 1. Remove the Fuel Pump relay from the Power Distribution Center (PDC). For location of the relay, refer to the label on the underside of the PDC cover. 2. Start and run engine until it stalls. 3. Attempt restarting engine until it will no longer run. 4. Turn ignition key to OFF position. CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within the fuel rail. Do not attempt to use the following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber. 5. Unplug connector from any injector. 6. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 7. Connect the other end of the jumper wire to the positive side of the battery 8. Connect one end of a second jumper wire to the remaining injector terminal. CAUTION: Supplying power to an injector for more than 4 seconds will permanently damage the injector. Do not leave the injector connected to power for more than 4 seconds. 9. Momentarily touch the other end of this jumper wire to the negative terminal of the battery for no more than 4 seconds. 10. Place a rag or towel below the fuel line at the quick connect to the rail. 11. Disconnect the quick connect fitting to the rail. Refer to Quick-Connect Fittings. 12. Return the fuel pump relay to the PDC. 13. One or more Diagnostic Trouble Codes (DTC's) may have been stored in the PCM memory due to fuel pump relay removal. The DRB scan tool must be used to erase a DTC. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Engine Firing Order - 3.9L Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks and Indicators > System Information > Locations Timing Marks and Indicators: Locations Align Timing Marks The timing marks are located on the timing cover, next to the vibration damper. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction Technical Service Bulletin # 18-48-98 Date: 981230 Ignition System - Cross Fire/Ignition Wire Induction NO: 18-48-98 GROUP: Vehicle Performance DATE: Dec. 30, 1998 SUBJECT: Ignition System Cross Fire/Secondary Ignition Wire Induction MODELS: 1994 - 1999 (AN) Dakota 1994 - 1999 (BR/BE)Ram Truck 1998 - 1999 (DN) Durango 1995 - 1998 (ZG) Grand Cherokee (International Market) 1994 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 3.9L, 5.2L, OR 5.9L ENGINE. AB MODELS WILL BE ADDED LATER (NEW PARTS REQUIRED). SYMPTOM/CONDITION: Some vehicles may exhibit one or more of the following: Spark knock complaints when the vehicle is under load. Various single cylinder misfire (1, 3, 7), especially 5 and/or 8. Surge in 4th gear with the Electronically Modulated Converter Clutch (EMCC) engaged (around 45 mph). Perceived torque converter EMCC engagement/disengagement around 45 mph. DIAGNOSIS: Using the Mopar Diagnostic System (MDS/MDS 2) or the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If other than mentioned Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present or if the above symptoms/conditions have been described by the customer, perform the Repair Procedure. NOTE: THIS REROUTING PROCEDURE SHOULD BE PERFORMED BEFORE ANY OTHER MISFIRE, SURGE, OR SPARK KNOCK REPAIRS ARE ATTEMPTED. PARTS REQUIRED: 3 56028186 Clip, Single Wire 2 06503441 Clip, Wire To Hose (5.2L & 5.9L) 1 04364375 Convolute, 10 ft Roll POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-12-15-92 - 3.9L (All) 0.2 Hrs. 08-12-15-93 (ZJ) 5.2/5.9L 0.2 Hrs. (AN/DN) 5.2/5.9L 0.3 Hrs. (BR/BE) 5.2/5.9L 0.4 Hrs. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction > Page 1100 FAILURE CODE: 9X - Routed Improperly Repair Procedure This bulletin involves rerouting the coil wire for all engines listed and rerouting the 4, 5, 7, and 8 plug wires for the 5.2/5.9L applications to minimize induction effects. NOTE: IF WIRES MUST CROSS DURING THE REROUTE PROCEDURE, THEY MUST CROSS AT A 90° ANGLE. 5.2L and 5.9L Engine Procedures 1. Coil Wire Routing (Figure 1 and 2) A. Remove the coil wire from the distributor cap coil wire tower terminal. B. Remove the coil wire from the rear five-wire clip, the center three-wire clip, and the front one-wire clip located along the lower side of the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover. Use the studs of the valve cover retaining bolts (Figure 1). NOTE: SOME APPLICATIONS MAY ONLY HAVE STUD LOCATIONS FOR 3 OF THE ONE-WIRE CLIPS. D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths 203 mm (8 in.), 101.5 mm (4 in.), and 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the 203 mm (8 in.) and the 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction > Page 1101 H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 2). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM AND/OR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. I. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. 2. No.8 Cylinder Plug Wire Routing (Figure 3) A. Remove the No.8 cylinder plug wire from the distributor cap tower terminal. B. Remove the No.8 cylinder plug wire from the five-wire clip located at the lower rear of the valve cover. C. Route the No.8 cylinder plug wire over the rear quarter of the right valve cover (Figure 3). D. Position the original piece convolute from the No.8 cylinder plug wire to prevent chafing at the right valve cover and with other engine components. E. Secure the No.8 cylinder plug wire and its convolute in place with the hose to wire clip p/n 06503441. The small end of the clip is positioned over the convolute. The large end of the clip is fastened to a heater hose (A/C line on ZJ models). NOTE: MAKE SURE THE NO.8 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE COIL WIRE AND THE NO.4 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. F. Install the No.8 cylinder plug wire to its distributor cap terminal. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction > Page 1102 3. No.4 Cylinder Plug Wire Routing (Figure 4 and 5) A. Remove the No.4 cylinder plug wire from the distributor cap terminal. B. At the three-wire clip (located at the center of the lower side of the right valve cover), keep the two wires from crossing and chafing each other. Position the No.2 cylinder plug wire in the top wire slot and the No.4 cylinder plug wire in the bottom wire slot. Leave the middle wire slot empty (Figure 5). C. At the five-wire clip (located at the right rear lower side of the valve cover), keep the plug wires from crossing and chafing each other. Position the No.4 cylinder plug wire in a slot that will obtain the maximum amount of distance allowable from the No.8 cylinder plug wire (Figure 6). Remove any slack in the No.4 cylinder plug wire between the three-wire and the five-wire clips. NOTE: EARLIER MODEL FIVE-WIRE CLIPS LOOK SLIGHTLY DIFFERENT BUT THE SAME WIRING LAYOUT APPLIES. D. Route the No.4 cylinder plug wire behind the transmission dipstick tube and heater hoses. On ZJ models this may not be possible due to the location of the bulkhead. NOTE: MAKE SURE THAT THE NO.4 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH AWAY FROM THE NO.8 CYLINDER PLUG WIRE. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction > Page 1103 E. Install the No.4 cylinder plug wire to its distributor cap terminal (Figure 7). 4. No.7 Cylinder Plug Wire Routing (Figure 8 and 9) A. Verify that the No.7 cylinder plug wire crosses over the distributor cap and leaves the distributor cap between the No.3 and the No.6 tower terminals (Figure 8). This is the original wire routing for 1998 and prior model years. B. For 1999 M.Y. vehicles the No.7 cylinder plug wire was shortened. Reroute the No.7 cylinder plug wire so that it crosses the distributor cap and leaves the distributor cap between the No.6 and the No.5 tower terminals (Figure 9). NOTE: MAKE SURE THE NO.7 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH, AWAY FROM THE NO.5 CYLINDER PLUG WIRE. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction > Page 1104 5. No. 5 Cylinder Plug Wire Routing (Figure 10) A. Remove the No.5 cylinder plug wire from its distributor cap terminal. B. Remove the No.5 cylinder plug wire from the five-wire clip located at the lower rear of the left valve cover. C. Route the No.5 cylinder plug wire over the left valve cover and in front of the breather tube elbow. D. Position the original convolute from the No.5 cylinder plug wire to prevent chafing against the valve cover and any engine components. Secure the small end of the hose to wire clip p/n 06503441 over the convolute. Secure the large end of the hose to wire clip to the breather hose. NOTE: MAKE SURE THE NO.5 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE NO.7 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. 3.9L Engine Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction > Page 1105 1. Coil Wire Routing (Figure 11 and 12) A. Remove the coil wire from the distributor cap tower terminal. B. Remove the coil wire from the right rear five-wire clip, the center three wire clip and the front one-wire clip on the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover studs (Figure 11). D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths. Two (2) at 101.5 mm (4 in.), and one (1) at 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the two 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 12). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM ANDIOR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction Technical Service Bulletin # 18-48-98 Date: 981230 Ignition System - Cross Fire/Ignition Wire Induction NO: 18-48-98 GROUP: Vehicle Performance DATE: Dec. 30, 1998 SUBJECT: Ignition System Cross Fire/Secondary Ignition Wire Induction MODELS: 1994 - 1999 (AN) Dakota 1994 - 1999 (BR/BE)Ram Truck 1998 - 1999 (DN) Durango 1995 - 1998 (ZG) Grand Cherokee (International Market) 1994 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 3.9L, 5.2L, OR 5.9L ENGINE. AB MODELS WILL BE ADDED LATER (NEW PARTS REQUIRED). SYMPTOM/CONDITION: Some vehicles may exhibit one or more of the following: Spark knock complaints when the vehicle is under load. Various single cylinder misfire (1, 3, 7), especially 5 and/or 8. Surge in 4th gear with the Electronically Modulated Converter Clutch (EMCC) engaged (around 45 mph). Perceived torque converter EMCC engagement/disengagement around 45 mph. DIAGNOSIS: Using the Mopar Diagnostic System (MDS/MDS 2) or the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If other than mentioned Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present or if the above symptoms/conditions have been described by the customer, perform the Repair Procedure. NOTE: THIS REROUTING PROCEDURE SHOULD BE PERFORMED BEFORE ANY OTHER MISFIRE, SURGE, OR SPARK KNOCK REPAIRS ARE ATTEMPTED. PARTS REQUIRED: 3 56028186 Clip, Single Wire 2 06503441 Clip, Wire To Hose (5.2L & 5.9L) 1 04364375 Convolute, 10 ft Roll POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-12-15-92 - 3.9L (All) 0.2 Hrs. 08-12-15-93 (ZJ) 5.2/5.9L 0.2 Hrs. (AN/DN) 5.2/5.9L 0.3 Hrs. (BR/BE) 5.2/5.9L 0.4 Hrs. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1111 FAILURE CODE: 9X - Routed Improperly Repair Procedure This bulletin involves rerouting the coil wire for all engines listed and rerouting the 4, 5, 7, and 8 plug wires for the 5.2/5.9L applications to minimize induction effects. NOTE: IF WIRES MUST CROSS DURING THE REROUTE PROCEDURE, THEY MUST CROSS AT A 90° ANGLE. 5.2L and 5.9L Engine Procedures 1. Coil Wire Routing (Figure 1 and 2) A. Remove the coil wire from the distributor cap coil wire tower terminal. B. Remove the coil wire from the rear five-wire clip, the center three-wire clip, and the front one-wire clip located along the lower side of the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover. Use the studs of the valve cover retaining bolts (Figure 1). NOTE: SOME APPLICATIONS MAY ONLY HAVE STUD LOCATIONS FOR 3 OF THE ONE-WIRE CLIPS. D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths 203 mm (8 in.), 101.5 mm (4 in.), and 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the 203 mm (8 in.) and the 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1112 H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 2). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM AND/OR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. I. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. 2. No.8 Cylinder Plug Wire Routing (Figure 3) A. Remove the No.8 cylinder plug wire from the distributor cap tower terminal. B. Remove the No.8 cylinder plug wire from the five-wire clip located at the lower rear of the valve cover. C. Route the No.8 cylinder plug wire over the rear quarter of the right valve cover (Figure 3). D. Position the original piece convolute from the No.8 cylinder plug wire to prevent chafing at the right valve cover and with other engine components. E. Secure the No.8 cylinder plug wire and its convolute in place with the hose to wire clip p/n 06503441. The small end of the clip is positioned over the convolute. The large end of the clip is fastened to a heater hose (A/C line on ZJ models). NOTE: MAKE SURE THE NO.8 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE COIL WIRE AND THE NO.4 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. F. Install the No.8 cylinder plug wire to its distributor cap terminal. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1113 3. No.4 Cylinder Plug Wire Routing (Figure 4 and 5) A. Remove the No.4 cylinder plug wire from the distributor cap terminal. B. At the three-wire clip (located at the center of the lower side of the right valve cover), keep the two wires from crossing and chafing each other. Position the No.2 cylinder plug wire in the top wire slot and the No.4 cylinder plug wire in the bottom wire slot. Leave the middle wire slot empty (Figure 5). C. At the five-wire clip (located at the right rear lower side of the valve cover), keep the plug wires from crossing and chafing each other. Position the No.4 cylinder plug wire in a slot that will obtain the maximum amount of distance allowable from the No.8 cylinder plug wire (Figure 6). Remove any slack in the No.4 cylinder plug wire between the three-wire and the five-wire clips. NOTE: EARLIER MODEL FIVE-WIRE CLIPS LOOK SLIGHTLY DIFFERENT BUT THE SAME WIRING LAYOUT APPLIES. D. Route the No.4 cylinder plug wire behind the transmission dipstick tube and heater hoses. On ZJ models this may not be possible due to the location of the bulkhead. NOTE: MAKE SURE THAT THE NO.4 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH AWAY FROM THE NO.8 CYLINDER PLUG WIRE. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1114 E. Install the No.4 cylinder plug wire to its distributor cap terminal (Figure 7). 4. No.7 Cylinder Plug Wire Routing (Figure 8 and 9) A. Verify that the No.7 cylinder plug wire crosses over the distributor cap and leaves the distributor cap between the No.3 and the No.6 tower terminals (Figure 8). This is the original wire routing for 1998 and prior model years. B. For 1999 M.Y. vehicles the No.7 cylinder plug wire was shortened. Reroute the No.7 cylinder plug wire so that it crosses the distributor cap and leaves the distributor cap between the No.6 and the No.5 tower terminals (Figure 9). NOTE: MAKE SURE THE NO.7 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH, AWAY FROM THE NO.5 CYLINDER PLUG WIRE. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1115 5. No. 5 Cylinder Plug Wire Routing (Figure 10) A. Remove the No.5 cylinder plug wire from its distributor cap terminal. B. Remove the No.5 cylinder plug wire from the five-wire clip located at the lower rear of the left valve cover. C. Route the No.5 cylinder plug wire over the left valve cover and in front of the breather tube elbow. D. Position the original convolute from the No.5 cylinder plug wire to prevent chafing against the valve cover and any engine components. Secure the small end of the hose to wire clip p/n 06503441 over the convolute. Secure the large end of the hose to wire clip to the breather hose. NOTE: MAKE SURE THE NO.5 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE NO.7 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. 3.9L Engine Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1116 1. Coil Wire Routing (Figure 11 and 12) A. Remove the coil wire from the distributor cap tower terminal. B. Remove the coil wire from the right rear five-wire clip, the center three wire clip and the front one-wire clip on the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover studs (Figure 11). D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths. Two (2) at 101.5 mm (4 in.), and one (1) at 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the two 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 12). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM ANDIOR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 1117 Ignition Cable: Specifications Minimum ..................................................................................................................................................... 250 ohms per inch (3,000 ohms per foot) Maximum ............................................................................................................................................... 1,000 ohms per inch (12,000 ohms per foot) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 1118 Ignition Cable: Description and Operation DESCRIPTION Spark plug cables are sometimes referred to as secondary ignition wires. The resistive spark plug cables are of nonmetallic construction. OPERATION These cables transfer electrical current from the ignition coil(s) and/or distributor, to individual spark plugs at each cylinder. The cables provide suppression of radio frequency emissions from the ignition system. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 1119 Ignition Cable: Service and Repair Fig. 11 Cable Removal CAUTION: When disconnecting a high voltage cable from a spark plug or from the distributor cap, twist the rubber boot slightly (1/2 turn) to break it loose. Grasp the boot (not the cable) and pull it off with a steady, even force. When replacing the spark plug and coil cables, route the cables correctly and secure in the proper retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise. It could also cause cross ignition of the plugs or short circuit the cables to ground. When installing new cables, make sure a positive connection is made. A snap should be felt when a good connection is made between the plug cable and the distributor cap tower. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Cap > Component Information > Testing and Inspection Distributor Cap: Testing and Inspection Fig. 22 Cap Inspection - External - Typical (V6 Shown) Fig. 23 Cap Inspection - Internal - Typical (V6 Shown) Remove the distributor cap and wipe it clean with a dry lint free cloth. Visually inspect the cap for cracks, carbon paths, broken towers or damaged rotor button. Also check for white deposits on the inside (caused by condensation entering the cap through cracks). Replace any cap that displays charred or eroded terminals. NOTE: A small amount of erosion is expected from normal operation. Examine the terminal ends for evidence of mechanical interference with the rotor tip. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Testing and Inspection Ignition Rotor: Testing and Inspection Fig. 24 Rotor Inspection - Typical Visually inspect the rotor for cracks, evidence of corrosion, or the effects of arcing on the metal tip. Also check for evidence of mechanical interference with the cap. Some charring is normal on the end of the metal tip. The silicone-dielectric-varnish-compound applied to the rotor tip for radio interference noise suppression, will appear charred. This is normal. Do not remove the charred compound. Test the spring for insufficient tension. Replace a rotor that displays any of these adverse conditions. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Electrode Gap ...................................................................................................................................... ..................................................... 1.01 mm (0.040 in) Torque ............................................................ ............................................................................................................................................. 41 Nm (30 ft. lb.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1130 Spark Plug: Application and ID Plug Type ............................................................................................................................................ .................................................................... RC12LC4 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1131 Spark Plug: Description and Operation DESCRIPTION All engines use resistor type spark plugs. 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 recommended intervals. Spark plugs that have low milage may be cleaned and reused if not otherwise defective, carbon or oil fouled. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator Spark Plug: Testing and Inspection Broken, Cracked or Chipped 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 Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1134 Spark Plug: Testing and Inspection Brown to Gray/Tan Color - Normal Operating Condition Normal Operation And Carbon Fouling The few deposits present on the spark plug will probably be light tan or slightly gray in color. This is evident with most grades of commercial gasoline. There will not be evidence of electrode burning. Gap growth will not average more than approximately 0.025 mm (.001 in) per 1600 km (1000 miles) of operation. Spark plugs that have normal wear can usually be cleaned, have the electrodes filed, have the gap set and then be installed. Some fuel refiners in several areas of the United States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT causes the entire tip of the spark plug to be coated with a rust colored deposit. This rust color can be misdiagnosed as being caused by coolant in the combustion chamber. Spark plug performance is not affected by MMT deposits. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1135 Spark Plug: Testing and Inspection Dry, Fluffy Black Deposits - Cold or Carbon Fouling Normal Operation And Carbon Fouling Cold fouling is sometimes referred to as carbon fouling. The deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or defective spark plug cables. Cold (carbon) fouling of the entire set of spark plugs may be caused by a clogged air filter or repeated short operating times (short trips). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1136 Spark Plug: Testing and Inspection 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 Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1137 Spark Plug: Testing and Inspection Broken, Cracked or Chipped 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. Brown to Gray/Tan Color - Normal Operating Condition Normal Operation And Carbon Fouling The few deposits present on the spark plug will probably be light tan or slightly gray in color. This is evident with most grades of commercial gasoline. There will not be evidence of electrode burning. Gap growth will not average more than approximately 0.025 mm (.001 in) per 1600 km (1000 miles) of operation. Spark plugs that have normal wear can usually be cleaned, have the electrodes filed, have the gap set and then be installed. Some fuel refiners in several areas of the United States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT causes the entire tip of the spark plug to be coated with a rust colored deposit. This rust color can be misdiagnosed as being caused by coolant in the combustion chamber. Spark plug performance is not affected by MMT deposits. Dry, Fluffy Black Deposits - Cold or Carbon Fouling Normal Operation And Carbon Fouling Cold fouling is sometimes referred to as carbon fouling. The deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or defective spark plug cables. Cold (carbon) fouling of the entire set of spark plugs may be caused by a clogged air filter or repeated short operating times (short trips). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1138 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. 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. Overheating Spark Plug Overheating Overheating is indicated by a white or gray center electrode insulator that also appears blistered. The increase in electrode gap will be considerably in excess of 0.001 inch per 1000 miles of operation. This suggests that a plug with a cooler heat range rating should be used. Over advanced ignition Premature Electrode Wear - Preignition Damage Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1139 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.) 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. 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 Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 1140 Spark Plug: Service and Repair Fig. 31 Heat Shields Spark plug cable heat shields are pressed into the cylinder head to surround each cable boot and spark plug. If removal of the heat shield(s) is necessary, remove the spark plug cable and compress the sides of shield for removal. Each shield is slotted to allow for compression and removal. To install the shields, align shield to machined opening in cylinder head and tap into place with a block of wood. Fig. 11 Cable Removal PLUG REMOVAL 1. Always remove spark plug or ignition coil cables by grasping at the cable boot. Turn the cable boot 1/2 turn and pull straight back in a steady motion. Never pull directly on the cable. Internal damage to cable will result. 2. Prior to removing the spark plug, spray compressed air around the spark plug hole and the area around the spark plug. This will help prevent foreign material from entering the combustion chamber. 3. Remove the spark plug using a quality socket with a rubber or foam insert. 4. Inspect the spark plug condition. PLUG CLEANING The plugs may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file the center electrode flat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator and will cause plug misfire. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 1141 Fig. 44 Setting Spark Plug Gap - Typical PLUG GAP ADJUSTMENT Check the spark plug gap with a gap gauge tool. If the gap is not correct, adjust it by bending the ground electrode. Never attempt to adjust the gap by bending the center electrode. SPARK PLUG GAP 1.01 mm (0.040 in). PLUG INSTALLATION Special care should be taken when installing spark plugs into the cylinder head spark plug wells. Be sure the plugs do not drop into the plug wells as electrodes can be damaged. Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap or a cracked porcelain insulator. When replacing the spark plug and ignition coil cables, route the cables correctly and secure them in the appropriate retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise. It could cause cross ignition of the spark plugs or short circuit the cables to ground. 1. Start the spark plug into the cylinder head by hand to avoid cross threading. 2. Tighten spark plugs to 35-41 Nm (26-30 ft lb) torque. 3. Install spark plug cables over spark plugs. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression should not be less than 689 kPa (100 psi) and not vary more than 172 kPa (25 psi) from cylinder to cylinder. If cylinder(s) have abnormally low compression pressures, repeat procedure. - If the same cylinder(s) repeat an abnormally low reading, it could indicate the existence of a problem in the cylinder. NOTE: The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should NOT be disassembled to determine the cause of low compression unless some malfunction is present. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1145 Compression Check: Testing and Inspection NOTE: - 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. CAUTION: DO NOT overspeed the engine. a. Check engine oil level and add oil, if necessary. b. Drive the vehicle until engine reaches normal operating temperature. c. Select a route free from traffic and other forms of congestion, observe all traffic laws and briskly accelerate through the gears several times. The higher engine speed may help clean out valve seat deposits which can prevent accurate compression readings. d. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for abnormal firing indicators-fouled, hot, oily, etc. Record cylinder number of spark plug for future reference. e. Disconnect coil wire from distributor and secure to good ground to prevent a spark from starting a fire. f. Be sure throttle blades are fully open during the compression check. g. Insert compression gauge adapter into the No. 1 spark plug hole. Crank engine until maximum pressure is reached on gauge. Record this pressure as No.1 cylinder pressure. h. Repeat above step for all remaining cylinders. i. Compression should not be less than 689 kPa (100 psi) and not vary more than 172 kPa (25 psi) from cylinder to cylinder. j. If cylinder(s) have abnormally low compression pressures, repeat procedure. k. If the same cylinder(s) repeat an abnormally low reading, it could indicate the existence of a problem in the cylinder. NOTE: The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should NOT be disassembled to determine the cause of low compression unless some malfunction is present. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates this engine is equipped with hydraulic lifters or lash adjusters and therefore does not require adjustment. See "Rocker Arm: Service and Repair" for further information. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications Drive Belt: Specifications Do not attempt to check belt tension with a tension gauge. Belt is equipped with ab automatic tensioner. Belt tension is not adjustable. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications > Page 1152 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications > Page 1153 Drive Belt: Description and Operation The accessory drive components are operated by a single, crankshaft driven, serpentine drive belt. An automatic belt tensioner is used to maintain correct belt tension at all times. Correct accessory drive belt tension is required to be sure of optimum performance of belt driven engine accessories. If specified tension is not maintained, belt slippage may cause; engine overheating, lack of power steering assist, loss of air conditioning capacity, reduced generator output rate and greatly reduced belt life. NOTE: Due to the use of this belt tensioner, do not attempt to use a belt tension gauge. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications > Page 1154 Drive Belt: Testing and Inspection Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications > Page 1155 When diagnosing serpentine drive belts, small cracks that run across ribbed surface of belt from rib to rib, are considered normal. These are not a reason to replace belt. However, cracks running along a rib (not across) are not normal. Any belt with cracks running along a rib must be replaced. Also replace belt if it has excessive wear, frayed cords or severe glazing. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications > Page 1156 Drive Belt: Service and Repair NOTE: The drive belt is equipped with a spring loaded automatic belt tensioner. This belt tensioner will be used on all belt configurations, such as with or without power steering or air conditioning. REMOVAL 1. Attach a socket/wrench to pulley mounting bolt of automatic tensioner. 2. Rotate tensioner assembly clockwise (as viewed from front) until tension has been relieved from belt. 3. Remove belt from idler pulley first. 4. Remove belt from vehicle. CAUTION: When installing serpentine accessory drive belt, belt must be routed correctly. If not, engine may overheat due to water pump rotating in wrong direction. Refer to illustration for correct engine belt routing. The correct belt with correct length must be used. INSTALLATION 1. Position drive belt over all pulleys except idler pulley. This pulley is located between generator and A/C compressor. 2. Attach a socket/wrench to pulley mounting bolt of automatic tensioner. 3. Rotate socket/wrench clockwise. Place belt over idler pulley. Let tensioner rotate back-into place. Remove wrench. Be sure belt is properly seated on all pulleys. 4. Check belt indexing marks. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications > Page 1157 5. The tensioner is equipped with an indexing arrow on back of tensioner and an indexing mark on tensioner housing. If a new belt is being installed, arrow must be within approximately 3 mm (1/8 inch) of indexing mark (Point B). Belt is considered new if it has been used 15 minutes or less. If this specification cannot be met, check for: The wrong belt being installed (incorrect length/ width). - Worn bearings on an engine accessory (A/C compressor, power steering pump, water pump, idler pulley or generator). - A pulley on an engine accessory being loose. - Misalignment of an engine accessory. - Belt incorrectly routed. Refer to illustration. NOTE: A used belt should be replaced if tensioner indexing arrow has moved beyond point A. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Specifications Fluid Filter - A/T: Specifications Mounting Screw ................................................................................................................................... ................................................... 4 Nm (35 inch lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Specifications > Page 1162 Fluid Filter - A/T: Service and Repair NOTE: The service fluid fill after a filter change is approximately 3.8 liters (4.0 quarts). REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan. 3. Remove bolts holding front and sides of pan to transmission. 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 bolt 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 screws holding filter to valve body. 10. Separate filter from valve body and pour fluid in filter into drain pan. 11. Dispose of used bans fluid and filter properly. INSPECTION Inspect bottom of pan and magnet for excessive amounts of metal or fiber contamination. A light coating of clutch or band material on the bottom of the pan does not indicate a problem unless accompanied by slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts or debris. Check the adjustment of the front and rear bands, adjust if necessary. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Specifications > Page 1163 CLEANING 1. Using a suitable solvent, clean pan and magnet. 2. Using a suitable gasket scraper, clean gasket material from gasket surface of transmission case and the gasket flange around the pan. INSTALLATION 1. Place replacement filter in position on valve body. 2. Install screws to hold filter to valve body. Tighten screws to 4 Nm (35 inch lbs.) torque. 3. Place new gasket in position on pan and install pan on transmission. 4. Place pan in position on transmission. 5. Install screws to hold pan to transmission. Tighten bolts to 17 Nm (150 inch lbs.) torque. 6. Lower vehicle and fill transmission with MOPAR ATF+4, type 9602 fluid, or equivalent. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > With Pressure Test Port Fuel Pressure Release: Service and Repair With Pressure Test Port WARNING: BECAUSE THE FUEL SYSTEM IS UNDER CONSTANT FUEL PRESSURE, IT MUST BE RELEASED BEFORE SERVICING ANY FUEL SYSTEM COMPONENT THIS DOES NOT APPLY TO THROTTLE BODY REMOVAL. NOTE: The fuel pressure test port is used on certain engines only. If equipped, the test port will be located on fuel rail. A sealing cap is screwed onto test port. - The fuel system is under constant fuel pressure (even with engine off). 1. Disconnect negative battery cable. 2. Remove fuel tank filler tube cap to release fuel tank pressure. 3. Remove protective cap from pressure test port on fuel rail. This is located on top of fuel rail. WARNING: DO NOT ALLOW FUEL TO SPILL ONTO ENGINE INTAKE OR EXHAUST MANIFOLDS. PLACE SHOP TOWELS UNDER AND AROUND PRESSURE PORT TO ABSORB FUEL WHEN PRESSURE IS RELEASED FROM FUEL RAIL. WARNING: WEAR PROPER EYE PROTECTION WHEN RELEASING FUEL SYSTEM PRESSURE. 4. Obtain fuel pressure gauge/hose assembly from fuel pressure gauge tool set 5069. Remove gauge from hose. 5. Place one end of hose (gauge end) into an approved gasoline container. 6. Place a shop towel under test port. 7. To release fuel pressure, screw other end of hose onto fuel pressure test port. 8. After fuel pressure has been released, remove hose from test port. 9. Install protective cap to fuel test port. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > With Pressure Test Port > Page 1169 Fuel Pressure Release: Service and Repair Without Pressure Test Port NOTE: Use the following procedure if the fuel rail is not equipped with a fuel pressure test port. 1. Remove the Fuel Pump relay from the Power Distribution Center (PDC). For location of the relay, refer to the label on the underside of the PDC cover. 2. Start and run engine until it stalls. 3. Attempt restarting engine until it will no longer run. 4. Turn ignition key to OFF position. CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within the fuel rail. Do not attempt to use the following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber. 5. Unplug connector from any injector. 6. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 7. Connect the other end of the jumper wire to the positive side of the battery 8. Connect one end of a second jumper wire to the remaining injector terminal. CAUTION: Supplying power to an injector for more than 4 seconds will permanently damage the injector. Do not leave the injector connected to power for more than 4 seconds. 9. Momentarily touch the other end of this jumper wire to the negative terminal of the battery for no more than 4 seconds. 10. Place a rag or towel below the fuel line at the quick connect to the rail. 11. Disconnect the quick connect fitting to the rail. Refer to Quick-Connect Fittings. 12. Return the fuel pump relay to the PDC. 13. One or more Diagnostic Trouble Codes (DTC's) may have been stored in the PCM memory due to fuel pump relay removal. The DRB scan tool must be used to erase a DTC. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications Oil Filter: Specifications Bypass Valve Setting ........................................................................................................................... ............................................ 62 - 103 kPa (9 - 15 psi) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications > Page 1173 Oil Filter: Description and Operation This engine is equipped with a high quality full-flow, disposable type oil filter. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications > Page 1174 Oil Filter: Service and Repair REMOVAL 1. Position a drain pan under the oil filter. 2. Using a suitable oil filter wrench loosen filter. 3. Rotate the oil filter counterclockwise to remove it from the cylinder block oil filter boss. 4. When filter separates from adapter nipple, tip gasket end upward to minimize oil spill. Remove filter from vehicle. 5. With a wiping cloth, clean the gasket sealing surface of oil and grime. INSTALLATION 1. Lightly lubricate oil filter gasket with engine oil or chassis grease. 2. Thread filter onto adapter nipple. When gasket makes contact with sealing surface, hand tighten filter one full turn, do not over tighten. 3. Add oil, verify crankcase oil level and start engine. Inspect for oil leaks. NOTE: Care should be exercised when disposing of used engine oil after it has been drained from a vehicle's engine. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation Hose/Line HVAC: Description and Operation REFRIGERANT LINE The refrigerant lines are used to carry the refrigerant between the various air conditioning system components. A barrier hose design is used for the air conditioning system on this vehicle. The ends of the refrigerant hoses are made from lightweight aluminum, and use braze-less fittings. The refrigerant lines and hoses cannot be repaired and, if faulty or damaged, they must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Liquid Hose/Line Replacement Hose/Line HVAC: Service and Repair A/C Liquid Hose/Line Replacement Fig 28 Liquid Line Removal/Installation WARNING: Review the Service Precautions before performing the following operation. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. 3. Remove the engine air filter housing. 4. If the vehicle is so equipped, remove the nuts that secure the vehicle speed control servo mounting bracket to the studs on the cowl plenum panel and move the servo far enough to access the liquid line to evaporator coupler. 5. Disconnect the refrigerant line couplers at the condenser and the evaporator. See Refrigerant A/C Coupler for the procedures. Install plugs in, or tape over all of the open refrigerant fittings. 6. Disengage the two clips that secure the liquid line to the inner fender shield. 7. Remove the liquid line from the vehicle. INSTALLATION 1. Install the liquid line in the two clips on the inner fender shield. 2. Remove the tape or plugs from all of the refrigerant fittings, and install the refrigerant lines to the condenser and the evaporator. See Refrigerant A/C Coupler for the procedures. 3. If the vehicle is so equipped, reinstall the vehicle speed control servo mounting bracket to the studs on the cowl plenum panel. 4. Reinstall the engine air filter housing. 5. Connect the battery negative cable. 6. Evacuate and charge the refrigerant system. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Liquid Hose/Line Replacement > Page 1181 Hose/Line HVAC: Service and Repair Suction and Discharge Line Fig 14 Suction And Discharge Line Removal/Installation -- Typical WARNING: Review the Service Precautions before performing the following operation. REMOVAL 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 cut-off switch. 4. Disconnect the refrigerant line couplers at the condenser and the accumulator. See A/C Coupler for the procedures. Install plugs in, or tape over all of the open refrigerant fittings. 5. Remove the fastener that secures the refrigerant line support bracket near the compressor. 6. Remove the screw that secures the refrigerant line manifold to the compressor. Install plugs in, or tape over all of the open refrigerant fittings. 7. Remove the suction and discharge line from the vehicle. INSTALLATION 1. Remove the tape or plugs from all of the refrigerant fittings, and install the A/C Couplers to the condenser and the accumulator. 2. Install the refrigerant line manifold to the compressor. Tighten the mounting screw to 22 N.m (200 m. lbs.). 3. Install the compressor on the mounting bracket. Tighten the mounting screws to 27 N.m (20 ft. lbs.). 4. Install the fastener that secures the refrigerant line support bracket near the compressor. 5. Plug in the wire harness connector to the high pressure cut-off switch. 6. Connect the battery negative cable. 7. Evacuate and charge the refrigerant system. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications Pressure Line ...................................................................................................................................... ...................................................... 35 Nm (25 ft. lbs.) Return Line ..................................................... .......................................................................................................................................... 35 Nm (25 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Description and Operation Radiator Hose: Description and Operation GENERAL INFORMATION Rubber hoses route coolant to and from the radiator, intake manifold and heater core. Radiator lower hoses are spring-reinforced to prevent collapse from water pump suction at moderate and high engine speeds. WARNING: Constant tension hose clamps are used on most cooling system hoses. When removing or installing, use only tools designed for servicing this type of clamp, such as special clamp tool (number 6094). Snap-on clamp tool (number HPC-20) may be used for larger clamps. Always wear safety glasses when servicing constant tension clamps. CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only an original equipment clamp with matching number or letter. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications BRAKE FLUID Specification ........................................................................................................................................ .................................................................. DOT 3 Standard .............................................................................................................................................. ........................................................... SAE J1703 NOTE: The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar brake fluid or an equivalent from a tightly sealed container. CAUTION: Never use reclaimed brake fluid or fluid from a container which has been left open. An open container of brake fluid will absorb moisture from the air and contaminate the fluid. CAUTION: Never use any type of a petroleum based fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid, etc. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1192 Brake Fluid: Testing and Inspection 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, Anti-Lock Brake System (ABS) hydraulic unit and all hydraulic fluid hoses. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1193 Brake Fluid: Service and Repair FLUID SPECIFICATIONS 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 an container which has been left open. An open container 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. FLUID LEVEL INSPECTION CAUTION: Always clean the master cylinder reservoir and caps before checking fluid level. If not cleaned, dirt could enter the fluid. Brake Fluid Level Inspection The fluid fill level is indicated on the side of the master cylinder reservoir. The correct fluid level is to the FULL indicator on the side of the reservoir. If necessary, add fluid to the proper level. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Specifications Clutch Fluid: Specifications CLUTCH FLUID Use DOT 3 brake fluid. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Engine - Coolant Recommendations Coolant: Technical Service Bulletins Engine - Coolant Recommendations NO: 07-03-97 GROUP: Cooling DATE: May 9, 1997 SUBJECT: Engine Coolant Usage THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 07-05-93 DATED NOV. 26, 1993 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE 1993 TECHNICAL SERVICE BULLETIN BOOK (PUBLICATION NO. 81-699-94000). THE COMPLETE BULLETIN IS REVISED. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1997 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Pickup/Ram Cab & Chassis/Ramcharger/ Power Ram/Power Ram Cab & Chassis 1989 - 1993 (AG) Daytona 1989 (AH) Lancer/LeBaron GTS 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - 1997 (AN) Dakota 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 1997 (BR) Ram Truck 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1997 (FJ) Sebring/Avenger/Talon 1996 - 1997 (GS) Chrysler Voyager (European Market) 1995 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1989 - 1992 (MJ) Comanche 1996 - 1997 (NS) Town & Country/Caravan/Voyager 1995 - 1997 (PL) Neon 1997 (PR) Prowler 1992 - 1997 (SR) Viper/Viper Coupe 1997 (TJ) Wrangler 1989 - 1997 (XJ) Cherokee 1989 - 1995 (YJ) Wrangler 1993 - 1997 (ZJ) Grand Cherokee DISCUSSION: Some owners have expressed interest in using engine coolants made with propylene glycol instead of ethylene glycol due to its lower toxicity and resultant reduced hazards to children and animals. Based on recent test data, most owners should not experience significant effects on cooling system performance when using propylene glycol based coolant. The use of national brand propylene glycol based engine coolant that meets the same Chrysler ethylene glycol specification of MS-7170 (or equivalent ASTM D5216) is acceptable for Chrysler built vehicles. NOTE: ANTIFREEZE SOLD FOR PROTECTING PLUMBING ETC. (RV ANTIFREEZE) IS NOT A SUITABLE ENGINE COOLANT. However, owners should be discouraged from changing their engine coolant prior to the regularly scheduled maintenance period. Prematurely changing engine coolant unnecessarily adds to the risk of environmental exposure. Sufficient freeze protection for the region should be maintained. However, do not use more than a 55% solution (-35 F, -37 C). Use the chart that accompanies the propylene glycol coolant, since a higher concentration is required to obtain the same freeze points as ethylene glycol coolant. If the temperatures for your region fall below this, use ethylene glycol coolant. Under severe driving conditions (towing a trailer in hot weather etc.) there may be a slight loss in cooling performance. If this is noticed, the system should be changed back to ethylene glycol coolant. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Engine - Coolant Recommendations > Page 1201 The two types of coolant should not be mixed. The standard testers for measuring freeze protection will not provide an accurate reading when this occurs. If the cooling system is changed to propylene glycol, all the ethylene glycol coolant should be removed using an approved cooling system flush procedure. The freeze protection of propylene glycol cannot be measured with a standard cooling system hydrometer. A refractometer or hydrometer calibrated for propylene glycol is the preferred test tool. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant Capacity ................................................................................................................................. ............................................. 13.3 liters ( 14.0 quarts) NOTES: - Nominal refill capacities are shown. A variation may be observed from vehicle to vehicle due to manufacturing tolerances and refill procedures. - Capacities shown include vehicles with air conditioning and/or heavy-duty cooling systems. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1204 Coolant: Fluid Type Specifications PREFERRED MIXTURE The required ethylene-glycol (antifreeze) and water mixture depends upon the climate and vehicle operating conditions. The recommended mixture of 60/50 ethylene-glycol and water will provide protection against freezing to -37°C (-35°F). 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 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 the specific heat of antifreeze is lower than that of water. UNACCEPTABLE MIXTURES 100 Percent Ethylene-Glycol 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 Formulations Propylene-glycol formulations do not meet Chrysler coolant specifications. Its 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 in Chrysler vehicles, which are 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 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. CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Service Precautions > Technician Safety Information Coolant: Technician Safety Information 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 running temperature, personal injury can result. Avoid radiator cooling fan when engine compartment related service is performed, personal injury can result. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Service Precautions > Technician Safety Information > Page 1207 Coolant: Vehicle Damage Warnings CAUTION: Do not use straight antifreeze as engine coolant, inadequate engine running temperatures can result. Do not operate vehicle without proper concentration of recommended ethylene glycol coolant, high running temperatures and cooling system corrosion can result. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > General Information Coolant: Description and Operation General Information 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 running temperature, personal injury can result. Avoid radiator cooling fan when engine compartment related service is performed, personal injury can result. CAUTION: Do not use straight antifreeze as engine coolant, inadequate engine running temperatures can result. Do not operate vehicle without proper concentration of recommended ethylene glycol coolant, high running temperatures and cooling system corrosion can result. DESCRIPTION The cooling system is designed around the coolant. Coolant flows through the engine water jacket absorbing heat produced during engine operation. PURPOSE The coolant carries the heat to radiator and heater core fins. Here it is transferred to the ambient air passing through the radiator and heater core fins. The coolant also removes heat from the automatic transmision. MIXTURE The cooling system factory fill is a mixture of 50% Ethylene Glycol based antifreeze and 50% water. Using a suitable hydrometer, measure antifreeze concentration in the radiator when the engine is cool. If the cooling system has recently been serviced, allow coolant to circulate for at least 20 minutes before taking hydrometer reading. Properly mixed coolant will protect the cooling system to -37°C (-35°F). If the freeze protection is above -28°C (-20°F), drain enough coolant from the cooling system to allow room to add antifreeze to achieve adequate protection. NOTE: Chrysler Corporation recommends Mopar Antifreeze/Coolant or a high quality, ethylene glycol base antifreeze/coolant, with a silicate inhibitor. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > General Information > Page 1210 Coolant: Description and Operation Coolant Performance PREFERRED MIXTURE The required ethylene-glycol (antifreeze) and water mixture depends upon the climate and vehicle operating conditions. The recommended mixture of 60/50 ethylene-glycol and water will provide protection against freezing to -37°C (-35°F). 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 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 the specific heat of antifreeze is lower than that of water. UNACCEPTABLE MIXTURES 100 Percent Ethylene-Glycol 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 Formulations Propylene-glycol formulations do not meet Chrysler coolant specifications. Its 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 in Chrysler vehicles, which are 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 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. CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > General Information > Page 1211 Coolant: Description and Operation Selection and Additives The presence of aluminum components in the cooling system requires strict corrosion protection. Maintain coolant at specified level with a mixture of ethylene-glycol based antifreeze and water. Chrysler Corporation recommends Mopar Antifreeze or equivalent. If coolant becomes contaminated or looses color, drain and flush cooling system and fill with correctly mixed solution. A 0.25 percent emulsifiable oil is added to the radiator at the factory to prevent solder corrosion. CAUTION: Do not use coolant additives that are claimed to improve engine cooling. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > Page 1212 Coolant: Service and Repair Refer to Cooling System, Service and Repair for applicable service procedures. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage Fluid - A/T: Technical Service Bulletins A/T - ATF + 4 Fluid Usage NUMBER: 21-014-07 GROUP: Transmission DATE: October 16, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-010-06, DATED APRIL 14, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES THE ADDITION OF THE ASIAN WARNER (AW4) TRANSMISSION AND ADDITIONAL MODELS AND YEARS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - **2008** (CS) Pacifica 1998-2003 (DN) Durango 2002 - **2008** (DR/DH/D1) Ram Truck 2007 - **2008** (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (GS) Chrysler Voyager (International Market) 2004 - **2008** (HB) Durango **2008 (HG) Aspen** 1995 - 2000 (JA) Cirrus/Stratus/Breeze Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1217 2007 - **2008** (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - **2008** (JS) Avenger/Sebring/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible **2007 - 2008 (KA) Nitro** 2002 - 2007 (KJ) Liberty **2008 (KK) Liberty** **2008 (L2) 300C (China)** 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - **2008** (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - **2008** (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager **2008 (RT) Town & Country/Grand Caravan/Grand Voyager (U.S. & International Markets)** 1997-2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - **2008** (WK/WH) Grand Cherokee 2006 - **2008** (XK/XH) Commander 1989 - 1995 (YJ) Wrangler **1989 - 2001 (XJ) Cherokee** **1989 - 1993 (MJ) Comanche** 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: **AWA (Asian Warner) transmission are now included in this Service Bulletin. ATF+4(R) is recommended for AW-4 (Asian Warner) transmissions** NOTE: This Service Bulletin DOES NOT apply to Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1218 Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE LISTED IN THE NOTE ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4(R) can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4® is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4® BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1219 Fluid - A/T: Technical Service Bulletins A/T - ATF+4 Fluid Usage/Applications NUMBER: 21-010-06 GROUP: Transmission DATE: April 14, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-004-04, DATED MARCH 16, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - 2007 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2007 (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (CS) Chrysler Voyager (International Market) 2004 - 2007 (HB) Durango 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1220 2007 (JS) Avenger/Sebring 1996 - 2000 (JX) Sebring Convertible 2002 - 2007 (KJ) Liberty 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - 2007 (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - 2007 (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - 2007 (WK/WH) Grand Cherokee 2006 - 2007 (XK/XH) Commander 1989 - 1995 (YJ) Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: This Service Bulletin DOES NOT apply to AW-4 transmissions, Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE NOTED ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4 can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4(R) is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1221 BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid 42/44RE ............................................................................................................................................... ............................................. 9.0-10.4L (9.5-11.0 Qt) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 1224 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Type ............................................................................................................ ....................................................... MOPAR ATF +4 Type 9602 or Equivalent Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Level Check Fluid - A/T: Service and Repair Fluid Level Check NOTE: Transmission fluid level should be checked monthly under normal operation. If the vehicle is used for trailer towing or similar heavy load hauling, check fluid level and condition weekly. Fluid level is checked with the engine running at curb idle speed, the transmission in NEUTRAL and the transmission fluid at normal operating temperature. PROCEDURE 1. Transmission fluid must be at normal operating temperature for accurate fluid level check. Drive vehicle if necessary to bring fluid temperature up to normal hot operating temperature of 82°C (180°F). 2. Position vehicle on level surface. 3. Start and run engine at curb idle speed. 4. Apply parking brakes. 5. Shift transmission momentarily into all gear ranges. Then shift transmission back to Neutral. 6. Clean top of filler tube and dipstick to keep dirt from entering tube. 7. Remove dipstick and check fluid level as follows: a. Correct acceptable level is in crosshatch area. b. Correct maximum level is to MAX arrow mark. c. Incorrect level is at or below MIN line. d. If fluid is low, add only enough MOPAR ATF+4 to restore correct level. Do not overfill. CAUTION: Do not overfill the transmission. Overfilling may cause leakage out the pump vent which can be mistaken for a pump seal leak. Overfilling will also cause fluid aeration and foaming as the excess fluid is picked up and churned by the gear-train. This will significantly reduce fluid life. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Level Check > Page 1227 Fluid - A/T: Service and Repair Fluid and Filter Replacement NOTE: The service fluid fill after a filter change is approximately 3.8 liters (4.0 quarts). REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan. 3. Remove bolts holding front and sides of pan to transmission. 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 bolt 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 screws holding filter to valve body. 10. Separate filter from valve body and pour fluid in filter into drain pan. 11. Dispose of used bans fluid and filter properly. INSPECTION Inspect bottom of pan and magnet for excessive amounts of metal or fiber contamination. A light coating of clutch or band material on the bottom of the pan does not indicate a problem unless accompanied by slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts or debris. Check the adjustment of the front and rear bands, adjust if necessary. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Level Check > Page 1228 CLEANING 1. Using a suitable solvent, clean pan and magnet. 2. Using a suitable gasket scraper, clean gasket material from gasket surface of transmission case and the gasket flange around the pan. INSTALLATION 1. Place replacement filter in position on valve body. 2. Install screws to hold filter to valve body. Tighten screws to 4 Nm (35 inch lbs.) torque. 3. Place new gasket in position on pan and install pan on transmission. 4. Place pan in position on transmission. 5. Install screws to hold pan to transmission. Tighten bolts to 17 Nm (150 inch lbs.) torque. 6. Lower vehicle and fill transmission with MOPAR ATF+4, type 9602 fluid, or equivalent. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications Four Wheel Drive Transmission Fluid .............................................................................................................................. .......................................................... 3.1L (6.5 Pints) The correct transmission lubricant level is to the bottom edge of the fill plug hole. Two Wheel Drive Transmission Fluid .............................................................................................................................. .......................................................... 3.1L (6.5 Pints) The correct transmission lubricant level is to the bottom edge of the fill plug hole. NV3500 Manual Transmission Transmission Fluid .............................................................................................................................. .......................................................... 2.2L (4.8 Pints) The correct transmission lubricant level is to the bottom edge of the fill plug hole. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 1233 Fluid - M/T: Fluid Type Specifications AX15 Manual Transmission Transmission Fluid Grade ................................................................................................................................................... ............................................. API GL-5 or equivalent Viscosity .............................................................................................................................................. .............................................................. SAE 75W-90 NV3500 Manual Transmission Transmission Fluid Required lubricant for the NV3500 is MOPAR Manual Transmission Lubricant, P/N 4761526. This is the only lubricant to be used in NV3500 transmissions. No other lubricants are acceptable, or recommended. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Page 1234 Fluid - M/T: Service Precautions DO NOT over fill transmission beyond normal fluid level markings. Fluid foaming and transmission damage may occur. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Front Axle - 194FIA Differential Oil Capacity Lube Capacity ...................................................................................................................................... ............................................... 1.72 liters (3.60 pints) 8 1/4 Axle Differential Oil Capacity Lube Capacity ...................................................................................................................................... ................................................ 2.22 Liters (4.7 pints) Trac-lok Additive .............................................. ........................................................................................................................................ 148 ml (5 ounces) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 1239 Fluid - Differential: Fluid Type Specifications Differential Fluid Type Grade ................................................................................................................................................... ................................................................... API GL-5 Viscosity .............................................................................................................................................. ..................................................................... 80W-90 If equipped with TRAC-LOK, include the specified amount of friction modifier. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Page 1240 Fluid - Differential: Service Precautions DO NOT over fill differential beyond normal fluid level. Fluid foaming and damage may occur. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications NV231 Transfer Case Transfer Case ...................................................................................................................................... ......................................................... 1.2L (2.5 Pints) Correct fill level is to the bottom edge of the fill plug hole. NV242 Transfer Case Transfer Case ...................................................................................................................................... ....................................................... 1.3L (2.8 Pints) Correct fill level is to the bottom edge of the fill plug hole. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 1245 Fluid - Transfer Case: Fluid Type Specifications Transfer Case Fluid MOPAR Dexron II, or ATF Plus type 9602 automatic transmission fluid Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Page 1246 Fluid - Transfer Case: Service Precautions DO NOT over fill transfer case beyond normal fluid level. Fluid foaming and damage may occur. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil Without Filter Change .......................................................................................................................... ............................................................. 3.3L (3.5 Qt) Capacity shown is without filter. When replacing filter. additional oil may be needed. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1251 Engine Oil: Fluid Type Specifications Engine Oil API Classification ................................................................................................................................. ........................................... SH or SH/CD or Above Above 0°F (-18°C).............................................. ........................................................................................................................................................ 10W-30 Below 32°F (0°C).................................................................................................................... ..................................................................................... 5W-30 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1252 Engine Oil: Service Precautions WARNING: NEW OR USED ENGINE OIL CAN BE IRRITATING TO THE SKIN. AVOID PROLONGED OR REPEATED SKIN CONTACT WITH ENGINE OIL. CONTAMINANTS IN USED ENGINE OIL, CAUSED BY INTERNAL COMBUSTION, CAN BE HAZARDOUS TO YOUR HEALTH. THOROUGHLY WASH EXPOSED SKIN WITH SOAP AND WATER. DO NOT WASH SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO NOT POLLUTE, DISPOSE OF USED ENGINE OIL PROPERLY. CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1253 Engine Oil: Description and Operation CAUTION: Do not use non-detergent or straight mineral oil when adding or changing crankcase lubricant. Engine failure can result. API SERVICE GRADE CERTIFIED Use an engine oil that is API Service Grade Certified or an oil that conforms to the API Service Grade SH or SH/CD. SAE VISCOSITY An SAE viscosity grade is used to specify the viscosity of engine oil. SAE 30 specifies a single viscosity engine oil. Engine oils also have multiple viscosities. These are specified with a dual SAE viscosity grade which indicates the cold-to-hot temperature viscosity range. Select an engine oil that is best suited to your particular temperature range and variation. ENERGY CONSERVING OIL An Energy Conserving type oil is recommended for gasoline engines. They are designated as either ENERGY CONSERVING or ENERGY CONSERVING II. CONTAINER IDENTIFICATION Standard engine oil identification notations have been adopted to aid in the proper selection of engine oil. The identifying notations are located on the label of engine oil plastic bottles and the top of engine oil cans. ENGINE OIL ADDITIVES In some instances, such as infrequent operation, short trip driving, and during break-in after a major overhaul, addition of special materials containing anti-rust and anti-scuff additives are beneficial. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1254 Engine Oil: Testing and Inspection CAUTION: Do not overfill crankcase with engine oil, oil foaming and oil pressure loss can result. NOTE: To ensure proper lubrication of an engine, the engine oil must be maintained at an acceptable level. The acceptable levels are indicated between the ADD and SAFE marks on the engine oil dipstick. 1. Position vehicle on level surface. 2. With engine OFF, allow approximately ten minutes for oil to settle to bottom of crankcase, remove engine oil dipstick. 3. Wipe dipstick clean. 4. Install dipstick and verify it is seated in the tube. 5. Remove dipstick, with handle held above the tip, take oil level reading. 6. Add oil only if level is below the add mark on the dipstick. 7. Replace dipstick. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1255 Engine Oil: Service and Repair NOTE: Run engine until achieving normal operating temperature. 1. Position the vehicle on a level surface and turn engine off. 2. Hoist and support vehicle on safety stands. 3. Remove oil fill cap. 4. Place a suitable drain pan under crankcase drain. 5. Remove drain plug from crankcase and all oil to drain into pan. Inspect drain plug threads for stretching or other damage. Replace drain plug and gasket if damaged. 6. Install drain plug in crankcase. 7. Lower vehicle and fill crankcase with specified type and amount of engine oil. 8. Install oil fill cap. 9. Start engine and inspect for leaks. 10. Stop engine and inspect oil level. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage Power Steering Fluid: Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 1260 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 1261 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 1262 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 1263 Power Steering Fluid: Specifications The OE Service Manual does not provide a Power Steering Fluid Type Specification. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Refrigerant Capacity 0.907 kg (32 oz) Refrigerant Oil Capacity - A/C System = 230 ml (7.75 oz) - Accumulator = 120 ml (4 oz) - Condenser = 30 ml (1 oz) - Evaporator = 60 ml (2 oz) - Compressor = Drain and measure the oil from the old compressor. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1268 Refrigerant: Fluid Type Specifications Hydrofluorocarbon (HFC), ................................................................................................................... ............................................... R-134a liquefied gas Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 1269 Refrigerant: Description and Operation REFRIGERANT The R-134a refrigerant used in this air conditioning system is a non-toxic, non-flammable, clear, and colorless liquefied gas. R-134a refrigerant is not compatible with R-12 refrigerant in an air conditioning system. Even a small amount of R-12 added to a R-134a refrigerant system, will cause compressor failure, refrigerant oil sludge, or poor air conditioning system performance. The refrigerant system service ports have been designed to ensure that the system is not accidentally filled with the wrong refrigerant (R-12). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Total System ........................................................................................................................................ ........................................................... 230 ml 7.75 oz. Accumulator ......................................................................................................................................... ............................................................ 120 ml 4.0 oz. Condenser ........................................................................................................................................... ................................................................ 30 ml 1.0 oz. Evaporator ........................................................................................................................................... ............................................................... 60 ml 2.0 oz. Compressor ............................................................................................................................................. Drain and measure the oil from the old compressor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 1274 Refrigerant Oil: Fluid Type Specifications Synthetic-based, Polyalkylene Glycol .................................................................................................. ......................................................................... SP-20 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 1275 Refrigerant Oil: Service and Repair Refrigerant Oil Capacities Refrigerant Oil Level When an air conditioning system is assembled at the factory, all components (except the compressor are refrigerant oil free. After the system has been charged and operated, the oil in the compressor is dispersed throughout the refrigerant system. The accumulator, evaporator, condenser, and compressor will each retain a significant amount of oil. It is important to have the correct amount of oil in the refrigerant system. This will ensure proper lubrication of the compressor. Too little oil will result in damage to the compressor. Too much oil will reduce the cooling capacity of the system. It will not be necessary to check the oil level in the compressor or to add oil, unless there has been an oil loss. This may be due to a rupture or leak from a refrigerant line, a compressor shaft seal, an evaporator, or a condenser. If a rupture occurs, add 30 ml (1 ounce) of oil to the system after the repair has been made. Oil loss at a leak point will be evident by the presence of a wet, shiny surface around the leak. Refrigerant oil must be added when a accumulator, evaporator, or condenser are replaced. See the Refrigerant Oil Capacities chart. When a compressor is replaced, the oil must be drained from the old compressor and measured. Drain all the oil from the new compressor, then fill the new compressor with the same amount of oil that was drained out of the old compressor. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Bleeding Procedures Brake Bleeding: Service and Repair Antilock Brake System Bleeding Procedures W/ Four Wheel Antilock Brakes Anti-Lock Brake System (ABS) bleeding requires conventional bleeding methods plus use of the Diagnostic Readout Box (DRB) scan tool. The procedure involves performing a base brake bleeding, followed by use of the scan tool to cycle and bleed the Hydraulic Control Unit (HCU) pump and solenoids. A second base brake bleeding procedure is then required to remove any air remaining in the system. 1. Perform base brake bleeding procedure. See: 2. Connect scan tool to the Data Link Connector (DLC). 3. Select ANTILOCK BRAKES, followed by MISCELLANEOUS, then ABS BRAKES. Follow the instructions displayed. When scan tool displays TEST COMPLETE, disconnect scan tool and proceed. 4. Perform base brake bleeding a second time. 5. Top off master cylinder fluid level and verify proper brake operation before moving vehicle. W/ Rear Wheel Antilock Brakes Rear Wheel Anti-Lock (RWAL) brake bleeding can be performed manually, or with vacuum/pressure equipment. Bleed only one brake component at a time. Recommended bleed sequence is: 1. Master Cylinder 2. Combination Valve 3. Rear Anti-Lock Valve 4. Left Rear Wheel 5. Right Rear Wheel 6. Right Front Wheel 7. Left Front Wheel Use Mopar DOT 3 brake fluid, or an equivalent meeting SAE J1703-F and DOT 3 standards, to fill and bleed the system. Use a bleed hose at each caliper/cylinder bleed screw. Attach one end of the hose to the bleed screw and insert the opposite end in glass container partially filled with brake fluid. A glass container makes it easier to see air bubbles as they exit the bleed hose. Be sure the end of the bleed hose remains immersed in fluid. This prevents air from being drawn back into the system. Do not allow the master cylinder to run out of fluid when bleeding the brakes. An empty cylinder will allow air to be drawn back into the system. Check fluid level frequently during bleeding operations. Be sure to tighten each brake line fitting, or bleed screw once bleeding is completed. Loose fittings and bleed screws allow air to enter the system. Vacuum Bleeding If vacuum bleeding equipment is being used, it is not necessary to hold the front brake metering valve open. Simply bleed the brakes following the bleed equipment manufacturer's instructions. Pressure Bleeding If pressure bleeding equipment will be used, the front brake metering valve will have to be held open to bleed the front brakes. The valve stem is located in the forward end of the combination valve. The stem must either be pressed inward, or held outward slightly. a spring clip tool or helper is needed to hold the valve stem in position. Follow the manufacturer's instructions carefully when using pressure equipment. Do not exceed the tank manufacturer's pressure recommendations. Generally, a tank pressure of 15-20 psi is more than sufficient for bleeding purposes. Fill the bleeder tank with recommended fluid and purge air from the tank lines before bleeding. NOTE: ^ Do not pressure bleed without a proper master cylinder adapter. The wrong adapter can lead to leakage, or drawing air back into the system. ^ Make sure the front brake metering valve in the combination valve is held open. A spring clip tool is best for securing the valve stem in an open position. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Bleeding Procedures > Page 1280 Brake Bleeding: Service and Repair Base Brake System Bleeding BASE BRAKE SYSTEM BLEEDING NOTE: The following procedure describes a manual bleed of the base brake system. Additional steps may be required for Anti-Lock Brake System (ABS) components. CAUTION: - Use Mopar brake fluid or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. - Do not pump the brake pedal at any time while bleeding. Air in the system will be compressed into small bubbles that are distributed throughout the hydraulic system. This will make additional bleeding operations necessary. - Do not allow the master cylinder to run out of fluid during bleed operations. An empty cylinder will allow additional air to be drawn into the system. Check the cylinder fluid level frequently and add fluid as needed. NOTE: The brakes should be bled in sequence: First, bleed the right rear wheel, then the left rear wheel. Next, move to the front brakes and bleed the right front wheel and, finally, the left front wheel. 1. Remove reservoir filler caps and fill reservoir with brake fluid. 2. If calipers or wheel cylinders were overhauled, open all caliper and wheel cylinder bleed screws. Then close each bleed screw as fluid starts to drip from it. Top off master cylinder reservoir once more before proceeding. 3. Attach one end of bleed hose to bleed screw and insert opposite end in glass container partially filled with brake fluid. Be sure end of bleed hose is immersed in fluid. 4. Open up bleeder, then have a helper press down the brake pedal. Once the pedal is down close the bleeder. Repeat bleeding until fluid stream is clear and free of bubbles, then move to the next wheel. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Arming and Disarming The airbag system is a sensitive, complex electromechanical unit. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components you must first disconnect and isolate the battery negative (ground) cable. Then wait two minutes for the system capacitor to discharge before further system service. This is the only sure way to disable the airbag system. Failure to do this could result in accidental air-bag deployment and possible personal injury. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > Customer Interest for Fuse: > 08-03-97 > Feb > 97 > Instrument Cluster - Gauges Inoperative Fuse: Customer Interest Instrument Cluster - Gauges Inoperative NO: 08-03-97 GROUP: Electrical DATE: Feb. 14, 1997 SUBJECT: Inoperative Gauges MODELS: 1997 (AN) Dakota SYMPTOM/CONDITION: Inoperative instrument cluster gauges and overhead console due to blown fuse 11 in the junction block. DIAGNOSIS: Inspect fuse 11 in the junction block to verify that the fuse is blown. If the fuse is blown, perform the following diagnostic procedure. If the instrument cluster gauges and/or overhead console is inoperative but fuse 11 is good, refer to the 1997 Dakota Service Manual (Publication No. 81-370-7110), Group 8E for instrument cluster service and Group 8V for overhead console service. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > Customer Interest for Fuse: > 08-03-97 > Feb > 97 > Instrument Cluster - Gauges Inoperative > Page 1293 For the above diagnosis, refer to the 1997 AN Service Manual (Publication No. 81-370- 7110), page 8W-40-2 for circuit identification. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 08-03-97 > Feb > 97 > Instrument Cluster - Gauges Inoperative Fuse: All Technical Service Bulletins Instrument Cluster - Gauges Inoperative NO: 08-03-97 GROUP: Electrical DATE: Feb. 14, 1997 SUBJECT: Inoperative Gauges MODELS: 1997 (AN) Dakota SYMPTOM/CONDITION: Inoperative instrument cluster gauges and overhead console due to blown fuse 11 in the junction block. DIAGNOSIS: Inspect fuse 11 in the junction block to verify that the fuse is blown. If the fuse is blown, perform the following diagnostic procedure. If the instrument cluster gauges and/or overhead console is inoperative but fuse 11 is good, refer to the 1997 Dakota Service Manual (Publication No. 81-370-7110), Group 8E for instrument cluster service and Group 8V for overhead console service. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 08-03-97 > Feb > 97 > Instrument Cluster - Gauges Inoperative > Page 1299 For the above diagnosis, refer to the 1997 AN Service Manual (Publication No. 81-370- 7110), page 8W-40-2 for circuit identification. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations Relay Box: Locations Power Distribution Center Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1303 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation MALFUNCTION INDICATOR LAMP (MIL) As a functional test, the MIL (check engine) illuminates at key-on before engine cranking. Whenever the Powertrain Control Module (PCM) sets a Diagnostic Trouble Code (DTC) that affects vehicle emissions, it illuminates the MIL. If a problem is detected, the PCM sends a message to the instrument cluster to illuminate the lamp. The PCM illuminates the MIL only for DTC's that affect vehicle emissions. There are some monitors that may take two consecutive trips, with a detected fault, before the MIL is illuminated. The MIL stays on continuously when the PCM has entered a Limp-In mode or identified a failed emission component. Also, the MIL either flashes or illuminates continuously when the PCM detects active engine misfire. Refer to Misfire Monitoring. Additionally, the PCM may reset (turn off) the MIL when one of the following occur: PCM does not detect the malfunction for 3 consecutive trips (except misfire and Fuel system Monitors). - PCM does not detect a malfunction while performing three successive engine misfire or fuel system tests. The PCM performs these tests while the engine is operating within +/- 375 RPM of and within 10% of the load of the operating condition at which the malfunction was first detected. BULB CHECK Each time the ignition key is turned to the ON position, the malfunction indicator (check engine) lamp on the instrument panel should illuminate for approximately 2 seconds then go out. This is done for a bulb check. CIRCUIT OPERATION The Powertrain Control Module (PCM) provides ground for the MIL on circuit G3. Circuit G3 connects to cavity C17 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 1308 Malfunction Indicator Lamp: Testing and Inspection The diagnosis found here addresses an inoperative malfunction indicator lamp condition. If the malfunction indicator lamp comes on and stays on with the engine running, refer to Instrument Panel, Gauges and Warning Indicators for diagnosis. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. If the malfunction indicator lamp fails to light during the bulb test (about two seconds after the ignition switch is turned to the On position), replace the malfunction indicator lamp bulb with a known good unit. If the indicator lamp still fails to operate, diagnosis of the Powertrain Control Module (PCM) and the Chrysler Collision Detection (CCD) data bus should be performed with a DRB scan tool. For diagnosis of the malfunction indicator lamp and the instrument cluster circuitry, see Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Instrument Cluster. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Description and Operation Spare Tire: Description and Operation The temporary spare tire is designed for emergency use only. The original tire should be repaired and reinstalled at the first opportunity, or replaced with a new. Do not exceed speeds of 50 MPH when the temporary spare tire is in use on the vehicle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Tire & Wheel - Runout Wheels: Technical Service Bulletins Tire & Wheel - Runout NO: 22-01-97 GROUP: Wheels & Tires DATE: Jun. 13, 1997 SUBJECT: Tire & Wheel Runout MODELS: 1994 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1994 - 1997 (AB) Ram Van/Wagon 1994 - 1995 (AJ) LeBaron Convertible 1994 - 1997 (AN) Dakota 1994 (AP) Shadow/Sundance 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1997 (BR) Ram Pickup 1994 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1997 (FJ) Sebring/Avenger/Talon 1996 - 1997 (GS) Chrysler Voyager (International Market) 1995 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1994 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1997 (NS) Town & Country/Caravan/Voyager 1995 - 1997 (PL) Neon 1994 - 1997 (SR) Viper/Viper GTS 1997 (TJ) Wrangler 1994 - 1997 (XJ) Cherokee 1994 - 1995 (YJ) Wrangler 1994 - 1997 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Radial runout is the vertical distance between the high and low points on the tire or wheel edge measured at the center line of the tread. Lateral runout is the horizontal movement of the tire or wheel measured near the shoulder of the tire. Runout of more than the preferred specification may cause the vehicle to shake. Refer to the following specifications and appropriate Service Manual procedures. PREFERRED TIRE & WHEEL RUNOUT Usually runout can be reduced by relocating the wheel and tire on the wheels studs and/or rotating the tire on the wheel (match mounting). POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1318 Wheels: Service Precautions CAUTION: Do not use chrome plated lug nuts with chrome plated wheels. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1319 Wheels: Description and Operation Fig. 1 Available rim sizes are on the safety certification label located on the drivers door shut face. Rim size is determined by the drivetrain package. Original equipment wheels are designed for operation up to the specified maximum vehicle capacity. All models use steel or cast aluminum wheels. Every wheel has raised sections between the rim flanges and rim drop well called safety humps. Initial inflation of the tire forces the bead over these raised sections. In case of rapid loss of air pressure, the raised sections help hold the tire on the wheel. Cast aluminum wheels require coated balance weights and special alignment equipment. The wheel studs and nuts are designed for specific applications and must be replaced with equivalent parts. Do not use replacement parts of lesser quality or a substitute design. All aluminum and some steel wheels have wheel stud nuts with an enlarged nose. This enlarged nose is necessary to ensure proper retention of the wheels. Before installing the wheel, remove any build up of corrosion on the wheel mounting surfaces. CAUTION: Installing wheels without good metal-to-metal contact could cause loosening of wheel nuts. This could adversely affect the safety and handling of your vehicle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1320 Wheels: Testing and Inspection CAUTION: - Failure to use equivalent replacement wheels may adversely affect the safety and handling of the vehicle. - Replacement with used wheels is not recommended. The service history of the rim may have included severe treatment or very high mileage. The rim could fail without warning. - Wheel repairs employing hammering, heating, welding or repairing leaks are not allowed. Wheels must be replaced if they: - Have excessive run out - Are bent or dented - Leak air from any area or surface of the rim - Have damaged wheel lug/ nut holes NOTE: Original equipment replacement wheels should be used. When obtaining replacement wheels, they should be equivalent in load carrying capacity. The physical dimensions (diameter, width, offset, pilot hole and bolt circle) of the wheel should be the same as the original wheel. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1321 Wheels: Service and Repair REPLACEMENT NOTES: Wheels must be replaced if they have: Excessive runout - Bent or dented - Leak air through welds - Have damaged bolt holes , NOTE: Wheel repairs employing hammering, heating, or welding are not allowed. Original equipment wheels are available through your dealer. Replacement wheels from any other source should be equivalent in: Load carrying capacity - Diameter - Width - Offset - Mounting configuration Failure to use equivalent replacement wheels may affect the safety and handling of your vehicle. Replacement with used wheels is not recommended. Their service history may have included severe treatment. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Front Hub Seals - Grease Purge Explanation Wheel Bearing: Technical Service Bulletins Front Hub Seals - Grease Purge Explanation NUMBER: 02-06-99 Rev. A GROUP: Suspension DATE: Dec. 17, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-06-99, DATED JUNE 11, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF 4X2 MODELS AND ADDITIONAL MODEL YEARS. SUBJECT: Front Wheel Bearing Grease Is Evident On The Bearing Seal Area. MODELS: 1997 - **2000** (AN) Dakota 1994 - **2000** (BR/BE) Ram Truck 1998 - **2000** (DN) Durango DISCUSSION: Front wheel bearings may be incorrectly diagnosed as faulty due to the evidence of wheel bearing grease on the bearing seal areas. This grease purge is a normal design condition. The factory fill of the bearings includes a slightly greater amount of grease than is required for the bearing lifetime lubricant. A portion of the grease purges through the self-venting seal in the initial few thousand miles to form an additional barrier in the area of the seal and the stamped slinger. This barrier aids in the prevention of contaminants passing through the seal and into the bearing. Do not remove or clean the purged grease as part of normal maintenance due to the fact that it provides additional protection and once removed, damage to the seal and bearing could result. NOTE: UNDER NORMAL CONDITIONS, THERE MAY BE A SPLATTERING OF GREASE RADIALLY OUTWARD ON THE STEERING KNUCKLE FROM THE GREASE BARRIER AREA THAT CAN BE AS THICK AS 4 MM (0.125 IN.). Front wheel bearings should be replaced only if: ^ The seal shows visible damage ^ The bearing endplay is greater than 0.13 mm (0.005 in.) ^ The bearing was operated without the proper clamping force from the spindle nut ^ The bearing has a rough, sticky feel when rotated POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Page 1326 Wheel Bearing: Specifications Lubricant Type Lubricant Type Wheel Bearing Grease NLGI GC rated automotive grease Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Page 1327 Wheel Bearing: Service and Repair REMOVAL 1. Raise and support vehicle. 2. Remove wheel and tire assembly. 3. Remove brake caliper and rotor, refer to Brakes and Traction Control. 4. Remove hub/bearing spindle nut. 5. Slide hub/bearing off spindle. INSTALLATION 1. Slide hub/bearing on spindle. 2. Install hub/bearing spindle nut and tighten to 251 Nm (185 ft. lbs.). 3. Install brake rotor and caliper, refer to Brakes and Traction Control. 4. Install wheel and tire assembly. 5. Remove support and lower vehicle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Nut ....................................................................................................................................................... ................................................. 251 Nm (185 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Tightening Sequence Wheel Fastener: Specifications Wheel Tightening Sequence Wheel Torque Sequence - Master Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Tightening Sequence > Page 1336 Wheel Fastener: Specifications Lug Nut Torque Lug Nut ................................................................................................................................................ ................................ 115 - 150 Nm (85 - 110 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 1337 Wheel Fastener: Service and Repair REMOVAL 1. Raise and support vehicle. 2. Remove wheel and tire assembly. 3. Remove brake caliper and rotor, refer to Brakes and Traction Control. 4. Remove stud from hub with Remover C-4150A, or equivalent. INSTALLATION 1. Install new stud into hub flange. 2. Install three washers onto stud, then install lug nut with the flat side of the nut against the washers. 3. Tighten lug nut until the stud is pulled into the hub flange. Verify that the stud is properly seated into the flange. 4. Remove lug nut and washers. 5. Install the brake rotor and caliper, refer to Brakes and Traction Control. 6. Install wheel and tire assembly, use new lug nut on stud or studs that were replaced. 7. Remove support and lower vehicle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications Compression should not be less than 689 kPa (100 psi) and not vary more than 172 kPa (25 psi) from cylinder to cylinder. If cylinder(s) have abnormally low compression pressures, repeat procedure. - If the same cylinder(s) repeat an abnormally low reading, it could indicate the existence of a problem in the cylinder. NOTE: The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should NOT be disassembled to determine the cause of low compression unless some malfunction is present. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 1343 Compression Check: Testing and Inspection NOTE: - 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. CAUTION: DO NOT overspeed the engine. a. Check engine oil level and add oil, if necessary. b. Drive the vehicle until engine reaches normal operating temperature. c. Select a route free from traffic and other forms of congestion, observe all traffic laws and briskly accelerate through the gears several times. The higher engine speed may help clean out valve seat deposits which can prevent accurate compression readings. d. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for abnormal firing indicators-fouled, hot, oily, etc. Record cylinder number of spark plug for future reference. e. Disconnect coil wire from distributor and secure to good ground to prevent a spark from starting a fire. f. Be sure throttle blades are fully open during the compression check. g. Insert compression gauge adapter into the No. 1 spark plug hole. Crank engine until maximum pressure is reached on gauge. Record this pressure as No.1 cylinder pressure. h. Repeat above step for all remaining cylinders. i. Compression should not be less than 689 kPa (100 psi) and not vary more than 172 kPa (25 psi) from cylinder to cylinder. j. If cylinder(s) have abnormally low compression pressures, repeat procedure. k. If the same cylinder(s) repeat an abnormally low reading, it could indicate the existence of a problem in the cylinder. NOTE: The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should NOT be disassembled to determine the cause of low compression unless some malfunction is present. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications Camshaft Bearing: Specifications BEARING DIAMETER: No. 1 .............................................................................................................................................................. 50.800 - 50.825 mm (2.0000 - 2.0010 inch) No. 2 .............................................................................................................................................................. 50.394 - 50.419 mm (1.9840 - 1.9850 inch) No. 3 .............................................................................................................................................................. 49.606 - 49.632 mm (1.9530 - 1.9540 inch) No. 4 .............................................................................................................................................................. 39.688 - 39.713 mm (1.5625 - 1.5635 inch) Diametrical Clearance ................................................................................................................................... 0.0254 - 0.0762 mm (0.0010 - 0.0030 inch) Max. Allowable ......................................................................................... .................................................................................. 0.127 mm (0.0050 inch) BEARING JOURNAL DIAMETER: No. 1 .............................................................................................................................................................. 50.749 - 50.775 mm (1.9980 - 1.9990 inch) No. 2 .............................................................................................................................................................. 50.343 - 50.368 mm (1.9820 - 1.9830 inch) No. 3 .............................................................................................................................................................. 49.555 - 49.581 mm (1.9510 - 1.9520 inch) No. 4 .............................................................................................................................................................. 39.637 - 39.662 mm (1.5605 - 1.5615 inch) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications > Page 1348 Camshaft Bearing: Service and Repair REMOVAL 1. With engine completely disassembled, drive out rear cam bearing core hole plug. 2. Install proper size adapters and horseshoe washers (part of Camshaft Bearing Remover/Installer Tool C-3132-A, or equivalent) at back of each bearing shell. Drive out bearing shells. INSTALLATION 1. Install new camshaft bearings with Camshaft Bearing Remover/Installer Tool C-3132-A, or equivalent by sliding the new camshaft bearing shell over proper adapter. 2. Position rear bearing in the tool. Install horseshoe lock and, by reversing removal procedure, carefully drive bearing shell into place. 3. Install remaining bearings in the same manner. Bearings must be carefully aligned to bring oil holes into full register with oil passages from the main bearing. If the camshaft bearing shell oil holes are not in exact alignment, remove and install them correctly. Install a new core hole plug at the rear of camshaft. Be sure this plug does not leak. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications > Page 1349 Cam Bearing Remover/Installer C-3132-A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Camshaft Sprocket Bolt ....................................................................................................................... .................................................... 68 Nm (50 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Thrust Plate > Component Information > Specifications Camshaft Thrust Plate: Specifications Mounting Bolts ..................................................................................................................................... .................................................... 24 Nm (18 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications Camshaft: Specifications End Play .............................................................................................................................................. ...................... 0.051 - 0.254 mm (0.002 - 0.010 inch) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Replacement Camshaft: Service and Repair Camshaft Replacement NOTES: - This procedure requires that the engine is removed from the vehicle. - The camshaft has an integral oil pump and distributor drive gear. REMOVAL 1. Remove intake manifold. 2. Remove cylinder head covers. 3. Remove timing case cover and timing chain. 4. Remove rocker arms. 5. Remove push rods and tappets. Identify each part so it can be installed in the original locations. 6. Remove distributor and lift out the oil pump and distributor drive shaft. 7. Remove camshaft thrust plate and note location of oil tab. 8. Install a long bolt into front of camshaft to facilitate removal of the camshaft. Remove camshaft, being careful not to damage cam bearings with the cam lobes. INSTALLATION 1. Lubricate camshaft lobes and camshaft bearing journals and insert the camshaft to within 51 mm (2 inches) of its final position in cylinder block. NOTE: Whenever an engine has been rebuilt, a new camshaft and/or new tappets installed, add one pint of Mopar Crankcase Conditioner, or equivalent. The oil mixture should be left in engine for a minimum of 805 km (500 miles). Drain at the next normal oil change. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Replacement > Page 1361 2. Install Camshaft Gear Installer Tool C-3509, or equivalent with tongue back of distributor drive gear. 3. Hold tool in position with a distributor lockplate bolt. This tool will restrict camshaft from being pushed in too far and prevent knocking out the Welch plug in rear of cylinder block. Tool should remain installed until the camshaft and crankshaft sprockets and timing chain have been installed. 4. Install camshaft thrust plate and chain oil tab. Be sure tang enters lower right hole in thrust plate. Tighten bolts to 24 Nm (210 inch lbs.) torque. Top edge of tab should be flat against thrust plate in order to catch oil for chain lubrication. 5. Place both camshaft sprocket and crankshaft sprocket on the bench with timing marks on an exact imaginary center line through both camshaft and crankshaft bores. 6. Place timing chain around both sprockets. 7. Turn crankshaft and camshaft to line up with keyway location in crankshaft sprocket and in camshaft sprocket. 8. Lift sprockets and chain (keep sprockets tight against the chain in position as described). 9. Slide both sprockets evenly over their respective shafts and use a straightedge to check alignment of timing marks. 10. Install the camshaft bolt/cup washer. Tighten bolt to 68 Nm (50 ft. lbs.) torque. 11. Measure camshaft end play. Refer to Specifications for proper clearance. If not within limits, install a new thrust plate. 12. Each tappet reused must be installed in the same position at which it was removed. When camshaft is replaced, all of the tappets must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Replacement > Page 1362 Camshaft: Service and Repair Shaft Prealignments NOTE: Before installing the distributor, the oil pump drive shaft must be aligned to number one cylinder. 1. Rotate crankshaft until No.1 cylinder is at top dead center on the firing stroke. 2. When in this position, the timing mark of vibration damper should be under "0" on the timing indicator. 3. Install the shaft so that after the gear spirals into place, it will index with the oil pump shaft. The slot on top of oil pump shaft should be aligned towards the left front intake manifold attaching bolt hole. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Page 1363 Camshaft Holder C-3509 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Hydraulic Tappet <--> [Lifter / Lash Adjuster, Valve] > Component Information > Specifications Hydraulic Tappet: Specifications Body Diameter .................................................................................................................................................. 22.949 - 22.962 mm (0.9035 - 0.9040 inch) Clearance in Block ............................................................................................................................................ 0.0279 0.0610 mm (0.0011 - 0.0024 inch) Dry Lash ....................................................................................... ............................................................................. 1.524 - 5.334 mm (0.060 - 0.210 inch) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Hydraulic Tappet <--> [Lifter / Lash Adjuster, Valve] > Component Information > Specifications > Page 1367 Hydraulic Tappet: Service Precautions CAUTION: The plunger and tappet bodies are not interchangeable. The plunger and valve must always be fitted to the original body. It is advisable to work on one tappet at a time to avoid mixing of parts. Mixed parts are not compatible. DO NOT disassemble a tappet on a dirty work bench. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Hydraulic Tappet <--> [Lifter / Lash Adjuster, Valve] > Component Information > Testing and Inspection > Pre-Checks Hydraulic Tappet: Testing and Inspection Pre-Checks CHECKING OIL PRESSURE Before disassembling any part of the engine to correct tappet noise, check the oil pressure. If vehicle has no oil pressure gauge, install a reliable gauge at the pressure sending unit. The pressure should be between 207 - 552 kPa (30 - 80 psi) at 3,000 RPM. CHECKING OIL LEVEL Check the oil level after the engine reaches normal operating temperature. Allow 5 minutes to stabilize oil level, check dipstick. The oil level in the pan should never be above the FULL mark or below the ADD OIL mark on dipstick. Either of these two conditions could be responsible for noisy tappets. High Oil Level If oil level is above the FULL mark, it is possible for the connecting rods to dip into the oil. With the engine running, this condition could create foam in the oil pan. Foam in oil pan would be fed to the hydraulic tappets by the oil pump causing them to lose length and allow valves to seat noisily. Low Oil Level Low oil level may allow oil pump to take in air. When air is fed to the tappets, they lose length, which allows valves to seat noisily. Any leaks on intake side of oil pump through which air can be drawn will create the same tappet action. Check the lubrication system from the intake strainer to the pump cover, including the relief valve retainer cap. When tappet noise is due to aeration, it may be intermittent or constant, and usually more than one tappet will be noisy. When oil level and leaks have been corrected, operate the engine at fast idle. Run engine for a sufficient time to allow all of the air inside the tappets to be bled out. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Hydraulic Tappet <--> [Lifter / Lash Adjuster, Valve] > Component Information > Testing and Inspection > Pre-Checks > Page 1370 Hydraulic Tappet: Testing and Inspection Noise Diagnosis 1. To determine source of tappet noise, operate engine at idle with cylinder head covers removed. 2. Feel each valve spring or rocker arm to detect noisy tappet. The noisy tappet will cause the affected spring and/or rocker arm to vibrate or feel rough in operation. NOTE: Worn valve guides or cocked springs are sometimes mistaken for noisy tappets. If such is the case, noise may be dampened by applying side thrust on the valve spring. If noise is not appreciably reduced, it can be assumed the noise is in the tappet. Inspect the rocker arm push rod sockets and push rod ends for wear. 3. Valve tappet noise ranges from light noise to a heavy click. A light noise is usually caused by excessive leak-down around the unit plunger, or by the plunger partially sticking in the tappet body cylinder. The tappet should be replaced. A heavy click is caused by a tappet check valve not seating, or by foreign particles wedged between the plunger and the tappet body. This will cause the plunger to stick in the down position. This heavy click will be accompanied by excessive clearance between the valve stem and rocker arm as valve closes. In either case, tappet assembly should be removed for inspection and cleaning. 4. The valve train generates a noise very much like a light tappet noise during normal operation. Care must be taken to ensure that tappets are making the noise. If more than one tappet seems to be noisy, it's probably not the tappets. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Hydraulic Tappet <--> [Lifter / Lash Adjuster, Valve] > Component Information > Service and Repair > Removal and Installation Hydraulic Tappet: Service and Repair Removal and Installation REMOVAL 1. Remove the air cleaner. 2. Remove cylinder head cover. 3. Remove rocker assembly and push rods. Identify push rods to ensure installation in original locations. 4. Remove intake manifold. 5. Remove yoke retainer and aligning yokes. 6. Slide Hydraulic Tappet Remover/Installer Tool C-4129-A, or equivalent through opening in cylinder head and seat tool firmly in the head of tappet. 7. Pull tappet out of bore with a twisting motion. If all tappets are to be removed, identify tappets to ensure installation in original location. 8. If the tappet or bore in cylinder block is scored, scuffed, or shows signs of sticking, ream the bore to next oversize. Replace with oversize tappet. INSTALLATION 1. Lubricate tappets. 2. Install tappets and push rods in their original positions. Ensure that the oil feed hole in the side of the tappet body faces up (away from the crankshaft). 3. Install aligning yokes with ARROW toward camshaft. 4. Install yoke retainer. Tighten the bolts to 23 Nm (200 inch lbs.) torque. Install intake manifold. 5. Install push rods in original positions. 6. Install rocker arms. 7. Install cylinder head cover. 8. Start and operate engine. Warm up to normal operating temperature. CAUTION: To prevent damage to valve mechanism, engine must not be run above fast idle until all hydraulic tappets have filled with oil and have become quiet. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Hydraulic Tappet <--> [Lifter / Lash Adjuster, Valve] > Component Information > Service and Repair > Removal and Installation > Page 1373 Hydraulic Tappet: Service and Repair Disassembly and Assembly CAUTION: The plunger and tappet bodies are not interchangeable. The plunger and valve must always be fitted to the original body. It is advisable to work on one tappet at a time to avoid mixing of parts. Mixed parts are not compatible. DO NOT disassemble a tappet on a dirty work bench. DISASSEMBLE 1. Pry out plunger retainer spring clip. 2. Clean varnish deposits from inside of tappet body above plunger cap. 3. Invert tappet body and remove plunger cap, plunger, check valve, check valve spring, check valve retainer, and plunger spring. Check valve could be flat or ball. ASSEMBLE 1. Clean all tappet parts in a solvent that will remove all varnish and carbon. 2. Replace tappets that are unfit for further service with new assemblies. 3. If plunger shows signs of scoring or wear, install a new tappet assembly. If valve is pitted, or valve seat on end of plunger is prevented from seating, install a new tappet assembly. 4. Assemble tappets. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod > Component Information > Specifications Push Rod: Specifications Length .................................................................................................................................................. ................. 175.64 - 176.15 mm (6.915 - 6.935 inch) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod > Component Information > Specifications > Page 1377 Push Rod: Service and Repair REMOVAL 1. Disconnect spark plug wires by pulling on the boot straight out in line with plug. 2. Remove cylinder head cover and gasket. 3. Remove the rocker arm bolts and pivots. Place them on a bench in the same order as removed. 4. Remove the push rods and place them on a bench in the same order as removed. CAUTION: DO NOT rotate or crank the engine during or immediately after rocker arm installation. Allow the hydraulic roller tappets adequate time to bleed down (about 5 minutes). INSTALLATION 1. Rotate the crankshaft until the "V6" mark lines up with the Top Dead Center (TDC) mark on the timing chain case cover. This mark is located 147 ° After Top Dead Center (ATDC) from the No.1 firing position. 2. Install the push rods in the same order as removed. 3. Install rocker arm and pivot assemblies in the same order as removed. Tighten the rocker arm bolts to 28 Nm (21 ft. lbs.) torque. 4. Install cylinder head cover. 5. Connect spark plug wires. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications Rocker Arm Bolts 21 ft.lb Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications > Page 1381 Rocker Arm Assembly: Service and Repair REMOVAL 1. Disconnect spark plug wires by pulling on the boot straight out in line with plug. 2. Remove cylinder head cover and gasket. 3. Remove the rocker arm bolts and pivots. Place them on a bench in the same order as removed. 4. Remove the push rods and place them on a bench in the same order as removed. CAUTION: DO NOT rotate or crank the engine during or immediately after rocker arm installation. Allow the hydraulic roller tappets adequate time to bleed down (about 5 minutes). INSTALLATION 1. Rotate the crankshaft until the "V6" mark lines up with the Top Dead Center (TDC) mark on the timing chain case cover. This mark is located 147 ° After Top Dead Center (ATDC) from the No.1 firing position. 2. Install the push rods in the same order as removed. 3. Install rocker arm and pivot assemblies in the same order as removed. Tighten the rocker arm bolts to 28 Nm (21 ft. lbs.) torque. 4. Install cylinder head cover. 5. Connect spark plug wires. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications Bearing Clearance .................................................................................................................................................... 0.013-0.056 mm (0.0005-0.0022 in) Max. Allowable .................................................................................................................................... .............................................. 0.08 mm (0.003 in) Side Clearance (Two Rods) ......................................................................................................................................... 0.152-0.356 mm (0.006-0.014 in) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Service and Repair > Fitting Connecting Rod Bearings Connecting Rod Bearing: Service and Repair Fitting Connecting Rod Bearings NOTES: - Fit all rods on a bank until completed. DO NOT alternate from one bank to another, because connecting rods and pistons are not interchangeable from one bank to another. - The bearing caps are not interchangeable and should be marked at removal to ensure correct assembly. - Each bearing cap has a small V-groove across the parting face. When installing the lower bearing shell, be certain that the V-groove in the shell is in line with the V-groove in the cap. This provides lubrication of the cylinder wall in the opposite bank. The bearing shells must be installed so that the tangs are in the machined grooves in the rods and caps. Limits of taper or out-of-round on any crankshaft journals should be held to 0.025 mm (0.001 inch). Bearings are available in 0.025 mm (0.001 inch), 0.051 mm (0.002 inch), 0.076 mm (0.003 inch), 0.254 mm (0.010 inch) and 0.305 mm (0.012 inch) undersize. Install the bearings in pairs. DO NOT use a new bearing half with an old bearing half. DO NOT file the rods or bearing caps. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Service and Repair > Fitting Connecting Rod Bearings > Page 1388 Connecting Rod Bearing: Service and Repair Connecting Rod Bearing Clearance Engine connecting rod bearing clearances can be determined by use of Plastigage, or equivalent. The following is the recommended procedures for the use of Plastigage: 1. Remove oil film from surface to be checked. Plastigage is soluble in oil. 2. Place a piece of Plastigage across the entire width of the bearing cap shell. Position the Plastigage approximately 6.35 mm (1/4 inch) off center and away from the oil holes. In addition, suspect areas can be checked by placing the Plastigage in the suspect area. 3. The crankshaft must be turned until the connecting rod to be checked starts moving toward the top of the engine. Only then should the rod cap with Plastigage in place be assembled. Tighten the rod cap nut to 61 Nm (45 ft. lbs.) torque. DO NOT rotate the crankshaft or the Plastigage may be smeared, giving inaccurate results. 4. Remove the bearing cap and compare the width of the flattened Plastigage with the scale provided on the package. Plastigage generally comes in 2 scales (one scale is in inches and the other is a metric scale). Locate the band closest to the same width. This band shows the amount of clearance. Differences in readings between the ends indicate the amount of taper present. Record all readings taken refer to Specifications. 5. Plastigage is available in a variety of clearance ranges. The 0.025 - 0.076 mm (0.001 - 0.003 inch) range is usually the most appropriate for checking engine bearing clearances. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Cap Bolts/Nuts Connecting Rod: Specifications Connecting Rod Cap Bolts/Nuts Cap Bolts ............................................................................................................................................. ................................................. 61 Nm (45 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Cap Bolts/Nuts > Page 1393 Connecting Rod: Specifications Connecting Rod Specifications Bearing Clearance ................................................................................................................................................. 0.013 0.056 mm (0.0005 - 0.0022 inch) Max. Allowable ............................................................................... .................................................................................................... 0.08 mm (0.003 inch) Piston Pin Bore Diameter .................................................................................................................................. 24.940 - 24.978 mm (0.9819 - 0.9834 inch) Side Clearance (Two Rods) ...................................................................................................................................... 0.152 - 0.356 mm (0.006 - 0.014 inch) Total Weight (Less Bearing) ......................................................................................................................................................... 726 grams (25.61 ounces) Cap Bolts ............................................................................................................................................. ..................................................... 61 Nm (45 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Removal and Installation Connecting Rod: Service and Repair Removal and Installation REMOVAL 1. Remove the engine from the vehicle. 2. Remove the cylinder head. 3. Remove the oil pan. 4. Remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pistons covered during this operation. 5. Be sure each connecting rod and connecting rod cap is identified with the cylinder number. Remove connecting rod cap. Install connecting rod bolt guide set on connecting rod bolts. 6. Pistons and connecting rods must be removed from top of cylinder block. When removing the assemblies from the engine, rotate crankshaft so that the connecting rod is centered in cylinder bore and at Bottom Dead Center (BDC). Be careful not to nick crankshaft journals. 7. After removal, install bearing cap on the mating rod. INSTALLATION 1. Be sure that compression ring gaps are staggered so that neither is in line with oil ring rail gap. 2. Before installing the ring compressor, be sure the oil ring expander ends are butted and the rail gaps located properly. 3. Immerse the piston head and rings in clean engine oil. Slide Piston Ring Compressor Tool C-385, or equivalent over the piston and tighten with the special wrench (part of Tool C-385, or equivalent). Be sure position of rings does not change during this operation. 4. Install connecting rod bolt protectors on rod bolts. The long protector should be installed on the numbered side of the connecting rod. 5. Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Be sure connecting rod and cylinder bore number are the same. Insert rod and piston into cylinder bore and guide rod over the crankshaft journal. 6. Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on crankshaft journal. 7. The notch, or groove, on top of piston must be pointing toward front of engine. The larger chamfer of the connecting rod bore must be installed toward crankshaft journal fillet. 8. Install rod caps. Be sure connecting rod, connecting rod cap, and cylinder bore number are the same. Install nuts on cleaned and oiled rod bolts and tighten nuts to 61 Nm (45 ft. lbs.) torque. 9. Install the oil pan. 10. Install the cylinder head. 11. Install the engine into the vehicle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Removal and Installation > Page 1396 Connecting Rod: Service and Repair Cleaning and Inspection 1. Check the crankshaft connecting rod journal for excessive wear, taper and scoring. 2. Check the cylinder block bore for out-of-round, taper, scoring and scuffing. 3. Check the pistons for taper and elliptical shape before they are fitted into the cylinder bore. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Rebuild Specifications Crankshaft Main Bearing: Specifications Rebuild Specifications Main Journal Diameter .............................................................................................................................................. .................... 63.487-63.513 mm (2.124-2.125 in,) Out-of-Round (Max) ............................................. ......................................................................................................................... 0.0254 mm (0.001 in.) Taper (Max) ......................................................................................................................................... .......................................... 0.0254 mm (0.001 in.) Bearing Clearance (# 1) .......................................................................................................................................... 0.013-0.038 mm (0.0005-0.0015 in.) Bearing Clearance (# 2-4) ....................................................................................................................................... 0.013-0.051 mm (0.0005-0.0020 in.) Service Limit .................................................................................................. ................................................................................ 0.064 mm (0.0025 in.) Crankshaft End Play End Play .............................................................................................................................................. ........................ 0.051-0.178 mm (0.002-0.007 in.) Service Limit ........................................................ ............................................................................................................................ 0.254 mm (0.010 in.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Rebuild Specifications > Page 1401 Crankshaft Main Bearing: Specifications Torque Specifications Cap Bolts ............................................................................................................................................. .................................................. 115 Nm (85 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 1402 Crankshaft Main Bearing: Description and Operation BEARING CAPS Bearing caps are NOT interchangeable and should be marked at removal to ensure correct assembly. BEARING HALVES Upper and lower bearing halves are NOT interchangeable. Lower main bearing halves of No.1 and 3 are interchangeable. THRUST BEARING Upper and lower No. 2 bearing halves are flanged to carry the crankshaft thrust loads. They are NOT interchangeable with any other bearing halves in the engine. AVAILABLE SIZES Bearing shells are available in standard and the following undersizes: 0.25 mm (0.001 inch), 0.051 mm (0.002 inch), 0.076 mm (0.003 inch), 0.254 mm (0.010 inch) and 0.305 mm (0.012 inch). Never install an undersize bearing that will reduce clearance below specifications. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Service and Repair > Removal and Installation Crankshaft Main Bearing: Service and Repair Removal and Installation REMOVAL 1. Remove the oil pan. 2. Remove the oil pump from the rear main bearing cap. 3. Identify bearing caps before removal. Remove bearing caps one at a time. 4. Remove upper half of bearing by inserting Crankshaft Main Bearing Remover/Installer Tool C-3059, or equivalent into the oil hole of crankshaft. 5. Slowly rotate crankshaft clockwise, forcing out upper half of bearing shell. CAUTIONS: - Only one main bearing should be selectively fitted while all other main bearing caps are properly tightened. - All bearing cap bolts removed during service procedures are to be cleaned and oiled before installation. - DO NOT use a new bearing half with an old bearing half. - When installing a new upper bearing shell, slightly chamfer the sharp edges from the plain side. INSTALLATION 1. Start bearing in place, and insert Crankshaft Main Bearing Remover/Installer Tool C-3059, or equivalent into oil hole of crankshaft. 2. Slowly rotate crankshaft counterclockwise sliding the bearing into position. Remove Tool C-3059, or equivalent. 3. Install the bearing caps. Clean and oil the bolts. Tighten the cap bolts to 115 Nm (85 ft. lbs.) torque. 4. Install the oil pump. 5. Install the oil pan. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Service and Repair > Removal and Installation > Page 1405 Crankshaft Main Bearing: Service and Repair Inspection PLASTIGAGE METHOD Engine crankshaft bearing clearances can be determined by use of Plastigage or equivalent. The following is the recommended procedure for the use of Plastigage: NOTE: The total clearance of the main bearings can only be determined by removing the weight of the crankshaft. This can be accomplished by either of two methods: Preferred Method Shimming the bearings adjacent to the bearing to be checked in order to remove the clearance between upper bearing shell and the crankshaft. This can be accomplished by placing a minimum of 0.254 mm (0.010 inch) shim (e.g. cardboard, match-book cover, etc.) between the bearing shell and the bearing cap on the adjacent bearings and tightening bolts to 18 Nm (13 ft. lbs.). The number of main bearing will vary from engine to engine. - When checking #1 main bearing shim # 2 main bearing. - When checking #2 main bearing shim #1 & #3 main bearing. - When checking #3 main bearing shim #2 & #4 main bearing. - When checking #4 main bearing shim #3 main bearing. CAUTION: Remove all shims before reassembling engine. Alternative Method The weight of the crankshaft can be supported by a jack under the counterweight adjacent to the bearing being checked. PLASTIGAGE PROCEDURE 1. Remove oil film from surface to be checked. Plastigage is soluble in oil. 2. Place a piece of Plastigage across the entire width of the bearing shell in the cap approximately 6.35 mm (1/4 inch) off center and away from the oil holes. (In addition, suspected areas can be checked by placing the Plastigage in the suspected area). Torque the bearing cap bolts of the bearing being checked to 115 Nm (85 ft. lbs.). 3. Remove the bearing cap and compare the width of the flattened Plastigage with the metric scale provided on the package. Locate the band closest to the same width. This band shows the amount of clearance in thousandths of a millimeter. Differences in readings between the ends indicate the amount of taper present. Record all readings taken. Plastigage generally is accompanied by two scales. One scale is in inches, the other is a metric scale. NOTE: Plastigage is available in a variety of clearance ranges. The 0.025 - 0.076 mm (0.001 0.003 inch) range is usually the most appropriate for checking engine bearing clearances. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Service and Repair > Page 1406 Crankshaft Main Bearing Remover and Installer C-3059 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Dimensions Crankshaft: Specifications Dimensions CONNECTING ROD JOURNAL: Diameter ............................................................................................................................................................ 53.950 - 53.975 mm (2.124 - 2.125 inch) Out-of-Round (Max.) .......................................................... ......................................................................................................... 0.0254 mm (0.001 inch) Taper (Max.) .................................................................................................................................................. .............................. 0.0254 mm (0.001 inch) DIAMETRICAL CLEARANCE: No. 1 .................................................................................................................................................... .............. 0.013 - 0.038 mm (0.0005 - 0.0015 inch) Nos. 2, 3, and 4 ................................................................................................................................................. 0.013 0.051 mm (0.0005 - 0.0020 inch) Max. Allowable (Nos. 2, 3, & 4) ................................................................................................................................................. 0.064 mm (0.0025 inch) END PLAY: Standard .............................................................................................................................................. .................. 0.051 - 0.178 mm (0.002 - 0.007 inch) Max. Allowable .................................................... ......................................................................................................................... 0.254 mm (0.010 inch) MAIN BEARING JOURNALS: Diameter ........................................................................................................................................................ 63.487 - 63.513 mm (2.4995 - 2.5005 inch) Out-of-Round (Max.) ...................................................... ............................................................................................................. 0.0254 mm (0.001 inch) Taper (Max.) ........................................................................................................................................ ........................................ 0.0254 mm (0.001 inch) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Dimensions > Page 1411 Crankshaft: Specifications Crankshaft Main Bearing Caps 85 ft.lb Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 1412 Crankshaft: Description and Operation GENERAL INFORMATION A crankshaft that has undersize journals is stamped with 1/4 inch letters near the notch of the No. 6 crankshaft counterweight. For Example: R2 stamped on the No. 6 crankshaft counterweight indicates that the No.2 rod journal is 0.025 mm (0.001 inch) undersize. M4 indicates that the No. 4 main journal is 0.025 mm (0.001 inch) undersize. R3 M2 indicates that the No. 3 rod journal and the No. 2 main journal are both 0.025 mm (0.001 inch) undersize. NOTE: When a crankshaft is replaced, all main and connecting rod bearings, should be replaced with new bearings. Therefore, selective fitting of the bearings is not required when a crankshaft and bearings are replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Removal and Installation Crankshaft: Service and Repair Removal and Installation REMOVAL 1. Remove the oil pan. 2. Remove the oil pump from the rear main bearing cap. 3. Remove vibration damper. 4. Remove the timing chain cover. 5. Identify bearing caps before removal. Remove bearing caps and bearings one at a time. 6. Lift the crankshaft out of the block. 7. Remove and discard the crankshaft rear oil seals. 8. Remove and discard the front crankshaft oil seal. INSTALLATION 1. Lightly oil the new upper seal lips with engine oil. 2. Install the new upper rear bearing oil seal with the white paint facing towards the rear of the engine. 3. Position the crankshaft into the cylinder block. 4. Lightly oil the new lower seal lips with engine oil. 5. Install the new lower rear bearing oil seal into the bearing cap with the white paint facing towards the rear of the engine oil. 6. Apply 5 mm (0.20 inch) drop of Loctite 518, or equivalent, on each side of the rear main bearing cap. DO NOT over apply sealant or allow the sealant to contact the rubber seal. Assemble bearing cap to cylinder block immediately after sealant application. 7. To align the bearing cap, use cap slot, alignment dowel and cap bolts. DO NOT remove excess material after assembly. DO NOT strike rear cap more than 2 times for proper engagement. 8. Clean and oil all cap bolts. Install all main bearing caps. Install all cap bolts and alternately tighten to 115 Nm (85 ft. lbs.) torque. 9. Install oil pump. 10. Install the timing chain cover. 11. Install the vibration damper. 12. Apply Mopar (R) Silicone Rubber Adhesive Sealant, or equivalent, at bearing cap to block joint to provide cap to block and oil pan sealing. Apply enough sealant until a small amount is squeezed out. Withdraw nozzle and wipe excess sealant off the oil pan seal groove. 13. Install new front crankshaft oil seal. 14. Immediately install the oil pan. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Removal and Installation > Page 1415 Crankshaft: Service and Repair Cleaning and Inspection TAPER AND OUT-OF-ROUND The crankshaft connecting rod and main journals should be checked for excessive wear, taper and scoring. The maximum taper or out-of-round on any crankshaft journal is 0.025 mm (0.001 inch). JOURNAL GRINDING Journal grinding should not exceed 0.305 mm (0.012 inch) under the standard journal diameter. CAUTION: - DO NOT grind thrust faces of No. 2 main bearing. DO NOT nick crank pin or bearing fillets. After grinding, remove rough edges from crankshaft oil holes and clean out all oil passages. - After any journal grind, it is important that the final paper or cloth polish be in the same direction as the engine rotates. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Specifications Engine Block Heater: Specifications Mounting Bolt ....................................................................................................................................... .................................................. 2 Nm (17 inch lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Specifications > Page 1419 Engine Block Heater: Description and Operation CAUTION: Do not operate engine unless block heater cord has been disconnected from power source and secured in place. The power cord must be secured in its retaining clips and routed away from exhaust manifolds and moving parts. DESCRIPTION An optional engine block heater is available on all models. The heater is equipped with a power cord. The cord is attached to an engine compartment component with tie-straps. The heater is mounted in a core hole of the engine cylinder block (in place of a freeze plug) with the heating element immersed in engine coolant. Connect the power cord to a grounded 110 - 120 volt AC electrical outlet with a grounded three wire extension cord. PURPOSE The heater warms the engine providing easier engine starting and faster warm-up in low temperatures. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Specifications > Page 1420 Engine Block Heater: Service and Repair REMOVAL 1. Disconnect negative battery cable from battery. 2. Drain coolant from radiator and cylinder block. 3. Remove power cord from block heater. 4. Loosen screw at center of block heater. Remove heater assembly. INSTALLATION 1. Thoroughly clean cylinder block core hole and block heater seat. 2. Insert block heater assembly with element loop pointing down. 3. With block heater fully seated, tighten center screw to 2 Nm (17 inch lbs.) torque. 4. Fill cooling system with recommended coolant. 5. Start and warm the engine. Check for leaks. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Core Plug <--> [Expansion/Freeze Plug] > Component Information > Description and Operation Core Plug: Description and Operation Engine core plugs have been pressed into the oil galleries behind the camshaft thrust plate. This will reduce internal leakage and help maintain higher oil pressure at idle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Core Plug <--> [Expansion/Freeze Plug] > Component Information > Description and Operation > Page 1424 Core Plug: Service and Repair REMOVAL 1. Using a blunt tool such as a drift or a screwdriver and a hammer, strike the bottom edge of the cup plug. 2. With the cup plug rotated, grasp firmly with pliers or other suitable . tool and remove plug. NOTE: Thoroughly clean inside of cup plug hole in cylinder block or head. Be sure to remove old sealer. Be certain the new plug is cleaned of all oil or grease. INSTALLATION 1. Coat edges of plug and core hole with Mopar (R) Gasket Maker, or equivalent. CAUTION: DO NOT drive cup plug into the casting, as restricted coolant flow can result and cause serious engine problems. 2. Using proper plug drive, drive cup plug into hole. The sharp edge of the plug should be at least 0.50 mm (0.020 inch) inside the lead-in chamfer. 3. It is not necessary to wait for curing of the sealant. The cooling system can be filled and the vehicle placed in service immediately. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Vibration Damper <--> [Harmonic Balancer - Crankshaft Pulley] > Component Information > Specifications > Crankshaft Pulley Vibration Damper: Specifications Crankshaft Pulley Mounting Bolts ..................................................................................................................................... ............................................... 24 Nm (210 inch lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Vibration Damper <--> [Harmonic Balancer - Crankshaft Pulley] > Component Information > Specifications > Crankshaft Pulley > Page 1429 Vibration Damper: Specifications Harmonic Balancer/Vibration Damper Mounting Bolt ....................................................................................................................................... ............................................... 183 Nm (135 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Vibration Damper <--> [Harmonic Balancer - Crankshaft Pulley] > Component Information > Specifications > Page 1430 Vibration Damper: Service and Repair REMOVAL 1. Disconnect the negative cable from the battery. 2. Remove fan shroud retainer bolts and set shroud back over engine. 3. Remove the cooling system fan. 4. Remove the serpentine belt. 5. Remove the vibration damper pulley. 6. Remove vibration damper bolt and washer from end of crankshaft. 7. Install bar and screw from Puller Tool Set C-3688, or equivalent. Install two bolts with washers through the puller tool and into the vibration damper. 8. Pull vibration damper off of the crankshaft. INSTALLATION 1. Position the vibration damper onto the crankshaft. 2. Place installing tool, part of Puller Tool Set C-3688, or equivalent, in position and press the vibration damper onto the crankshaft. 3. Install the crankshaft bolt and washer. Tighten the bolt to 183 Nm (135 ft. lbs.) torque. 4. Install the crankshaft pulley. Tighten the pulley bolts to 23 Nm (200 inch lbs.) torque. 5. Install the serpentine belt. 6. Install the cooling system fan. Tighten the bolts to 23 Nm (17 ft. lbs.) torque. 7. Position the fan shroud and install the bolts. Tighten the retainer bolts to 11 Nm (95 inch lbs.) torque. 8. Connect the negative cable to the battery. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 1434 Piston: Description and Operation The pistons are elliptically turned so that the diameter at the pin boss is less than its diameter across the thrust face. This allows for expansion under normal operating conditions. Under operating temperatures, expansion forces the pin bosses away from each other, causing the piston to assume a more nearly round shape. NOTE: All pistons are machined to the same weight, regardless of size, to maintain piston balance. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Removal and Installation Piston: Service and Repair Removal and Installation REMOVAL 1. Remove the engine from the vehicle. 2. Remove the cylinder head. 3. Remove the oil pan. 4. Remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pistons covered during this operation. 5. Be sure each connecting rod and connecting rod cap is identified with the cylinder number. Remove connecting rod cap. Install connecting rod bolt guide set on connecting rod bolts. 6. Pistons and connecting rods must be removed from top of cylinder block. When removing the assemblies from the engine, rotate crankshaft so that the connecting rod is centered in cylinder bore and at Bottom Dead Center (BDC). Be careful not to nick crankshaft journals. 7. After removal, install bearing cap on the mating rod. INSTALLATION 1. Be sure that compression ring gaps are staggered so that neither is in line with oil ring rail gap. 2. Before installing the ring compressor, be sure the oil ring expander ends are butted and the rail gaps located properly. 3. Immerse the piston head and rings in clean engine oil. Slide Piston Ring Compressor Tool C-385, or equivalent over the piston and tighten with the special wrench (part of Tool C-385, or equivalent). Be sure position of rings does not change during this operation. 4. Install connecting rod bolt protectors on rod bolts. The long protector should be installed on the numbered side of the connecting rod. 5. Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Be sure connecting rod and cylinder bore number are the same. Insert rod and piston into cylinder bore and guide rod over the crankshaft journal. 6. Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on crankshaft journal. 7. The notch, or groove, on top of piston must be pointing toward front of engine. The larger chamfer of the connecting rod bore must be installed toward crankshaft journal fillet. 8. Install rod caps. Be sure connecting rod, connecting rod cap, and cylinder bore number are the same. Install nuts on cleaned and oiled rod bolts and tighten nuts to 61 Nm (45 ft. lbs.) torque. 9. Install the oil pan. 10. Install the cylinder head. 11. Install the engine into the vehicle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Removal and Installation > Page 1437 Piston: Service and Repair Fitting Pistons NOTES: - Check the cylinder block bore for out-of-round, taper, scoring, or scuffing. - Check the pistons for taper and elliptical shape before they are fitted into the cylinder bore. FITTING Piston and cylinder wall must be clean and dry. Specified clearance between the piston and the cylinder wall is 0.013 - 0.038 mm (0.0005 - 0.0015 inch) at 21°C (70°F). Piston diameter should be measured at the top of skirt, 90° to piston pin axis. Cylinder bores should be measured halfway down the cylinder bore and transverse to the engine crankshaft center line. Pistons and cylinder bores should be measured at normal room temperature, 21°C (70°F). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications Piston Pin: Specifications Clearance In Piston ................................................................................................................................... 0.00635 0.01905 mm (0.00025 - 0.00075 inch) In Rod (Interference) ......................................................................................................................................... 0.0178 0.0356 mm (0.0007 - 0.0014 inch) Diameter ............................................................................................................................................................ 24.996 - 25.001 mm (0.9841 - 0.9843 inch) Length ............................................................................ ....................................................................................... 75.946 - 76.454 mm (2.990 - 3.010 inch) End Play .............................................................................................................................................. ........................................................................ NONE Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications > Page 1441 Piston Pin: Description and Operation The piston pin rotates in the piston only and is retained by the press interference fit of the piston pin in the connecting rod. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications RING GAP: Compression Rings ............................................................................................................................................... 0.254 0.508 mm (0.010 - 0.020 inch) Oil Control (Steel Rails) ........................................................................................................................................ 0.254 1.270 mm (0.010 - 0.050 inch) RING SIDE CLEARANCE: Compression Rings ........................................................................................................................................... 0.038 0.076 mm (0.0015 - 0.0030 inch) Oil Ring (Steel Rails) ................................................................................................................................................ 0.06 0.21 mm (0.002 - 0.008 inch) RING WIDTH: Compression Rings ........................................................................................................................................... 1.971 1.989 mm (0.0776 - 0.0783 inch) Oil Ring (Steel Rails) ........................................................................................................................................ 3.848 3.975 mm (0.1515 - 0.1565 inch) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Service and Repair > Fitting Piston Rings Piston Ring: Service and Repair Fitting Piston Rings FITTING RINGS 1. Measurement of end gaps: a. Measure piston ring gap 2 inches from bottom of cylinder bore. An inverted piston can be used to push the rings down to ensure positioning rings squarely in the cylinder bore before measuring. b. Insert feeler gauge in the gap. The top compression ring gap should be between 0.254 - 0.508 mm (0.010 - 0.020 inch). The second compression ring gap should be between 0.508 - 0.762 mm (0.020 - 0.030 inch). The oil ring gap should be 0.254 - 1.270 mm (0.010 - 0.050 inch). c. Rings with insufficient end gap may be properly filed to the correct dimension. Rings with excess gaps should not be used. 2. Install rings, and confirm ring side clearance: a. Install oil rings being careful not to nick or scratch the piston. Install the oil control rings according to instructions in the package. It is not necessary to use a tool to install the upper and lower rails. Insert oil rail spacer first, then side rails. b. Install the second compression rings using Installation Tool C-4184, or equivalent. The compression rings must be installed with the identification mark face up (toward top of piston) and chamfer facing down. An identification mark on the ring is a drill point, a stamped letter "O", an oval depression, or the word "TOP". Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Service and Repair > Fitting Piston Rings > Page 1447 c. Using a ring installer, install the top compression ring with the chamfer facing up. An identification mark on the ring is a drill point, a stamped letter "O", an oval depression or the word "TOP" facing up. d. Measure side clearance between piston ring and ring land. Clearance should be 0.074 - 0.097 mm (0.0029 - 0.0038 inch) for the compression rings. The steel rail oil ring should be free in groove, but should not exceed 0.246 mm (0.0097 inch) side clearance. e. Pistons with insufficient, or excessive, side clearance should be replaced. 3. Orient the rings: a. Arrange top compression ring 90° counterclockwise from the oil ring rail gap. b. Arrange second compression ring 90° clockwise from the oil ring rail gap. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Service and Repair > Fitting Piston Rings > Page 1448 Piston Ring: Service and Repair Service Procedures FITTING RINGS 1. Measurement of end gaps: a. Measure piston ring gap 2 inches from bottom of cylinder bore. An inverted piston can be used to push the rings down to ensure positioning rings squarely in the cylinder bore before measuring. b. Insert feeler gauge in the gap. The top compression ring gap should be between 0.254 - 0.508 mm (0.010 - 0.020 inch). The second compression ring gap should be between 0.508 - 0.762 mm (0.020 - 0.030 inch). The oil ring gap should be 0.254 - 1.270 mm (0.010 - 0.050 inch). c. Rings with insufficient end gap may be properly filed to the correct dimension. Rings with excess gaps should not be used. 2. Install rings, and confirm ring side clearance: a. Install oil rings being careful not to nick or scratch the piston. Install the oil control rings according to instructions in the package. It is not necessary to use a tool to install the upper and lower rails. Insert oil rail spacer first, then side rails. b. Install the second compression rings using Installation Tool C-4184, or equivalent. The compression rings must be installed with the identification mark face up (toward top of piston) and chamfer facing down. An identification mark on the ring is a drill point, a stamped letter "O", an oval depression, or the word "TOP". Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Service and Repair > Fitting Piston Rings > Page 1449 c. Using a ring installer, install the top compression ring with the chamfer facing up. An identification mark on the ring is a drill point, a stamped letter "O", an oval depression or the word "TOP" facing up. d. Measure side clearance between piston ring and ring land. Clearance should be 0.074 - 0.097 mm (0.0029 - 0.0038 inch) for the compression rings. The steel rail oil ring should be free in groove, but should not exceed 0.246 mm (0.0097 inch) side clearance. e. Pistons with insufficient, or excessive, side clearance should be replaced. 3. Orient the rings: a. Arrange top compression ring 90° counterclockwise from the oil ring rail gap. b. Arrange second compression ring 90° clockwise from the oil ring rail gap. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Service and Repair > Page 1450 Piston Ring Compressor C-385 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates this engine is equipped with hydraulic lifters or lash adjusters and therefore does not require adjustment. See "Rocker Arm: Service and Repair" for further information. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > With Pressure Test Port Fuel Pressure Release: Service and Repair With Pressure Test Port WARNING: BECAUSE THE FUEL SYSTEM IS UNDER CONSTANT FUEL PRESSURE, IT MUST BE RELEASED BEFORE SERVICING ANY FUEL SYSTEM COMPONENT THIS DOES NOT APPLY TO THROTTLE BODY REMOVAL. NOTE: The fuel pressure test port is used on certain engines only. If equipped, the test port will be located on fuel rail. A sealing cap is screwed onto test port. - The fuel system is under constant fuel pressure (even with engine off). 1. Disconnect negative battery cable. 2. Remove fuel tank filler tube cap to release fuel tank pressure. 3. Remove protective cap from pressure test port on fuel rail. This is located on top of fuel rail. WARNING: DO NOT ALLOW FUEL TO SPILL ONTO ENGINE INTAKE OR EXHAUST MANIFOLDS. PLACE SHOP TOWELS UNDER AND AROUND PRESSURE PORT TO ABSORB FUEL WHEN PRESSURE IS RELEASED FROM FUEL RAIL. WARNING: WEAR PROPER EYE PROTECTION WHEN RELEASING FUEL SYSTEM PRESSURE. 4. Obtain fuel pressure gauge/hose assembly from fuel pressure gauge tool set 5069. Remove gauge from hose. 5. Place one end of hose (gauge end) into an approved gasoline container. 6. Place a shop towel under test port. 7. To release fuel pressure, screw other end of hose onto fuel pressure test port. 8. After fuel pressure has been released, remove hose from test port. 9. Install protective cap to fuel test port. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > With Pressure Test Port > Page 1459 Fuel Pressure Release: Service and Repair Without Pressure Test Port NOTE: Use the following procedure if the fuel rail is not equipped with a fuel pressure test port. 1. Remove the Fuel Pump relay from the Power Distribution Center (PDC). For location of the relay, refer to the label on the underside of the PDC cover. 2. Start and run engine until it stalls. 3. Attempt restarting engine until it will no longer run. 4. Turn ignition key to OFF position. CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within the fuel rail. Do not attempt to use the following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber. 5. Unplug connector from any injector. 6. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 7. Connect the other end of the jumper wire to the positive side of the battery 8. Connect one end of a second jumper wire to the remaining injector terminal. CAUTION: Supplying power to an injector for more than 4 seconds will permanently damage the injector. Do not leave the injector connected to power for more than 4 seconds. 9. Momentarily touch the other end of this jumper wire to the negative terminal of the battery for no more than 4 seconds. 10. Place a rag or towel below the fuel line at the quick connect to the rail. 11. Disconnect the quick connect fitting to the rail. Refer to Quick-Connect Fittings. 12. Return the fuel pump relay to the PDC. 13. One or more Diagnostic Trouble Codes (DTC's) may have been stored in the PCM memory due to fuel pump relay removal. The DRB scan tool must be used to erase a DTC. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications Rocker Arm Bolts 21 ft.lb Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications > Page 1463 Rocker Arm Assembly: Service and Repair REMOVAL 1. Disconnect spark plug wires by pulling on the boot straight out in line with plug. 2. Remove cylinder head cover and gasket. 3. Remove the rocker arm bolts and pivots. Place them on a bench in the same order as removed. 4. Remove the push rods and place them on a bench in the same order as removed. CAUTION: DO NOT rotate or crank the engine during or immediately after rocker arm installation. Allow the hydraulic roller tappets adequate time to bleed down (about 5 minutes). INSTALLATION 1. Rotate the crankshaft until the "V6" mark lines up with the Top Dead Center (TDC) mark on the timing chain case cover. This mark is located 147 ° After Top Dead Center (ATDC) from the No.1 firing position. 2. Install the push rods in the same order as removed. 3. Install rocker arm and pivot assemblies in the same order as removed. Tighten the rocker arm bolts to 28 Nm (21 ft. lbs.) torque. 4. Install cylinder head cover. 5. Connect spark plug wires. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Valve Cover Gasket > Component Information > Description and Operation Valve Cover Gasket: Description and Operation A steel-backed silicone gasket is used with the cylinder head cover. This gasket is reuseable. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Service and Repair Valve Guide: Service and Repair CHECKING VALVE GUIDE CLEARANCE Measure valve stem guide clearance as follows: 1. Install Valve Guide Sleeve Tool C-3973, or equivalent over valve stem and install valve. The special sleeve places the valve at the correct height for checking with a dial indicator. 2. Attach Dial Indicator Tool C-3339, or equivalent to cylinder head and set it at right angle of valve stem being measured. 3. Move valve to and from the indicator. The total dial indicator reading should not exceed 0.432 mm (0.017 inch). Ream the guides for valves with oversize stems if dial indicator reading is excessive or if the stems are scuffed or scored. NOTE: Service valves with oversize stems are available. OVERSIZING VALVE STEMS Slowly turn reamer by hand and clean guide thoroughly before installing new valve. Ream the valve guides from standard to 0.381 mm (0.015 inch). Use a 2 step procedure so the valve guides are reamed true in relation to the valve seat: Step 1-Ream to 0.0763 mm (0.003 inch). - Step 2-Ream to 0.381 mm (0.015 inch). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications Valve Seat: Specifications Angle ................................................................................................................................................... ......................................................... 44.25° - 44.75° Runout (Max.) ...................................................................................................................................... ........................................... 0.0762 mm (0.003 inch) WIDTH FINISH: Intake ................................................................................................................................................... ................... 1.016 - 1.524mm (0.040 - 0.060 inch) Exhaust ............................................................... ................................................................................................... 1.524 - 2.032 mm (0.060 - 0.080 inch) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications > Page 1474 Valve Seat: Service and Repair NOTE: The intake and exhaust valves have a 43-1/4° to 43-3/4° face angle and a 44-1/4° to 44-3/4° seat angle. CAUTION: DO NOT un-shroud valves during valve seat refacing. 1. When refacing valve seats, it is important that the correct size valve guide pilot be used for reseating stones. A true and complete surface must be obtained. 2. Measure the concentricity of valve seat using a dial indicator. Total runout should not exceed 0.051 mm (0.002 inch) total indicator reading. 3. Inspect the valve seat with Prussian blue to determine where the valve contacts the seat. To do this, coat valve seat LIGHTLY with Prussian blue then set valve in place. Rotate the valve with light pressure. If the blue is transferred to the center of valve face, contact is satisfactory. If the blue is transferred to the top edge of valve face, lower valve seat with a 15° stone. If the blue is transferred to bottom edge of valve face raise valve seat with a 60° stone. 4. When seat is properly positioned the width of intake seats should be 1.016 - 1.524 mm (0.040 0.060 inch). The width of the exhaust seats should be 1.524 - 2.032 mm (0.060 - 0.080 inch). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Valve Spring Lock > Component Information > Service and Repair > Off Vehicle Service Valve Spring Lock: Service and Repair Off Vehicle Service REMOVAL 1. Compress valve springs using Valve Spring Compressor Tool MD-998772-A, or equivalent. 2. Remove valve retaining locks, valve spring retainers, valve stem seals, and valve springs. 3. Before removing valves, remove any burrs from valve stem lock grooves to prevent damage to the valve guides. Identify valves to ensure installation in original locations. INSTALLATION 1. Coat valve stems with lubrication oil and insert them in cylinder head. 2. If valves or seats are reground, check valve stem height. If valve is too long, replace cylinder head. 3. Install new seals on all valve guides. Install valve springs and valve retainers. 4. Compress valve springs with Valve Spring Compressor Tool MD-998772A, or equivalent, install locks and release tool. If valves and/or seats are ground, measure the installed height of springs. Be sure the measurement is taken from bottom of spring seat in cylinder head to the bottom surface of spring retainer. If spacers are installed, measure from the top of spacer. If height is greater than 42.86 mm (1-11/16 inch), install a 1.587 mm (1/16 inch) spacer in head counterbore. This should bring spring height back to normal 41.27 42.86 mm (1-5/8 - 1-11/16 inch). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Valve Spring Lock > Component Information > Service and Repair > Off Vehicle Service > Page 1480 Valve Spring Lock: Service and Repair In Vehicle Service REMOVAL 1. Set engine basic timing to Top Dead Center (TDC). 2. Remove the air cleaner. 3. Remove cylinder head covers and spark plugs. 4. Remove coil wire from distributor and secure to good ground to prevent engine from starting. 5. Using suitable socket and flex handle at crankshaft retaining bolt, turn engine so the No.1 piston is at Top Dead Center on the compression stroke. 6. Remove rocker arms. 7. With air hose attached to an adapter installed in No.1 spark plug hole, apply 620 - 689 kPa (90 - 100 psi) air pressure. 8. Using Valve Spring Compressor Tool MD-998772A, or equivalent compress valve spring and remove retainer valve locks and valve string INSTALLATION 1. Install seals on the exhaust valve stem and position down against valve guides. 2. The intake valve stem seals should be pushed firmly and squarely over the valve guide using the valve stem as a guide. DO NOT force seal against top of guide. When installing the valve retainer locks, compress the spring only enough to install the locks. 3. Follow the same procedure on the remaining 5 cylinders using the firing sequence 1-6-5-4-3-2. Make sure piston in cylinder is at TDC on the valve spring that is being removed. 4. Remove adapter from the No.1 spark plug hole. 5. Install rocker arms. 6. Install covers and coil wire to distributor. 7. Install air cleaner. 8. Road test vehicle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications Valve: Specifications HEAD DIAMETER: Intake ................................................................................................................................................... ........................................ 48.666 mm (1.916 inch) Exhaust ................................................................ ........................................................................................................................ 41.250 mm (1.624 inch) LENGTH (OVERALL): Intake ................................................................................................................................................... .............. 124.28 - 125.92 mm (4.893 - 4.918 inch) Exhaust .............................................................................................................................................................. 124.64 - 125.27 mm (4.907 - 4.932 inch) GENERAL: Lift (Zero Lash) .................................................................................................................................... ....................................... 10.973 mm (0.432 inch) Stem Diameter ....................................................................................................................................................... 7.899 - 7.925 mm (0.311 - 0.312 inch) Stem-to-Guide Clearance .................................................................................................................................. 0.0254 - 0.0762 mm (0.001 - 0.003 inch) Max. Allowable (Rocking Method) ............................................................................................................................................. 0.4318 mm (0.017 inch) Guide Bore Diameter (STD) ................................................................................................................................. 7.950 - 7.976 mm (0.313 - 0.314 inch) Face Angle ................................................................................................... .............................................................................................. 43.25° - 43.75° Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications > Page 1484 Valve: Description and Operation The valves are arranged in-line and are inclined 18°. The rocker pivot support and the valve guides are cast integral with the heads. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications > Page 1485 Valve: Testing and Inspection CLEANING Clean valves thoroughly. Discard burned, warped and cracked valves. Remove carbon and varnish deposits from inside of valve guides with a reliable guide cleaner. INSPECTION Measure valve stems for wear. If wear exceeds 0.051 mm (0.002 inch), replace the valve. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal and Installation Valve: Service and Repair Removal and Installation REMOVAL 1. Compress valve springs using Valve Spring Compressor Tool MD-998772-A, or equivalent. 2. Remove valve retaining locks, valve spring retainers, valve stem seals, and valve springs. 3. Before removing valves, remove any burrs from valve stem lock grooves to prevent damage to the valve guides. Identify valves to ensure installation in original locations. INSTALLATION 1. Coat valve stems with lubrication oil and insert them in cylinder head. 2. If valves or seats are reground, check valve stem height. If valve is too long, replace cylinder head. 3. Install new seals on all valve guides. Install valve springs and valve retainers. 4. Compress valve springs with Valve Spring Compressor Tool MD-998772A, or equivalent, install locks and release tool. If valves and/or seats are ground, measure the installed height of springs. Be sure the measurement is taken from bottom of spring seat in cylinder head to the bottom surface of spring retainer. If spacers are installed, measure from the top of spacer. If height is greater than 42.86 mm (1-11/16 inch), install a 1.587 mm (1/16 inch) spacer in head counterbore. This should bring spring height back to normal 41.27 42.86 mm (1-5/8 - 1-11/16 inch). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal and Installation > Page 1488 Valve: Service and Repair Refacing Valves and Valve Seats NOTE: The intake and exhaust valves have a 43-1/4° to 43-3/4° face angle and a 44-1/4° to 44-3/4° seat angle. Inspect the remaining margin after the valves are refaced. Valves with less than 1.190 mm (0.047 inch) margin should be discarded. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications Drive Belt: Specifications Do not attempt to check belt tension with a tension gauge. Belt is equipped with ab automatic tensioner. Belt tension is not adjustable. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications > Page 1493 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications > Page 1494 Drive Belt: Description and Operation The accessory drive components are operated by a single, crankshaft driven, serpentine drive belt. An automatic belt tensioner is used to maintain correct belt tension at all times. Correct accessory drive belt tension is required to be sure of optimum performance of belt driven engine accessories. If specified tension is not maintained, belt slippage may cause; engine overheating, lack of power steering assist, loss of air conditioning capacity, reduced generator output rate and greatly reduced belt life. NOTE: Due to the use of this belt tensioner, do not attempt to use a belt tension gauge. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications > Page 1495 Drive Belt: Testing and Inspection Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications > Page 1496 When diagnosing serpentine drive belts, small cracks that run across ribbed surface of belt from rib to rib, are considered normal. These are not a reason to replace belt. However, cracks running along a rib (not across) are not normal. Any belt with cracks running along a rib must be replaced. Also replace belt if it has excessive wear, frayed cords or severe glazing. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications > Page 1497 Drive Belt: Service and Repair NOTE: The drive belt is equipped with a spring loaded automatic belt tensioner. This belt tensioner will be used on all belt configurations, such as with or without power steering or air conditioning. REMOVAL 1. Attach a socket/wrench to pulley mounting bolt of automatic tensioner. 2. Rotate tensioner assembly clockwise (as viewed from front) until tension has been relieved from belt. 3. Remove belt from idler pulley first. 4. Remove belt from vehicle. CAUTION: When installing serpentine accessory drive belt, belt must be routed correctly. If not, engine may overheat due to water pump rotating in wrong direction. Refer to illustration for correct engine belt routing. The correct belt with correct length must be used. INSTALLATION 1. Position drive belt over all pulleys except idler pulley. This pulley is located between generator and A/C compressor. 2. Attach a socket/wrench to pulley mounting bolt of automatic tensioner. 3. Rotate socket/wrench clockwise. Place belt over idler pulley. Let tensioner rotate back-into place. Remove wrench. Be sure belt is properly seated on all pulleys. 4. Check belt indexing marks. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications > Page 1498 5. The tensioner is equipped with an indexing arrow on back of tensioner and an indexing mark on tensioner housing. If a new belt is being installed, arrow must be within approximately 3 mm (1/8 inch) of indexing mark (Point B). Belt is considered new if it has been used 15 minutes or less. If this specification cannot be met, check for: The wrong belt being installed (incorrect length/ width). - Worn bearings on an engine accessory (A/C compressor, power steering pump, water pump, idler pulley or generator). - A pulley on an engine accessory being loose. - Misalignment of an engine accessory. - Belt incorrectly routed. Refer to illustration. NOTE: A used belt should be replaced if tensioner indexing arrow has moved beyond point A. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications Drive Belt Tensioner: Specifications Pulley Bolt ............................................................................................................................................ .................................................... 61 Nm (45 ft. lbs.) To Bracket Bolts ................................................ ....................................................................................................................................... 67 Nm (50 ft. lbs.) Bracket to Block Bolts .................................................................................................................. ............................................................ 41 Nm (30 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications > Page 1502 Drive Belt Tensioner: Description and Operation GENERAL INFORMATION Correct accessory drive belt tension is required to be sure of optimum performance of belt driven engine accessories. If specified tension is not maintained, belt slippage may cause; engine overheating, lack of power steering assist, loss of air conditioning capacity, reduced generator output rate and greatly reduced belt life. PURPOSE It is not necessary to adjust belt tension on any engine. All engines are equipped with an automatic belt tensioner. The tensioner maintains correct belt tension at all times. Due to use of this belt tensioner, do not attempt to use a belt tension gauge on any engine. USAGE Drive belts on all engines are equipped with a spring loaded automatic belt tensioner. This belt tensioner will be used with all belt configurations, such as with or without power steering or air conditioning. NOTE: Do not attempt to check belt tension with a belt tension gauge on vehicles equipped with an automatic belt tensioner. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications > Page 1503 GENERAL INFORMATION The tensioner is equipped with an indexing arrow on back of tensioner and an indexing mark on tensioner housing. New Belt If a new belt is being installed, arrow must be within approximately 3 mm (1/8 inch) of indexing mark (point B). Belt is considered new if it has been used 15 minutes or less. If this specification cannot be met, check for: The wrong belt being installed (incorrect length/width) - Worn bearings on an engine accessory (A/C compressor, power steering pump, water pump, idler pulley or generator) - A pulley on an engine accessory being loose - Misalignment of an engine accessory - Belt incorrectly routed. Used Belt A used belt should be replaced if tensioner indexing arrow has moved to point A. Tensioner travel stops at point A. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications > Page 1504 Drive Belt Tensioner: Service and Repair REMOVAL 1. Attach a socket/wrench to mounting bolt of automatic tensioner pulley bolt. 2. Rotate tensioner assembly clockwise (as viewed from front) until tension has been relieved from belt. 3. Remove belt from idler pulley first. 4. Remove belt from other pulleys. 5. Disconnect wiring and secondary cable from ignition coil. 6. Remove ignition coil from coil mounting bracket (two bolts). Do not remove coil mounting bracket from cylinder head. 7. Remove tensioner assembly from mounting bracket (one nut). WARNING: Because of high spring pressure, do not attempt to disassemble automatic tensioner. Unit is serviced as an assembly (except for pulley). 8. Remove pulley bolt. Remove pulley from tensioner. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications > Page 1505 INSTALLATION 1. Install pulley and pulley bolt to tensioner. Tighten bolt to 61 Nm (45 ft. lbs.). 2. Install tensioner assembly to mounting bracket. An indexing tab is located on back of tensioner. Align this tab to slot in mounting bracket. Tighten nut to 67 Nm (50 ft. lbs.) torque. 3. Connect all wiring to ignition coil. 4. Install coil to coil bracket. If nuts and bolts are used to secure coil to coil bracket, tighten to 11 Nm (100 inch lbs.) torque. If coil mounting bracket has been tapped for coil mounting bolts, tighten bolts to 5 Nm (50 inch lbs.) torque. CAUTION: To prevent damage to coil case, coil mounting bolts must be torqued. 5. Position belt over all pulleys except idler pulley (located between generator and A/C compressor). CAUTION: When installing serpentine accessory drive belt, belt must be routed correctly. If not, engine may overheat due to water pump rotating in wrong direction. Refer to illustration for correct engine belt routing. The correct belt with correct length must be used. 6. Attach a socket/wrench to pulley mounting bolt of automatic tensioner. 7. Rotate socket/wrench clockwise. Place belt over idler pulley. Let tensioner rotate back into place. Remove wrench. Be sure belt is properly seated on all pulleys. 8. Check belt indexing marks. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Specifications Engine Accessory Bracket: Specifications Adjusting Strap Bolt ............................................................................................................................. ............................................... 23 Nm (200 inch lbs.) Generator Mounting Bolt .................................. ........................................................................................................................................ 41 Nm (30 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Specifications Engine Mount: Specifications FRONT MOUNTS: Through Bolt ........................................................................................................................................ ................................................ 95 Nm (70 ft. lbs.) Insulator To Block Bolts ........................................ .............................................................................................................................. 95 Nm (70 ft. lbs.) REAR MOUNTS: Insulator To Bracket ............................................................................................................................ ................................................. 68 Nm (50 ft. lbs.) Insulator To Crossmember Nut ............................................................................................................................................................. 41 Nm (30 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount Engine Mount: Service and Repair Front Mount REMOVAL 1. Disconnect the negative cable from the battery. 2. Raise hood and position fan to assure clearance for radiator top tank and hose. CAUTION: DO NOT lift the engine by the intake manifold. 3. Install engine lifting fixture. 4. Raise vehicle on hoist. 5. Remove the insulator through bolt. 6. Raise engine with lifting fixture SLIGHTLY. Remove insulator retaining bolts and remove the insulator assembly. 7. Remove insulator heat shield and transfer to new insulator. INSTALLATION 1. With the engine raised SLIGHTLY, position insulator assembly onto the engine block and install bolts. Tighten the bolts to 41 Nm (30 ft. lbs.) torque. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount > Page 1514 2. Lower engine with lifting fixture while guiding insulator assembly into the engine insulator bracket. 3. Install insulator to bracket through bolt. Tighten the through bolt nut to 68 Nm (50 ft. lbs.) torque. 4. Remove lifting fixture. 5. Connect the negative cable to the battery. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount > Page 1515 Engine Mount: Service and Repair Rear Mount REMOVAL 1. Disconnect the negative cable from the battery. 2. Raise the vehicle on a hoist. 3. Support the transmission with a jack. Automatic Transmission Remove engine support bracket-insulator through bolt. - Raise the transmission and engine slightly. - Remove stud nuts attaching insulator to crossmember. Remove insulator. Manual Transmission Remove the stud nuts attaching the insulator to the transmission extension. - Raise the transmission and engine slightly. - Remove stud nuts attaching insulator to crossmember. Remove insulator. INSTALLATION 1. If the engine support bracket (Automatic Transmissions) was removed, position the bracket to the transmission extension. Tighten the bolts to 68 Nm (50 ft. lbs.) torque. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount > Page 1516 Automatic Transmission Install the insulator onto crossmember. Tighten the stud nuts to 41 Nm (30 ft. lbs.) torque. - Lower the transmission and engine while aligning the engine support bracket to the insulator. - Install through bolt in bracket and insulator. Tighten through bolt nut to 68 Nm (50 ft. lbs.) torque. Manual Transmission Install the insulator onto crossmember. Tighten the stud nuts to 41 Nm (30 ft. lbs.) torque. - Lower the transmission and engine while aligning the insulator studs into the transmission extension. - Install the stud nuts. Tighten the stud nuts to 41 Nm (30 ft. lbs.) torque. 2. Remove transmission jack. 3. Lower the vehicle. 4. Connect the negative cable to the battery. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Specifications Idler Pulley: Specifications Mounting Bolt ....................................................................................................................................... ................................................... 61 Nm (45 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications OIL PRESSURE @ Curb Idle (Min.)* .............................................................................................................................. ................................................... 41.4 kPa (6 psi) @ 3000 rpm .......................................................... ................................................................................................................... 207 - 552 kPa (30 - 80 psi) Bypass Valve Setting .................................................................................................................... ............................................... 62 - 103 kPa (9 - 15 psi) Switch Actuating pressure ......................................................................................................................................................... 34.5 - 48.3 kPa (5 - 7 psi) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications > Page 1524 Engine Oil Pressure: Testing and Inspection 1. Remove oil pressure sending unit. 2. Install Oil Pressure Line and Gauge Tool C-3292, or equivalent. Start engine and record pressure. OIL PRESSURE: At Curb Idle .......................................................................................................................................... .................................................... 41.4 kPa (6 psi) At 3000 RPM ........................................................ .................................................................................................................. 207 - 552 kPa (30 - 80 psi) CAUTION: If oil pressure is zero at curb idle, do not run engine. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Locations Engine Oil Dip Stick - Dip Stick Tube: Locations The engine oil level indicator is located at the right front of the engine, left of the generator. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Drain Plug > Component Information > Specifications Engine Oil Drain Plug: Specifications Oil Drain Plug 25 ft.lb Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil Without Filter Change .......................................................................................................................... ............................................................. 3.3L (3.5 Qt) Capacity shown is without filter. When replacing filter. additional oil may be needed. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1535 Engine Oil: Fluid Type Specifications Engine Oil API Classification ................................................................................................................................. ........................................... SH or SH/CD or Above Above 0°F (-18°C).............................................. ........................................................................................................................................................ 10W-30 Below 32°F (0°C).................................................................................................................... ..................................................................................... 5W-30 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 1536 Engine Oil: Service Precautions WARNING: NEW OR USED ENGINE OIL CAN BE IRRITATING TO THE SKIN. AVOID PROLONGED OR REPEATED SKIN CONTACT WITH ENGINE OIL. CONTAMINANTS IN USED ENGINE OIL, CAUSED BY INTERNAL COMBUSTION, CAN BE HAZARDOUS TO YOUR HEALTH. THOROUGHLY WASH EXPOSED SKIN WITH SOAP AND WATER. DO NOT WASH SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO NOT POLLUTE, DISPOSE OF USED ENGINE OIL PROPERLY. CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 1537 Engine Oil: Description and Operation CAUTION: Do not use non-detergent or straight mineral oil when adding or changing crankcase lubricant. Engine failure can result. API SERVICE GRADE CERTIFIED Use an engine oil that is API Service Grade Certified or an oil that conforms to the API Service Grade SH or SH/CD. SAE VISCOSITY An SAE viscosity grade is used to specify the viscosity of engine oil. SAE 30 specifies a single viscosity engine oil. Engine oils also have multiple viscosities. These are specified with a dual SAE viscosity grade which indicates the cold-to-hot temperature viscosity range. Select an engine oil that is best suited to your particular temperature range and variation. ENERGY CONSERVING OIL An Energy Conserving type oil is recommended for gasoline engines. They are designated as either ENERGY CONSERVING or ENERGY CONSERVING II. CONTAINER IDENTIFICATION Standard engine oil identification notations have been adopted to aid in the proper selection of engine oil. The identifying notations are located on the label of engine oil plastic bottles and the top of engine oil cans. ENGINE OIL ADDITIVES In some instances, such as infrequent operation, short trip driving, and during break-in after a major overhaul, addition of special materials containing anti-rust and anti-scuff additives are beneficial. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 1538 Engine Oil: Testing and Inspection CAUTION: Do not overfill crankcase with engine oil, oil foaming and oil pressure loss can result. NOTE: To ensure proper lubrication of an engine, the engine oil must be maintained at an acceptable level. The acceptable levels are indicated between the ADD and SAFE marks on the engine oil dipstick. 1. Position vehicle on level surface. 2. With engine OFF, allow approximately ten minutes for oil to settle to bottom of crankcase, remove engine oil dipstick. 3. Wipe dipstick clean. 4. Install dipstick and verify it is seated in the tube. 5. Remove dipstick, with handle held above the tip, take oil level reading. 6. Add oil only if level is below the add mark on the dipstick. 7. Replace dipstick. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 1539 Engine Oil: Service and Repair NOTE: Run engine until achieving normal operating temperature. 1. Position the vehicle on a level surface and turn engine off. 2. Hoist and support vehicle on safety stands. 3. Remove oil fill cap. 4. Place a suitable drain pan under crankcase drain. 5. Remove drain plug from crankcase and all oil to drain into pan. Inspect drain plug threads for stretching or other damage. Replace drain plug and gasket if damaged. 6. Install drain plug in crankcase. 7. Lower vehicle and fill crankcase with specified type and amount of engine oil. 8. Install oil fill cap. 9. Start engine and inspect for leaks. 10. Stop engine and inspect oil level. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Specifications Oil Filter: Specifications Bypass Valve Setting ........................................................................................................................... ............................................ 62 - 103 kPa (9 - 15 psi) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Specifications > Page 1543 Oil Filter: Description and Operation This engine is equipped with a high quality full-flow, disposable type oil filter. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Specifications > Page 1544 Oil Filter: Service and Repair REMOVAL 1. Position a drain pan under the oil filter. 2. Using a suitable oil filter wrench loosen filter. 3. Rotate the oil filter counterclockwise to remove it from the cylinder block oil filter boss. 4. When filter separates from adapter nipple, tip gasket end upward to minimize oil spill. Remove filter from vehicle. 5. With a wiping cloth, clean the gasket sealing surface of oil and grime. INSTALLATION 1. Lightly lubricate oil filter gasket with engine oil or chassis grease. 2. Thread filter onto adapter nipple. When gasket makes contact with sealing surface, hand tighten filter one full turn, do not over tighten. 3. Add oil, verify crankcase oil level and start engine. Inspect for oil leaks. NOTE: Care should be exercised when disposing of used engine oil after it has been drained from a vehicle's engine. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Line Plug <--> [Oil Line, Engine] > Component Information > Locations Oil Line Plug: Locations The oil line plug is located in the vertical passage at the rear of the block between the oil-to-filter and oil-from-filter passages. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Line Plug <--> [Oil Line, Engine] > Component Information > Locations > Page 1548 Oil Line Plug: Description and Operation The oil line plug is located in the vertical passage at the rear of the block between the oil-to-filter and oil-from-filter passages. Improper installation or plug missing could cause erratic, low, or no oil pressure. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Line Plug <--> [Oil Line, Engine] > Component Information > Locations > Page 1549 Oil Line Plug: Service and Repair NOTE: The oil plug must come out the bottom. Use flat dowel, down the oil pressure sending unit hole from the top, to remove oil plug. 1. Remove oil pressure sending unit from back of block. 2. Insert a 3.175 mm (1/8 inch) finish wire, or equivalent, into passage. 3. Plug should be 190.0 to 195.2 mm (7-1/2 to 7-11/16 inch) from machined surface of block. If plug is too high, use a suitable flat dowel to position properly. 4. If plug is too low, remove oil pan and No. 4 main bearing cap. Use suitable flat dowel to position properly. Coat outside diameter of plug with Mopar Stud and Bearing Mount Adhesive, or equivalent. Plug should be 54.0 to 57.7 mm (2-1/8 to 2-5/16 inch) from bottom of the block. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications Oil Pan Bolts 200 in.lb Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Removal and Installation Oil Pan: Service and Repair Removal and Installation REMOVAL 1. Disconnect the negative cable from the battery. 2. Remove engine oil dipstick. 3. Disconnect distributor cap and position away from cowl. 4. Raise vehicle. 5. Drain engine oil. 6. Remove exhaust pipe. 7. Remove engine mount insulator through bolts. 8. Raise engine by way of oil pan using a block of wood between the jack and oil pan. 9. When engine is high enough, place mount through bolts in the engine mount attaching points on the frame brackets. 10. Lower engine so bottom of engine mounts rest on the replacement bolts placed in the engine mount frame brackets. 11. Remove oil pan and one-piece gasket. INSTALLATION 1. Fabricate 4 alignment dowels from 5/16 x 1 1/2 inch bolts. Cut the head off the bolts and cut a slot into the top of the dowel. This will allow easier installation and removal with a screwdriver. 2. Install the dowels in the cylinder block. 3. Apply small amount of Mopar (R) Silicone Rubber Adhesive Sealant, or equivalent in the corner of the cap and the cylinder block. 4. Slide the one-piece gasket over the dowels and onto the block. 5. Position the oil pan over the dowels and onto the gasket. 6. Install the oil pan bolts. Tighten the bolts to 24 Nm (215 inch lbs.) torque. 7. Remove the dowels. Install the remaining oil pan bolts. Tighten these bolts to 24 Nm (215 inch lbs.) torque. 8. Install the drain plug. Tighten drain plug to 34 Nm (25 ft. lbs.) torque. 9. Raise engine by way of oil pan with a wood block placed between jack and oil pan. 10. Remove temporary bolts from frame brackets and lower engine. Install mount insulator through bolts and tighten to 95 Nm (70 ft. lbs.). 11. Install exhaust pipe. 12. Lower vehicle. 13. Connect the distributor cap. 14. Install dipstick. 15. Connect the negative cable to the battery. 16. Fill crankcase with oil to proper level. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Removal and Installation > Page 1555 Oil Pan: Service and Repair Cleaning and Inspection CLEANING - Clean the block and pan gasket surfaces. - Trim or remove excess sealant film in the rear main cap oil pan gasket groove. DO NOT remove the sealant inside the rear main cap slots. - If present, trim excess sealant from inside the engine. - Clean oil pan in solvent and wipe dry with a clean cloth. - Clean oil screen and pipe thoroughly in clean solvent. Inspect condition of screen. INSPECTION - Inspect oil drain plug and plug hole for stripped or damaged threads. Repair as necessary. - Inspect oil pan mounting flange for bends or distortion. Straighten flange, if necessary. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Description and Operation Oil Pressure Gauge: Description and Operation SYSTEM OPERATION The oil pressure gauge gives an indication of the engine oil pressure. The instrument cluster circuitry controls the gauge pointer position. The instrument cluster circuitry calculates the proper gauge pointer position based upon an engine oil pressure message received from the Powertrain Control Module (PCM) on the Chrysler Collision Detection (CCD) data bus. The PCM uses an input from the engine oil pressure sensor and internal programming to decide what engine oil pressure message is required. The PCM then sends the proper message to the instrument cluster on the CCD data bus. If the PCM message indicates that oil pressure is too low, the instrument cluster circuitry moves the gauge needle to the 0 PSI graduation on the gauge face, turns on the Check Gauges lamp, and sends a chime tone request to the Central Timer Module (CTM). If the PCM message indicates that oil pressure is too high, the instrument cluster circuitry moves the gauge needle to 110 PSI graduation on the gauge face. The engine oil pressure sensor is installed in a threaded hole that penetrates an oil passage of the engine. The engine oil pressure sensor contains a flexible diaphragm and a variable resistor coil. The diaphragm moves in response to changes in the engine oil pressure, which changes the internal electrical resistance of the sensor. CIRCUIT OPERATION The instrument cluster micro-processor calculates engine oil pressure gauge needle position based on the oil pressure data received over the CCD bus. The Powertrain Control Module (PCM) transmits the data over the CCD bus. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Description and Operation > Page 1559 Oil Pressure Gauge: Testing and Inspection If the problem being diagnosed is related to oil pressure gauge accuracy, be certain to confirm that the problem is with the gauge and not with the engine oiling system performance. The actual engine oil pressure should be checked with a test gauge and compared to the instrument cluster gauge readings before you proceed with gauge diagnosis. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.v Diagnosis of the oil pressure sensor and circuit, the Chrysler Collision Detection (CCD) data bus, and/or the Powertrain Control Module (PCM) should be performed with a DRB scan tool. For diagnosis of the oil pressure gauge and the instrument cluster circuitry, see Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Instrument Cluster. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Description and Operation Oil Pressure Sensor: Description and Operation Sends a signal from the oil pressure sending unit to the Powertrain Control Module (PCM) relating to engine oil pressure. CIRCUIT OPERATION The engine oil pressure sensor is a variable resistor. As engine oil pressure changes the resistance on circuit G60 changes. The G60 circuit connects to cavity B23 of the Powertrain Control Module (PCM) connector. Ground for the sensor is supplied on circuit K4. This circuit connects to cavity A4 of the PCM connector. This circuit is the ground circuit for many of the components in the fuel/ignition system. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump Cover > Component Information > Specifications Oil Pump Cover: Specifications Bolts ..................................................................................................................................................... ................................................. 11 Nm (95 inch lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications OIL PRESSURE @ Curb Idle (Min.)* .............................................................................................................................. ................................................... 41.4 kPa (6 psi) @ 3000 rpm .......................................................... ................................................................................................................... 207 - 552 kPa (30 - 80 psi) Bypass Valve Setting .................................................................................................................... ............................................... 62 - 103 kPa (9 - 15 psi) Switch Actuating pressure ......................................................................................................................................................... 34.5 - 48.3 kPa (5 - 7 psi) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications > Page 1570 Engine Oil Pressure: Testing and Inspection 1. Remove oil pressure sending unit. 2. Install Oil Pressure Line and Gauge Tool C-3292, or equivalent. Start engine and record pressure. OIL PRESSURE: At Curb Idle .......................................................................................................................................... .................................................... 41.4 kPa (6 psi) At 3000 RPM ........................................................ .................................................................................................................. 207 - 552 kPa (30 - 80 psi) CAUTION: If oil pressure is zero at curb idle, do not run engine. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Oil Pressure Regulator Valve > Component Information > Testing and Inspection Oil Pressure Regulator Valve: Testing and Inspection 1. Inspect oil pressure relief valve plunger for scoring and free operation in its bore. Small marks may be removed with 400-grit wet or dry sandpaper. 2. The relief valve spring has a free length of approximately 49.5 mm (1.95 inch). The spring should test between 19.5 and 20.5 pounds when compressed to 34 mm (1 11/32 inch). Replace spring that fails to meet these specifications. NOTE: If oil pressure was low and pump is within specifications, inspect for worn engine bearings or other reasons for oil pressure loss. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption Intake Manifold: Customer Interest Engine - Spark Knock/Oil Consumption NUMBER: 09-05-00 GROUP: Engine DATE: Feb.25, 2000 MODELS: 1994 - 1999 (AB) Ram Van 1994 - 1999 (AN) Dakota 1994 - 1999 (BRIBE) Ram Truck 1998 - 1999 (DN) Durango 1994 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-06-99, DATED SEP.10, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Spark Knock And Engine Oil Consumption Due To Intake Manifold Pan Gasket Oil Leak OVER VIEW: This bulletin involves the replacement of the engine intake manifold plenum pan gasket. NOTE: THIS BULLETIN APPLIES TO VEHICLE EQUIPPED WITH A 3.9L, 5.2L. OR 5.9L GASOLINE ENGINE. SYMPTOM/CONDITION: An engine intake manifold plenum pan gasket oil leak may occur on some V-6 and V-8 style engines. The oil leak is internal to the engine so no external oil leakage will be present. Two symptoms of this oil leak condition may be present. The vehicle operator may experience an engine spark knock during acceleration and/or an increase in the amount of engine oil consumed by the engine. DIAGNOSIS: Make sure Technical Service Bulletin (TSB) 18-48-98 has been performed. NOTE: IT IS IMPORTANT THAT THE COIL AND SPARK PLUG WIRES ARE ROUTED EXACTLY AS SPECIFIED IN TSB 18-48-98 TO ACHIEVE THE MOST BENEFIT. Inspect the Positive Crankcase Ventilation (PCV) valve. Shake the PCV valve to verify that the pintle inside of the PCV valve is free. Replace the PVC if the pintle is not free. If the intake manifold plenum pan gasket is leaking, an additional vacuum source will be created inside of the engine at the location of the pan gasket leakage. Engine combustion blow-by gases, oil vapor, and air from the crankcase filter/breather may be drawn past the leaking pan gasket and into the intake manifold. In most cases when this condition occurs, an engine at idle will create the highest vacuum and lowest amount of engine blow-by. 1. Allow the engine to reach normal operating temperature. 2. Stop the engine. 3. Disconnect the breather hose from the air cleaner. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1582 4. Attach a vacuum/pressure gauge to the end of the breather hose (Figure 1). 5. Disconnect the PCV valve hose from the intake manifold. 6. Seal off the intake manifold PCV valve hose port opening. 7. Seal off the open end of the PCV valve hose (Figure 2). NOTE: DURING THIS DIAGNOSIS, IT WOULD BE NORMAL FOR THE ENGINE TO DEVELOP PRESSURE WITHIN THE ENGINE CRANKCASE. THIS IS DUE TO THE NORMAL PROCESS OF EXHAUST BLOW-BY GASES LEAKING PAST THE ENGINE PISTON RINGS AND ACCUMULATING IN THE ENGINE CRANKCASE. DO NOT ALLOW MORE THAN 3 PSI (20.7 kpa) OF PRESSURE TO BUILD WITHIN THE ENGINE WHEN PERFORMING THE FOLLOWING DIAGNOSTIC PROCEDURE. 8. Start the warmed engine and observe the vacuum gauge. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1583 9. Allow the engine to idle for approximately 30 seconds. Do not allow more than 3 psi (20.7 kPa) of pressure to develop in the engine crankcase. 10. If the attached vacuum / pressure gauge does not indicate that a vacuum is present in the engine crankcase, then the intake manifold plenum pan gasket is good and no further internal engine vacuum leak diagnosis is required. 11. If an internal vacuum leak is present then perform the Repair Procedure. PARTS REQUIRED: For the 5.2L / 5.9L: 1 04897383AC Package, Intake Manifold Flange Gasket and Bolts 1 05017208AA Gasket, Intake Manifold Plenum Pan 15 06034583 Bolt, Intake Manifold Plenum Pan 1 53030541 Gasket, Throttle Body 2(AR) 04318001 Conditioner, Combustion Chamber For the 3.9L: 1 04897382AC Package, Intake Manifold Flange Gasket and Bolts 1 05017207AA Gasket, Intake Manifold Plenum Pan 14 06034583 Bolt, Intake Manifold Plenum Pan 1 53030541 Gasket, Throttle Body 2(AR)04318001 Conditioner, Combustion Chamber REPAIR PROCEDURE: 1. Refer to the appropriate year Service Manual, Section 9: ENGINE for removal and installation instructions. NOTE: CLEAN ALL OIL RESIDUE FROM THE INTERIOR SURFACES OF THE PLENUM PAN AND THE INTAKE MANIFOLD PLENUM CHAMBER. NOTE: THE PROPER BOLT TORQUE AND TIGHTENING SEQUENCE IS CRITICAL AND MUST BE FOLLOWED WHEN TIGHTENING BOTH THE PLENUM PAN BOLTS AND THE INTAKE MANIFOLD FLANGE BOLTS. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1584 3.9L Bolt Tightening Sequence and Torque Procedure: 3.9 Plenum Pan Bolt Torque Procedure 3.9 Intake Manifold Flange Bolt Torque Procedure Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1585 5.2L / 5.9L Plenum Bolt Tightening Sequence and Torque Procedure: 5.2L / 5.9L Plenum Pan Bolt Torque Procedure Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1586 5.2L / 5.9L Intake Manifold Flange Bolt Torque Procedure 2. With the engine reassembled, inspect the coil and spark plug wires for proper routing. Refer to TSB 09-48-98 for additional assistance. 3. Start the engine and allow it to warm to normal engine operating temperature. 4. Decarbon the combustion chamber using Mopar Combustion Chamber Conditioner (p/n 04318001) per the instructions. NOTE: ALLOW THE COMBUSTION CHAMBER CLEANER TO SOAK INSIDE OF THE ENGINE FOR 2 TO 2.5 HOURS. NOTE: A SECOND APPLICATION OF THE COMBUSTION CHAMBER CONDITIONER MAY BE REQUIRED IF THERE WAS A LARGE QUANTITY OF OIL LEAKAGE PAST THE INTAKE PLENUM PAN GASKET. 5. Verify proper engine oil level. POLICY: Reimbursable within the provisions of the warranty. Time Allowance FAILURE CODE: P8- New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption Intake Manifold: All Technical Service Bulletins Engine - Spark Knock/Oil Consumption NUMBER: 09-05-00 GROUP: Engine DATE: Feb.25, 2000 MODELS: 1994 - 1999 (AB) Ram Van 1994 - 1999 (AN) Dakota 1994 - 1999 (BRIBE) Ram Truck 1998 - 1999 (DN) Durango 1994 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-06-99, DATED SEP.10, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Spark Knock And Engine Oil Consumption Due To Intake Manifold Pan Gasket Oil Leak OVER VIEW: This bulletin involves the replacement of the engine intake manifold plenum pan gasket. NOTE: THIS BULLETIN APPLIES TO VEHICLE EQUIPPED WITH A 3.9L, 5.2L. OR 5.9L GASOLINE ENGINE. SYMPTOM/CONDITION: An engine intake manifold plenum pan gasket oil leak may occur on some V-6 and V-8 style engines. The oil leak is internal to the engine so no external oil leakage will be present. Two symptoms of this oil leak condition may be present. The vehicle operator may experience an engine spark knock during acceleration and/or an increase in the amount of engine oil consumed by the engine. DIAGNOSIS: Make sure Technical Service Bulletin (TSB) 18-48-98 has been performed. NOTE: IT IS IMPORTANT THAT THE COIL AND SPARK PLUG WIRES ARE ROUTED EXACTLY AS SPECIFIED IN TSB 18-48-98 TO ACHIEVE THE MOST BENEFIT. Inspect the Positive Crankcase Ventilation (PCV) valve. Shake the PCV valve to verify that the pintle inside of the PCV valve is free. Replace the PVC if the pintle is not free. If the intake manifold plenum pan gasket is leaking, an additional vacuum source will be created inside of the engine at the location of the pan gasket leakage. Engine combustion blow-by gases, oil vapor, and air from the crankcase filter/breather may be drawn past the leaking pan gasket and into the intake manifold. In most cases when this condition occurs, an engine at idle will create the highest vacuum and lowest amount of engine blow-by. 1. Allow the engine to reach normal operating temperature. 2. Stop the engine. 3. Disconnect the breather hose from the air cleaner. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1592 4. Attach a vacuum/pressure gauge to the end of the breather hose (Figure 1). 5. Disconnect the PCV valve hose from the intake manifold. 6. Seal off the intake manifold PCV valve hose port opening. 7. Seal off the open end of the PCV valve hose (Figure 2). NOTE: DURING THIS DIAGNOSIS, IT WOULD BE NORMAL FOR THE ENGINE TO DEVELOP PRESSURE WITHIN THE ENGINE CRANKCASE. THIS IS DUE TO THE NORMAL PROCESS OF EXHAUST BLOW-BY GASES LEAKING PAST THE ENGINE PISTON RINGS AND ACCUMULATING IN THE ENGINE CRANKCASE. DO NOT ALLOW MORE THAN 3 PSI (20.7 kpa) OF PRESSURE TO BUILD WITHIN THE ENGINE WHEN PERFORMING THE FOLLOWING DIAGNOSTIC PROCEDURE. 8. Start the warmed engine and observe the vacuum gauge. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1593 9. Allow the engine to idle for approximately 30 seconds. Do not allow more than 3 psi (20.7 kPa) of pressure to develop in the engine crankcase. 10. If the attached vacuum / pressure gauge does not indicate that a vacuum is present in the engine crankcase, then the intake manifold plenum pan gasket is good and no further internal engine vacuum leak diagnosis is required. 11. If an internal vacuum leak is present then perform the Repair Procedure. PARTS REQUIRED: For the 5.2L / 5.9L: 1 04897383AC Package, Intake Manifold Flange Gasket and Bolts 1 05017208AA Gasket, Intake Manifold Plenum Pan 15 06034583 Bolt, Intake Manifold Plenum Pan 1 53030541 Gasket, Throttle Body 2(AR) 04318001 Conditioner, Combustion Chamber For the 3.9L: 1 04897382AC Package, Intake Manifold Flange Gasket and Bolts 1 05017207AA Gasket, Intake Manifold Plenum Pan 14 06034583 Bolt, Intake Manifold Plenum Pan 1 53030541 Gasket, Throttle Body 2(AR)04318001 Conditioner, Combustion Chamber REPAIR PROCEDURE: 1. Refer to the appropriate year Service Manual, Section 9: ENGINE for removal and installation instructions. NOTE: CLEAN ALL OIL RESIDUE FROM THE INTERIOR SURFACES OF THE PLENUM PAN AND THE INTAKE MANIFOLD PLENUM CHAMBER. NOTE: THE PROPER BOLT TORQUE AND TIGHTENING SEQUENCE IS CRITICAL AND MUST BE FOLLOWED WHEN TIGHTENING BOTH THE PLENUM PAN BOLTS AND THE INTAKE MANIFOLD FLANGE BOLTS. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1594 3.9L Bolt Tightening Sequence and Torque Procedure: 3.9 Plenum Pan Bolt Torque Procedure 3.9 Intake Manifold Flange Bolt Torque Procedure Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1595 5.2L / 5.9L Plenum Bolt Tightening Sequence and Torque Procedure: 5.2L / 5.9L Plenum Pan Bolt Torque Procedure Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1596 5.2L / 5.9L Intake Manifold Flange Bolt Torque Procedure 2. With the engine reassembled, inspect the coil and spark plug wires for proper routing. Refer to TSB 09-48-98 for additional assistance. 3. Start the engine and allow it to warm to normal engine operating temperature. 4. Decarbon the combustion chamber using Mopar Combustion Chamber Conditioner (p/n 04318001) per the instructions. NOTE: ALLOW THE COMBUSTION CHAMBER CLEANER TO SOAK INSIDE OF THE ENGINE FOR 2 TO 2.5 HOURS. NOTE: A SECOND APPLICATION OF THE COMBUSTION CHAMBER CONDITIONER MAY BE REQUIRED IF THERE WAS A LARGE QUANTITY OF OIL LEAKAGE PAST THE INTAKE PLENUM PAN GASKET. 5. Verify proper engine oil level. POLICY: Reimbursable within the provisions of the warranty. Time Allowance FAILURE CODE: P8- New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 1597 Intake Manifold: Specifications INTAKE MANIFOLD SPECIFICATIONS: Plenum Pan Bolts Tighten the bolts, in sequence, as follows: Step 1-Tighten bolts to 2.7 Nm (24 inch lbs.) torque. - Step 2-Tighten bolts to 5.4 Nm (48 inch lbs.) torque. - Step 3-Tighten bolts to 9.5 Nm (84 inch lbs.) torque. - Step 4-Check that all bolts are tighten to 9.5 Nm (84 inch lbs.) torque. Manifold Bolts Install the intake manifold bolts and tighten as follows: Step 1-Tighten bolts 1 and 2 to 8 Nm (72 inch lbs.) torque. Tighten in alternating steps 1.4 Nm (12 inch lbs.) torque at a time. - Step 2-Tighten bolts 3 through 12, in sequence, to 8 Nm (72 inch lbs.) torque. - Step 3-Check that all bolts are tighten to 8 Nm (72 inch lbs.) torque. - Step 4-Tighten all bolts, in sequence, to 16 Nm (12 ft. lbs.) torque. - Step 5-Check that all bolts are tighten to 16 Nm (12 ft. lbs.) torque. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 1598 Intake Manifold: Service Precautions WARNING: Use extreme caution when the engine is operating. do not put your hands near the pulleys, belts or the fan. do not wear loose clothing. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 1599 Intake Manifold: Description and Operation The aluminum intake manifold is a single plane design with equal length runners. The manifold is sealed by flange side gaskets with front and rear cross-over gaskets. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 1600 Intake Manifold: Testing and Inspection WARNING: Use extreme caution when the engine is operating. do not put your hands near the pulleys, belts or the fan. do not wear loose clothing. LOW MANIFOLD VACUUM An intake manifold leak is characterized by lower than normal manifold vacuum. Also, one or more cylinder may not be functioning. PROCEDURE 1. Start the engine. 2. Spray a small stream of water on the suspect area. 3. If there is a change in RPM the suspected leak has been found. 4. Repair as required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Cleaning and Inspection Intake Manifold: Service and Repair Cleaning and Inspection CLEANING - Clean manifold in solvent and blow dry with compressed air. - Clean cylinder block front and rear gasket surfaces using a suitable solvent. - The plenum pan rail must be clean and dry (free of all foreign material). INSPECTION - Inspect manifold for cracks. - Inspect mating surfaces of manifold for flatness with a straightedge. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Cleaning and Inspection > Page 1603 Intake Manifold: Service and Repair Intake Manifold Replacement Removal PROCEDURE 1. Disconnect the negative cable from the battery. 2. Drain the cooling system (refer Cooling System for the proper procedures). 3. Remove the generator. 4. Remove the air cleaner. 5. Perform the Fuel System Pressure release procedure (refer to Fuel Delivery and Air Induction System). Disconnect the fuel lines. 6. Disconnect the accelerator linkage and if so equipped, the speed control and transmission kickdown cables. 7. Remove the return spring. 8. Remove the distributor cap and wires. 9. Disconnect the coil wires. 10. Disconnect the heat indicator sending unit wire. 11. Disconnect the heater hoses and bypass hose. 12. Remove the closed crankcase ventilation and evaporation control systems. 13. Remove intake manifold bolts. 14. Lift the intake manifold and throttle body out of the engine compartment as an assembly. 15. Remove and discard the flange side gaskets and the front and rear cross-over gaskets. Throttle Body Assembly 16. Remove the throttle body bolts and lift the throttle body off the intake manifold. Discard the gasket. 17. Remove the plenum pan as follows: - Turn the intake manifold upside down. Support the manifold. - Remove the bolts and lift the pan off the manifold. Discard the gasket. Installation 1. Install the plenum pan, if removed, as follows: a. Turn the intake manifold upside down. Support the manifold. b. Place a new plenum pan gasket onto the seal rail of the intake manifold. Position the pan over the gasket. Align all the gasket and pan holes with the intake manifold. c. Hand start all bolts. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Cleaning and Inspection > Page 1604 Tightening Sequence d. Tighten the bolts, in sequence as follows: Step 1 - Tighten bolts to 2.7 Nm (24 in. lbs.) torque. Step 2 - Tighten bolts to 5.4 Nm (48 in. lbs.) torque. Step 3 - Tighten bolts to 9.5 Nm (84 in. lbs.) torque. Step 4 - Check that all bolts are tightened to 9.5 Nm (84 in. lbs.) torque. 2. Using a new gasket, install the throttle body onto the intake manifold. Tighten the bolts to 23 Nm (200 in. lbs.) torque. Cross-Over Gaskets And Locator Dowels 3. Place the 4 plastic locator dowels into the holes in the block. 4. Apply Mopar Silicone Rubber Adhesive Sealant, or equivalent, to the four corner joints. An excessive amount of sealant is not required to ensure a leak proof seal. However, an excessive amount of sealant may reduce the effectiveness of the flange gasket. The sealant should be slightly higher than the cross-over gaskets, approximately 5 mm (0.2 in). 5. Install the front and rear cross-over gaskets onto the dowels. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Cleaning and Inspection > Page 1605 Intake Manifold Flange Gasket Alignment 6. Install the flange gaskets. Ensure that the vertical port alignment tab is resting on the deck face of the block. Also the horizontal alignment tabs must be in position with the mating cylinder head gasket tabs. The words MANIFOLD SIDE should be visible on the center of each flange gasket. 7. Carefully lower intake manifold into. position on the cylinder block and cylinder heads. Use the alignment dowels in the cross-over gaskets to position the intake manifold. After intake manifold is in place, inspect to make sure seals are in place. 8. Install the intake manifold bolts and tighten as follows: Intake Manifold Bolt Tightening Sequence Step 1 - Tighten bolts 1 and 2 to 8 Nm (72 in. lbs.) torque. Tighten in alternating steps 1.4 Nm (12 in. lbs.) torque at a time. Step 2 - Tighten bolts 3 through 12, in sequence, to 8 Nm (72 in. lbs.) torque. Step 3 - Check that all bolts are tightened to 8 Nm (72 in. lbs.) torque. Step 4 - Tighten all bolts, in sequence, to 16 Nm (12 ft. lbs.) torque. Step 5 - Check that all bolts are tightened to 16 Nm (12 ft. lbs.) torque. 9. Install closed crankcase ventilation and evaporation control systems. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Cleaning and Inspection > Page 1606 10. Connect the coil wires. 11. Connect the heat indicator sending unit wire. 12. Connect the heater hoses and bypass hose. 13. Install distributor cap and wires. 14. Hook up the return spring. 15. Connect the accelerator linkage and if so equipped, the speed control and transmission kickdown cables. 16. Install the fuel lines. 17. Install the generator and drive belt. Tighten generator mounting bolt to 41 Nm (30 ft. lbs.) torque. 18. Install the air cleaner. 19. Fill cooling system (refer to Cooling System for the proper procedure). 20. Connect the negative cable to the battery. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Description and Operation Oil Pressure Gauge: Description and Operation SYSTEM OPERATION The oil pressure gauge gives an indication of the engine oil pressure. The instrument cluster circuitry controls the gauge pointer position. The instrument cluster circuitry calculates the proper gauge pointer position based upon an engine oil pressure message received from the Powertrain Control Module (PCM) on the Chrysler Collision Detection (CCD) data bus. The PCM uses an input from the engine oil pressure sensor and internal programming to decide what engine oil pressure message is required. The PCM then sends the proper message to the instrument cluster on the CCD data bus. If the PCM message indicates that oil pressure is too low, the instrument cluster circuitry moves the gauge needle to the 0 PSI graduation on the gauge face, turns on the Check Gauges lamp, and sends a chime tone request to the Central Timer Module (CTM). If the PCM message indicates that oil pressure is too high, the instrument cluster circuitry moves the gauge needle to 110 PSI graduation on the gauge face. The engine oil pressure sensor is installed in a threaded hole that penetrates an oil passage of the engine. The engine oil pressure sensor contains a flexible diaphragm and a variable resistor coil. The diaphragm moves in response to changes in the engine oil pressure, which changes the internal electrical resistance of the sensor. CIRCUIT OPERATION The instrument cluster micro-processor calculates engine oil pressure gauge needle position based on the oil pressure data received over the CCD bus. The Powertrain Control Module (PCM) transmits the data over the CCD bus. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Description and Operation > Page 1611 Oil Pressure Gauge: Testing and Inspection If the problem being diagnosed is related to oil pressure gauge accuracy, be certain to confirm that the problem is with the gauge and not with the engine oiling system performance. The actual engine oil pressure should be checked with a test gauge and compared to the instrument cluster gauge readings before you proceed with gauge diagnosis. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.v Diagnosis of the oil pressure sensor and circuit, the Chrysler Collision Detection (CCD) data bus, and/or the Powertrain Control Module (PCM) should be performed with a DRB scan tool. For diagnosis of the oil pressure gauge and the instrument cluster circuitry, see Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Instrument Cluster. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Rear Crankshaft Seal <--> [Crankshaft Main Bearing Seal] > Component Information > Description and Operation Rear Crankshaft Seal: Description and Operation The service seal is a two piece, Viton seal. The upper seal half can be installed with crankshaft removed from engine or with crankshaft installed. When a new upper seal is installed, install a new lower seal. The lower seal half can be installed only with the rear main bearing cap removed. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Rear Crankshaft Seal <--> [Crankshaft Main Bearing Seal] > Component Information > Description and Operation > Page 1616 Rear Crankshaft Seal: Testing and Inspection Since it is sometimes difficult to determine the source of an oil leak in the rear seal area of the engine, a more involved inspection is necessary. The following steps should be followed to help pinpoint the source of the leak. If the leakage occurs at the crankshaft rear oil seal area: 1. Disconnect the battery. 2. Raise the vehicle. 3. Remove torque converter or clutch housing cover and inspect rear of block for evidence of oil. Use a black light to check for the oil leak. If a leak is present in this area remove transmission for further inspection. a. Circular spray pattern generally indicates seal leakage or crankshaft damage. b. Where leakage tends to run straight down, possible causes are a porous block, oil galley cup plug, bedplate to cylinder block mating surfaces and seal bore. See proper repair procedures for these items. 4. If no leaks are detected, pressurized the crankcase. CAUTION: Do not exceed 20.6 kPa (3 psi). 5. If the leak is not detected, very slowly turn the crankshaft and watch for leakage. If a leak is detected between the crankshaft and seal while slowly turning the crankshaft, it is possible the crankshaft seal surface is damaged. The seal area on the crankshaft could have minor nicks or scratches that can be polished out with emery cloth. CAUTION: Use extreme caution when crankshaft polishing is necessary to remove minor nicks and scratches. The crankshaft seal flange is especially machined to complement the function of the rear oil seal. 6. For bubbles that remain steady with shaft rotation, no further inspection can be done until disassembled. 7. After the oil leak root cause and appropriate corrective action have been identified. Replace rear main seal. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Rear Crankshaft Seal <--> [Crankshaft Main Bearing Seal] > Component Information > Service and Repair > Lower Seal Rear Crankshaft Seal: Service and Repair Lower Seal REMOVAL 1. Remove the oil pan. 2. Remove the oil pump from the rear main bearing cap. 3. Remove the rear main bearing cap and discard the old lower seal. INSTALLATION 1. Clean the rear main cap mating surfaces including the oil pan gasket groove. 2. Carefully install a new upper seal. Refer to Upper Seal Replacement-Crankshaft Installed procedure above. 3. Lightly oil the new lower seal lips with engine 0il. 4. Install a new lower seal in bearing cap with the white paint facing the rear of engine. 5. Apply 5 mm (0.20 inch) drop of Loctite 518, or equivalent, on each side of the rear main bearing cap. DO NOT over-apply sealant or allow the sealant to contact the rubber seal. Assemble bearing cap to cylinder block immediately after sealant application. 6. To align the bearing cap, use cap slot, alignment dowel, and cap bolts. DO NOT remove excess material after assembly. DO NOT strike rear cap more than two times for proper engagement. 7. Install the rear main bearing cap with cleaned and oiled cap bolts. Alternately tighten the cap bolts to 115 Nm (85 ft. lbs.) torque. 8. Install oil pump. 9. Apply Mopar Silicone Rubber Adhesive Sealant, or equivalent, at bearing cap-to-block joint to provide cap to block and oil pan sealing. Apply enough sealant so that a small amount is squeezed out. Withdraw nozzle and wipe excess sealant off the oil pan seal groove. 10. Immediately install the oil pan. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Rear Crankshaft Seal <--> [Crankshaft Main Bearing Seal] > Component Information > Service and Repair > Lower Seal > Page 1619 Rear Crankshaft Seal: Service and Repair Upper Seal With Crankshaft Removed REMOVAL 1. Remove the crankshaft. Discard the old upper seal. INSTALLATION 1. Clean the cylinder block rear cap mating surface. Be sure the seal groove is free of debris. Check for burrs at the oil hole on the cylinder block mating surface to rear cap. 2. Lightly oil the new upper seal lips with engine oil. 3. Install the new upper rear bearing oil seal with the white paint facing toward the rear of the engine. 4. Position the crankshaft into the cylinder block. 5. Lightly oil the new lower seal lips with engine oil. 6. Install the new lower rear bearing oil seal into the bearing cap with the white paint facing towards the rear of the engine. 7. Apply 5 mm (0.20 inch) drop of Loctite 518, or equivalent, on each side of the rear main bearing cap. DO NOT over-apply sealant or allow the sealant to contact the rubber seal. Assemble bearing cap to cylinder block immediately after sealant application. 8. To align the bearing cap, use cap slot, alignment dowel, and cap bolts. DO NOT remove excess material after assembly. DO NOT strike rear cap more than two times for proper engagement. 9. Clean and oil all cap bolts. Install all main bearing caps. Install all cap bolts and alternately tighten to 115 Nm (85 ft. lbs.) torque. 10. Install oil pump. 11. Apply Mopar (R) Silicone Rubber Adhesive Sealant, or equivalent, at bearing cap-to-block joint to provide cap to block and oil pan sealing. Apply enough sealant so that a small amount is squeezed out. Withdraw nozzle and wipe excess sealant off the oil pan seal groove. 12. Install new front crankshaft oil seal. 13. Immediately install the oil pan. With Crankshaft Installed REMOVAL 1. Remove the oil pan. 2. Remove the oil pump from the rear main bearing cap. 3. Remove the rear main bearing cap. Remove and discard the old lower oil seal. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Rear Crankshaft Seal <--> [Crankshaft Main Bearing Seal] > Component Information > Service and Repair > Lower Seal > Page 1620 4. Carefully remove and discard the old upper oil seal. INSTALLATION 1. Clean the cylinder block mating surfaces before oil seal installation. Check for burrs at the oil hole on the cylinder block mating surface to rear cap. 2. Lightly oil the new upper seal lips with engine oil. To allow ease of installation of the seal, loosen at least the two main bearing caps forward of the rear bearing cap. 3. Rotate the new upper seal into the cylinder block, being careful not to shave or cut the outer surface of the seal. To ensure proper installation, use the installation tool provided with the kit. Install the new seal with the white paint facing toward the rear of the engine. 4. Install the new lower rear bearing oil seal into the bearing cap with the white paint facing toward the rear of the engine. 5. Apply 5 mm (0.20 inch) drop of Loctite 518, or equivalent, on each side of the rear main bearing cap. DO NOT over-apply sealant or allow the sealant to contact the rubber seal. Assemble bearing cap to cylinder block immediately after sealant application. Be sure the white paint faces toward the rear of the engine. 6. To align the bearing cap, use cap slot, alignment dowel, and cap bolts. DO NOT remove excess material after assembly. DO NOT strike rear cap more than two times for proper engagement. 7. Install the rear main bearing cap with cleaned and oiled cap bolts. Alternately tighten ALL cap bolts to 115 Nm (85 ft. lbs.) torque. 8. Install oil pump. 9. Apply Mopar Silicone Rubber Adhesive Sealant, or equivalent, at bearing cap-to-block joint to provide cap-to-block and oil pan sealing. Apply enough sealant until a small amount is squeezed out. Withdraw nozzle and wipe excess sealant off the oil pan seal groove. 10. Immediately install the oil pan. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Testing and Inspection Cylinder Head Gasket: Testing and Inspection FAILURE DIAGNOSIS A leaking engine cylinder head gasket usually results in loss of power, loss of coolant and engine misfiring. An engine cylinder head gasket leak can be located between adjacent cylinders or between a cylinder and the adjacent water jacket. ^ An engine cylinder head gasket leaking between adjacent cylinders is indicated by a loss of power and/or engine misfire. ^ An engine cylinder head gasket leaking between a cylinder and an adjacent water jacket is indicated by coolant foaming or overheating and loss of coolant. Cylinder-To-Cylinder Leakage Test To determine if an engine cylinder head gasket is leaking between adjacent cylinders follow the procedures outlined in Cylinder Compression Pressure Test. An engine cylinder head gasket leaking between adjacent cylinders will result in approximately a 50 - 70% reduction in compression pressure. WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT STAND IN A DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELTS OR THE FAN. DO NOT WEAR LOOSE CLOTHING. Cylinder-To-Water Jacket Leakage Test 1. Remove the radiator cap. 2. Start the engine and allow it to warm up until the engine thermostat opens. ^ If a large combustion/compression pressure leak exists, bubbles will be visible in the coolant. ^ If bubbles are not visible, install a radiator pressure tester and pressurize the coolant system. ^ If a cylinder is leaking combustion pressure into the water jacket, the tester pointer will pulsate with every combustion stroke of the cylinder. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair Front Crankshaft Seal: Service and Repair NOTE: The oil seal can be replaced without removing the timing chain cover, provided that the cover is not misaligned. REMOVAL 1. Disconnect the negative cable from the battery. 2. Remove vibration damper. 3. If front seal is suspected of leaking, check front oil seal alignment to crankshaft. The seal installation/alignment Tool 6635, or equivalent, should fit with minimum interference. If tool does not fit, the cover must be removed and installed properly. 4. Place a suitable tool behind the lips of the oil seal to pry the oil seal outward. Be careful not to damage the crankshaft seal bore of cover. INSTALLATION 1. Place the smaller diameter of the oil seal over Front Oil Seal Installation Tool 6635, or equivalent. Seat the oil seal in the groove of the tool. 2. Position the seal and tool onto the crankshaft. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 1627 3. Using the vibration damper bolt, tighten the bolt to draw the seal into position on the crankshaft. 4. Remove the vibration damper bolt and seal installation tool. 5. Inspect the seal flange on the vibration damper. 6. Install the vibration damper. 7. Connect the negative cable to the battery. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 1628 Front Oil Seal Installer 6635 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold Gasket: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption Intake Manifold Gasket: Customer Interest Engine - Spark Knock/Oil Consumption NUMBER: 09-05-00 GROUP: Engine DATE: Feb.25, 2000 MODELS: 1994 - 1999 (AB) Ram Van 1994 - 1999 (AN) Dakota 1994 - 1999 (BRIBE) Ram Truck 1998 - 1999 (DN) Durango 1994 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-06-99, DATED SEP.10, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Spark Knock And Engine Oil Consumption Due To Intake Manifold Pan Gasket Oil Leak OVER VIEW: This bulletin involves the replacement of the engine intake manifold plenum pan gasket. NOTE: THIS BULLETIN APPLIES TO VEHICLE EQUIPPED WITH A 3.9L, 5.2L. OR 5.9L GASOLINE ENGINE. SYMPTOM/CONDITION: An engine intake manifold plenum pan gasket oil leak may occur on some V-6 and V-8 style engines. The oil leak is internal to the engine so no external oil leakage will be present. Two symptoms of this oil leak condition may be present. The vehicle operator may experience an engine spark knock during acceleration and/or an increase in the amount of engine oil consumed by the engine. DIAGNOSIS: Make sure Technical Service Bulletin (TSB) 18-48-98 has been performed. NOTE: IT IS IMPORTANT THAT THE COIL AND SPARK PLUG WIRES ARE ROUTED EXACTLY AS SPECIFIED IN TSB 18-48-98 TO ACHIEVE THE MOST BENEFIT. Inspect the Positive Crankcase Ventilation (PCV) valve. Shake the PCV valve to verify that the pintle inside of the PCV valve is free. Replace the PVC if the pintle is not free. If the intake manifold plenum pan gasket is leaking, an additional vacuum source will be created inside of the engine at the location of the pan gasket leakage. Engine combustion blow-by gases, oil vapor, and air from the crankcase filter/breather may be drawn past the leaking pan gasket and into the intake manifold. In most cases when this condition occurs, an engine at idle will create the highest vacuum and lowest amount of engine blow-by. 1. Allow the engine to reach normal operating temperature. 2. Stop the engine. 3. Disconnect the breather hose from the air cleaner. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold Gasket: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1637 4. Attach a vacuum/pressure gauge to the end of the breather hose (Figure 1). 5. Disconnect the PCV valve hose from the intake manifold. 6. Seal off the intake manifold PCV valve hose port opening. 7. Seal off the open end of the PCV valve hose (Figure 2). NOTE: DURING THIS DIAGNOSIS, IT WOULD BE NORMAL FOR THE ENGINE TO DEVELOP PRESSURE WITHIN THE ENGINE CRANKCASE. THIS IS DUE TO THE NORMAL PROCESS OF EXHAUST BLOW-BY GASES LEAKING PAST THE ENGINE PISTON RINGS AND ACCUMULATING IN THE ENGINE CRANKCASE. DO NOT ALLOW MORE THAN 3 PSI (20.7 kpa) OF PRESSURE TO BUILD WITHIN THE ENGINE WHEN PERFORMING THE FOLLOWING DIAGNOSTIC PROCEDURE. 8. Start the warmed engine and observe the vacuum gauge. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold Gasket: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1638 9. Allow the engine to idle for approximately 30 seconds. Do not allow more than 3 psi (20.7 kPa) of pressure to develop in the engine crankcase. 10. If the attached vacuum / pressure gauge does not indicate that a vacuum is present in the engine crankcase, then the intake manifold plenum pan gasket is good and no further internal engine vacuum leak diagnosis is required. 11. If an internal vacuum leak is present then perform the Repair Procedure. PARTS REQUIRED: For the 5.2L / 5.9L: 1 04897383AC Package, Intake Manifold Flange Gasket and Bolts 1 05017208AA Gasket, Intake Manifold Plenum Pan 15 06034583 Bolt, Intake Manifold Plenum Pan 1 53030541 Gasket, Throttle Body 2(AR) 04318001 Conditioner, Combustion Chamber For the 3.9L: 1 04897382AC Package, Intake Manifold Flange Gasket and Bolts 1 05017207AA Gasket, Intake Manifold Plenum Pan 14 06034583 Bolt, Intake Manifold Plenum Pan 1 53030541 Gasket, Throttle Body 2(AR)04318001 Conditioner, Combustion Chamber REPAIR PROCEDURE: 1. Refer to the appropriate year Service Manual, Section 9: ENGINE for removal and installation instructions. NOTE: CLEAN ALL OIL RESIDUE FROM THE INTERIOR SURFACES OF THE PLENUM PAN AND THE INTAKE MANIFOLD PLENUM CHAMBER. NOTE: THE PROPER BOLT TORQUE AND TIGHTENING SEQUENCE IS CRITICAL AND MUST BE FOLLOWED WHEN TIGHTENING BOTH THE PLENUM PAN BOLTS AND THE INTAKE MANIFOLD FLANGE BOLTS. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold Gasket: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1639 3.9L Bolt Tightening Sequence and Torque Procedure: 3.9 Plenum Pan Bolt Torque Procedure 3.9 Intake Manifold Flange Bolt Torque Procedure Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold Gasket: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1640 5.2L / 5.9L Plenum Bolt Tightening Sequence and Torque Procedure: 5.2L / 5.9L Plenum Pan Bolt Torque Procedure Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold Gasket: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1641 5.2L / 5.9L Intake Manifold Flange Bolt Torque Procedure 2. With the engine reassembled, inspect the coil and spark plug wires for proper routing. Refer to TSB 09-48-98 for additional assistance. 3. Start the engine and allow it to warm to normal engine operating temperature. 4. Decarbon the combustion chamber using Mopar Combustion Chamber Conditioner (p/n 04318001) per the instructions. NOTE: ALLOW THE COMBUSTION CHAMBER CLEANER TO SOAK INSIDE OF THE ENGINE FOR 2 TO 2.5 HOURS. NOTE: A SECOND APPLICATION OF THE COMBUSTION CHAMBER CONDITIONER MAY BE REQUIRED IF THERE WAS A LARGE QUANTITY OF OIL LEAKAGE PAST THE INTAKE PLENUM PAN GASKET. 5. Verify proper engine oil level. POLICY: Reimbursable within the provisions of the warranty. Time Allowance FAILURE CODE: P8- New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption Intake Manifold Gasket: All Technical Service Bulletins Engine - Spark Knock/Oil Consumption NUMBER: 09-05-00 GROUP: Engine DATE: Feb.25, 2000 MODELS: 1994 - 1999 (AB) Ram Van 1994 - 1999 (AN) Dakota 1994 - 1999 (BRIBE) Ram Truck 1998 - 1999 (DN) Durango 1994 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-06-99, DATED SEP.10, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Spark Knock And Engine Oil Consumption Due To Intake Manifold Pan Gasket Oil Leak OVER VIEW: This bulletin involves the replacement of the engine intake manifold plenum pan gasket. NOTE: THIS BULLETIN APPLIES TO VEHICLE EQUIPPED WITH A 3.9L, 5.2L. OR 5.9L GASOLINE ENGINE. SYMPTOM/CONDITION: An engine intake manifold plenum pan gasket oil leak may occur on some V-6 and V-8 style engines. The oil leak is internal to the engine so no external oil leakage will be present. Two symptoms of this oil leak condition may be present. The vehicle operator may experience an engine spark knock during acceleration and/or an increase in the amount of engine oil consumed by the engine. DIAGNOSIS: Make sure Technical Service Bulletin (TSB) 18-48-98 has been performed. NOTE: IT IS IMPORTANT THAT THE COIL AND SPARK PLUG WIRES ARE ROUTED EXACTLY AS SPECIFIED IN TSB 18-48-98 TO ACHIEVE THE MOST BENEFIT. Inspect the Positive Crankcase Ventilation (PCV) valve. Shake the PCV valve to verify that the pintle inside of the PCV valve is free. Replace the PVC if the pintle is not free. If the intake manifold plenum pan gasket is leaking, an additional vacuum source will be created inside of the engine at the location of the pan gasket leakage. Engine combustion blow-by gases, oil vapor, and air from the crankcase filter/breather may be drawn past the leaking pan gasket and into the intake manifold. In most cases when this condition occurs, an engine at idle will create the highest vacuum and lowest amount of engine blow-by. 1. Allow the engine to reach normal operating temperature. 2. Stop the engine. 3. Disconnect the breather hose from the air cleaner. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1647 4. Attach a vacuum/pressure gauge to the end of the breather hose (Figure 1). 5. Disconnect the PCV valve hose from the intake manifold. 6. Seal off the intake manifold PCV valve hose port opening. 7. Seal off the open end of the PCV valve hose (Figure 2). NOTE: DURING THIS DIAGNOSIS, IT WOULD BE NORMAL FOR THE ENGINE TO DEVELOP PRESSURE WITHIN THE ENGINE CRANKCASE. THIS IS DUE TO THE NORMAL PROCESS OF EXHAUST BLOW-BY GASES LEAKING PAST THE ENGINE PISTON RINGS AND ACCUMULATING IN THE ENGINE CRANKCASE. DO NOT ALLOW MORE THAN 3 PSI (20.7 kpa) OF PRESSURE TO BUILD WITHIN THE ENGINE WHEN PERFORMING THE FOLLOWING DIAGNOSTIC PROCEDURE. 8. Start the warmed engine and observe the vacuum gauge. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1648 9. Allow the engine to idle for approximately 30 seconds. Do not allow more than 3 psi (20.7 kPa) of pressure to develop in the engine crankcase. 10. If the attached vacuum / pressure gauge does not indicate that a vacuum is present in the engine crankcase, then the intake manifold plenum pan gasket is good and no further internal engine vacuum leak diagnosis is required. 11. If an internal vacuum leak is present then perform the Repair Procedure. PARTS REQUIRED: For the 5.2L / 5.9L: 1 04897383AC Package, Intake Manifold Flange Gasket and Bolts 1 05017208AA Gasket, Intake Manifold Plenum Pan 15 06034583 Bolt, Intake Manifold Plenum Pan 1 53030541 Gasket, Throttle Body 2(AR) 04318001 Conditioner, Combustion Chamber For the 3.9L: 1 04897382AC Package, Intake Manifold Flange Gasket and Bolts 1 05017207AA Gasket, Intake Manifold Plenum Pan 14 06034583 Bolt, Intake Manifold Plenum Pan 1 53030541 Gasket, Throttle Body 2(AR)04318001 Conditioner, Combustion Chamber REPAIR PROCEDURE: 1. Refer to the appropriate year Service Manual, Section 9: ENGINE for removal and installation instructions. NOTE: CLEAN ALL OIL RESIDUE FROM THE INTERIOR SURFACES OF THE PLENUM PAN AND THE INTAKE MANIFOLD PLENUM CHAMBER. NOTE: THE PROPER BOLT TORQUE AND TIGHTENING SEQUENCE IS CRITICAL AND MUST BE FOLLOWED WHEN TIGHTENING BOTH THE PLENUM PAN BOLTS AND THE INTAKE MANIFOLD FLANGE BOLTS. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1649 3.9L Bolt Tightening Sequence and Torque Procedure: 3.9 Plenum Pan Bolt Torque Procedure 3.9 Intake Manifold Flange Bolt Torque Procedure Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1650 5.2L / 5.9L Plenum Bolt Tightening Sequence and Torque Procedure: 5.2L / 5.9L Plenum Pan Bolt Torque Procedure Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 09-05-00 > Feb > 00 > Engine - Spark Knock/Oil Consumption > Page 1651 5.2L / 5.9L Intake Manifold Flange Bolt Torque Procedure 2. With the engine reassembled, inspect the coil and spark plug wires for proper routing. Refer to TSB 09-48-98 for additional assistance. 3. Start the engine and allow it to warm to normal engine operating temperature. 4. Decarbon the combustion chamber using Mopar Combustion Chamber Conditioner (p/n 04318001) per the instructions. NOTE: ALLOW THE COMBUSTION CHAMBER CLEANER TO SOAK INSIDE OF THE ENGINE FOR 2 TO 2.5 HOURS. NOTE: A SECOND APPLICATION OF THE COMBUSTION CHAMBER CONDITIONER MAY BE REQUIRED IF THERE WAS A LARGE QUANTITY OF OIL LEAKAGE PAST THE INTAKE PLENUM PAN GASKET. 5. Verify proper engine oil level. POLICY: Reimbursable within the provisions of the warranty. Time Allowance FAILURE CODE: P8- New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Cover Gasket > Component Information > Description and Operation Valve Cover Gasket: Description and Operation A steel-backed silicone gasket is used with the cylinder head cover. This gasket is reuseable. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Cylinder Head Off Valve Guide Seal: Service and Repair Cylinder Head Off REMOVAL 1. Compress valve springs using Valve Spring Compressor Tool MD-998772-A, or equivalent. 2. Remove valve retaining locks, valve spring retainers, valve stem seals, and valve springs. 3. Before removing valves, remove any burrs from valve stem lock grooves to prevent damage to the valve guides. Identify valves to ensure installation in original locations. INSTALLATION 1. Coat valve stems with lubrication oil and insert them in cylinder head. 2. If valves or seats are reground, check valve stem height. If valve is too long, replace cylinder head. 3. Install new seals on all valve guides. Install valve springs and valve retainers. 4. Compress valve springs with Valve Spring Compressor Tool MD-998772A, or equivalent, install locks and release tool. If valves and/or seats are ground, measure the installed height of springs. Be sure the measurement is taken from bottom of spring seat in cylinder head to the bottom surface of spring retainer. If spacers are installed, measure from the top of spacer. If height is greater than 42.86 mm (1-11/16 inch), install a 1.587 mm (1/16 inch) spacer in head counterbore. This should bring spring height back to normal 41.27 42.86 mm (1-5/8 - 1-11/16 inch). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Cylinder Head Off > Page 1659 Valve Guide Seal: Service and Repair Cylinder Head On REMOVAL 1. Set engine basic timing to Top Dead Center (TDC). 2. Remove the air cleaner. 3. Remove cylinder head covers and spark plugs. 4. Remove coil wire from distributor and secure to good ground to prevent engine from starting. 5. Using suitable socket and flex handle at crankshaft retaining bolt, turn engine so the No.1 piston is at Top Dead Center on the compression stroke. 6. Remove rocker arms. 7. With air hose attached to an adapter installed in No.1 spark plug hole, apply 620 - 689 kPa (90 - 100 psi) air pressure. 8. Using Valve Spring Compressor Tool MD-998772A, or equivalent compress valve spring and remove retainer valve locks and valve string INSTALLATION 1. Install seals on the exhaust valve stem and position down against valve guides. 2. The intake valve stem seals should be pushed firmly and squarely over the valve guide using the valve stem as a guide. DO NOT force seal against top of guide. When installing the valve retainer locks, compress the spring only enough to install the locks. 3. Follow the same procedure on the remaining 5 cylinders using the firing sequence 1-6-5-4-3-2. Make sure piston in cylinder is at TDC on the valve spring that is being removed. 4. Remove adapter from the No.1 spark plug hole. 5. Install rocker arms. 6. Install covers and coil wire to distributor. 7. Install air cleaner. 8. Road test vehicle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Description and Operation Oil Pressure Sensor: Description and Operation Sends a signal from the oil pressure sending unit to the Powertrain Control Module (PCM) relating to engine oil pressure. CIRCUIT OPERATION The engine oil pressure sensor is a variable resistor. As engine oil pressure changes the resistance on circuit G60 changes. The G60 circuit connects to cavity B23 of the Powertrain Control Module (PCM) connector. Ground for the sensor is supplied on circuit K4. This circuit connects to cavity A4 of the PCM connector. This circuit is the ground circuit for many of the components in the fuel/ignition system. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Camshaft Sprocket Bolt ....................................................................................................................... .................................................... 68 Nm (50 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Measuring Timing Chain Stretch Timing Chain: Service and Repair Measuring Timing Chain Stretch 1. Place a scale next to the timing chain so that any movement of the chain can be measured. 2. Place a torque wrench and socket over camshaft sprocket attaching bolt. Apply torque in the direction of crankshaft rotation to take up slack; 41 Nm (30 ft. lbs.) torque with cylinder head installed or 20 Nm (15 ft. lbs.) torque with cylinder head removed. With torque applied to the camshaft sprocket bolt, crankshaft should not be permitted to move. It may be necessary to block the crankshaft to prevent rotation. 3. Hold a scale with dimensional reading even with the edge of a chain link. With cylinder heads installed, apply 14 Nm (30 ft. lbs.) torque in the reverse direction. With the cylinder heads removed, apply 20 Nm (15 ft. lbs.) torque in the reverse direction. Note the amount of chain movement. 4. Install a new timing chain, if its movement exceeds 3.175 mm (1/8 inch). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Measuring Timing Chain Stretch > Page 1672 Timing Chain: Service and Repair Timing Chain & Sprockets Replacement REMOVAL 1. Remove timing chain cover. 2. Remove camshaft sprocket attaching bolt and remove timing chain with crankshaft and camshaft sprockets. INSTALLATION 1. Place both camshaft sprocket and crankshaft sprocket on the bench with timing marks on an exact imaginary center line through both camshaft and crankshaft bores. 2. Place timing chain around both sprockets. 3. Turn crankshaft and camshaft to line up with keyway location in crankshaft sprocket and in camshaft sprocket. 4. Lift sprockets and chain (keep sprockets tight against the chain in position as described). 5. Slide both sprockets evenly over their respective shafts and use a straightedge to check alignment of timing marks. 6. Install the camshaft bolt. Tighten the bolt to 68 Nm (50 ft. lbs.) torque. 7. Check camshaft end play. The end play should be 0.051 - 0.152 mm (0.002 - 0.006 inch) with a new thrust plate and up to 0.254 mm (0.010 inch) with a used thrust plate. If not within these limits install a new thrust plate. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Mounting Bolts ..................................................................................................................................... .................................................... 41 Nm (30 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Removal Timing Cover: Service and Repair Removal 1. Disconnect the negative cable from the battery. 2. Drain cooling system. 3. Remove the serpentine belt. 4. Remove water pump. 5. Remove power steering pump. 6. Remove vibration damper. 7. Loosen oil pan bolts and remove the front bolt at each side. 8. Remove the cover bolts. 9. Remove chain case cover and gasket using extreme caution to avoid damaging oil pan gasket. 10. Place a suitable tool behind the lips of the oil seal to pry the oil seal outward. Be careful not to damage the crankshaft seal surface of cover. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Removal > Page 1678 Timing Cover: Service and Repair Installation 1. Be sure mating surfaces of chain case cover and cylinder block are clean and free from burrs. 2. Using a new cover gasket, carefully install chain case cover to avoid damaging oil pan gasket. Use a small amount of Mopar Silicone Rubber Adhesive Sealant, or equivalent, at the joint between timing chain cover gasket and the oil pan gasket. Finger tighten the timing chain cover bolts at this time. CAUTION: If chain cover is replaced for any reason, be sure the oil hole (passenger side of cover) is plugged. 3. Place the smaller diameter of the oil seal over Front Oil Seal Installation Tool 6635, or equivalent. Seat the oil seal in the groove of the tool. 4. Position the seal and tool onto the crankshaft. 5. Tighten the four lower chain case cover bolts to 13 Nm (10 ft. lbs.) to prevent the cover from tipping during seal installation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Removal > Page 1679 6. Using the vibration damper bolt, tighten the bolt to draw the seal into position on the crankshaft. 7. Loosen the four bolts tightened in Step 4 to allow realignment of front cover assembly. 8. Tighten chain case cover bolts to 41 Nm (30 ft. lbs.) torque. Tighten oil pan bolts to 24 Nm (215 inch lbs.) torque. 9. Remove the vibration damper bolt and seal installation tool. 10. Inspect the seal flange on the vibration damper. 11. Install vibration damper. 12. Install water pump and housing assembly using new gaskets. Tighten bolts to 41 Nm (30 ft. lbs.) torque. 13. Install power steering pump. 14. Install the serpentine belt. 15. Install the cooling system fan. Tighten the bolts to 23 Nm (17 ft. lbs.) torque. 16. Position the fan shroud and install the bolts. Tighten the bolts to 11 Nm (95 inch lbs.) torque. 17. Fill cooling system. 18. Connect the negative cable to the battery. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Fuel Pressure Gauge Adapter - Usage Fuel Pressure: Technical Service Bulletins Fuel Pressure Gauge Adapter - Usage NO: 14-03-98 GROUP: Fuel DATE: May 1, 1998 SUBJECT: Fuel Pressure Gauge Adapter Usage MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) DISCUSSION: Currently, four different fuel pressure adapters are required, depending on application, to attach a fuel gauge for pressure testing. The matrix lists the adapter part numbers and their application. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Pressure, Vacuum and Temperature Specifications Fuel Pressure: Pressure, Vacuum and Temperature Specifications Fuel Pressure Engine at curb idle ............................................................................................................................... ........................................ 339 ± 34 kPa (49.2 ± 5 psi) Pressure Leakdown (fuel pump not engaged) ................................................................................................................. Not fall below 30 psi for 5 minutes Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Pressure, Vacuum and Temperature Specifications > Page 1687 Fuel Pressure: Capacity Specifications NOTE: Before performing this test, vent fuel pump pressure by performing the Fuel Pump Pressure Test. Use this test in conjunction with the Fuel Pressure Leak Down Test. 1. Release fuel system pressure. Refer to the Fuel Pressure Release Procedure. 2. Disconnect fuel supply line at fuel rail. Some engines may require air cleaner housing removal before line disconnection. 3. Connect appropriate Fuel Line Pressure Test Adapter Tool Hose (number 6631, 6923, 6541 or 6539) into disconnected fuel supply line. Insert other end of Adaptor Tool hose into a graduated container. 4. Remove fuel fill cap. 5. To activate fuel pump and pressurize system, obtain DRB scan tool and actuate ASD Fuel System Test. 6. A good fuel pump will deliver at least 1/4 liter of fuel in 7 seconds. Do not operate fuel pump for longer than 7 seconds with fuel line disconnected as fuel pump module reservoir may run empty. a. If capacity is lower than specification, but fuel pump can be heard operating through fuel fill cap opening, check for a kinked/damaged fuel supply line somewhere between fuel rail and fuel pump module. b. If line is not kinked/damaged, and fuel pressure is OK, but capacity is low, replace fuel filter/ fuel pressure regulator. The filter/regulator may be serviced separately on certain applications. Refer to Fuel Filter/Fuel Pressure Regulator Removal/Installation for additional information. c. If both fuel pressure and capacity are low, replace fuel pump module assembly Refer to Fuel Pump Module Removal/Installation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test Fuel Pressure: Testing and Inspection Fuel Pressure Leak Down Test Fig 11 Connecting Adapter Tool - Typical Fig 12 Connecting Adapter Tool - Typical NOTE: Use this test in conjunction with the Fuel Pump Pressure Test and Fuel Pump Capacity Test. Check Valve Operation: The electric fuel pump outlet contains a one-way check valve to prevent fuel flow back into the tank and to maintain fuel supply line pressure (engine warm) when pump is not operational. It is also used to keep the fuel supply line full of gasoline when pump is not operational. After the vehicle has cooled down, fuel pressure may drop to 0 psi (cold fluid contracts), but liquid gasoline will remain in fuel supply line between the check valve and fuel injectors. Fuel pressure that has dropped to 0 psi on a cooled down vehicle (engine off) is a normal condition. when the electric fuel pump is activated, fuel pressure should immediately rise to specification. Abnormally long periods of cranking to restart a hot engine that has been shut down for a short period of time may be caused by: ^ Fuel pressure bleeding past a fuel injector(s). ^ Fuel pressure bleeding past the check valve in the fuel pump module. Procedure 1. Disconnect the fuel inlet line at fuel rail. - On some engines, air cleaner housing removal may be necessary before fuel line disconnection. 2. Connect the appropriate Fuel Line Pressure Test Adapter Tool (number 6539, 6631, 6541 or 6923) between the disconnected fuel line and fuel rail (Fig. 11) or (Fig. 12). 3. Connect the 0-414 kPa (0-60 psi) fuel pressure test gauge (from Gauge Set 5069) to the test port on the appropriate Adaptor Tool. - The fittings on both tools must be in good condition and free from any small leaks before performing the proceeding test. 4. Start engine and bring to normal operating temperature. 5. Observe test gauge. Normal operating pressure should be 339 kPa +/- 34 kPa (49.2 psi +/- 5 psi). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 1690 6. Shut engine off. 7. Pressure should not fall below 30 psi for five minutes. 8. If pressure falls below 30 psi, it must be determined if a fuel injector, the check valve within the fuel pump module, or a fuel tube/line is leaking. 9. Again, start engine and bring to normal operating temperature. 10. Shut engine off. 11. Testing for fuel injector or fuel rail leakage: - Clamp off the rubber hose portion of Adaptor Tool between the fuel rail and the test port "T" on Adapter Tool. - If pressure now holds at or above 30 psi, a fuel injector or the fuel rail is leaking. 12. Testing for fuel pump check valve, filter/ regulator check valve or fuel tube/line leakage: - Clamp off the rubber hose portion of Adaptor Tool between the vehicle fuel line and test port "T" on Adapter Tool. - If pressure now holds at or above 30 psi, a leak may be found at a fuel tube/line. - If no leaks are found at fuel tubes or lines, one of the check valves in either the electric fuel pump or filter/ regulator may be leaking. NOTE: A quick loss of pressure usually indicates a defective check valve in the filter/regulator. A slow loss of pressure usually indicates a defective check valve in the electric fuel pump. The electric fuel pump is not serviced separately. Replace the fuel pump module assembly. The filter/regulator may be replaced separately on certain applications. Refer to Fuel Filter/Fuel Pressure Regulator Removal/Installation for additional information. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 1691 Fuel Pressure: Testing and Inspection Fuel Pressure Test - With Test Port Fig 8 Fuel Pressure Test Port - Typical WARNING: THE FUEL SYSTEM IS UNDER CONSTANT FUEL PRESSURE EVEN WITH THE ENGINE OFF. BEFORE DISCONNECTING FUEL LINE AT FUEL RAIL, THIS PRESSURE MUST BE RELEASED. REFER TO THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE. NOTE: Use this test in conjunction with the Fuel Pump Capacity Test and Fuel Pressure Leak Down Test found elsewhere. Check Valve Operation: The electric fuel pump outlet contains a one-way check valve to prevent fuel flow back into the tank and to maintain fuel supply line pressure (engine warm) when pump is not operational. - It is also used to keep the fuel supply line full of gasoline when pump is not operational. After the vehicle has cooled down, fuel pressure may drop to 0 psi (cold fluid contracts), but liquid gasoline will remain in fuel supply line between the check valve and fuel injectors. Fuel pressure that has dropped to 0 psi on a cooled down vehicle (engine off) is a normal condition. When the electric fuel pump is activated, fuel pressure should immediately rise to specification. NOTE: The fuel pressure test port is used on certain engines only. The test port is located on the fuel rail near the throttle position sensor (Fig. 8). A sealing cap is screwed onto the test port. All fuel systems are equipped with a fuel tank module mounted, combination fuel filter/fuel pressure regulator. The fuel pressure regulator is not controlled by engine vacuum. Procedure 1. Remove protective cap at fuel rail test port. Connect the 0-414 kPa (0-60 psi) fuel pressure gauge (from gauge set 5069) to test port pressure fitting on fuel rail. 2. Start and warm engine and note pressure gauge reading. Fuel pressure should be 339 kPa +/34 kPa (49.2 psi +/- 5 psi) at idle. 3. If engine runs but pressure is below 44.2 psi, check for a kinked fuel supply line somewhere between fuel rail and fuel pump module. If line is not kinked, replace fuel pump module assembly. Refer to Fuel Pump Module Removal/Installation. 4. If operating pressure is above 54.2 psi, electric fuel pump is OK, but fuel pressure regulator is defective. - Replace fuel filter/fuel pressure regulator. - Certain filter/regulators may be serviced separately and some require the replacement of the fuel pump module assembly Refer to Fuel Filter /Fuel Pressure Regulator Removal/Installation for more information. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 1692 Fuel Pressure: Testing and Inspection Fuel Pressure Test - Without Test Port Fig 10 Installing Adapter Tool And Pressure Gauge WARNING: THE FUEL SYSTEM IS UNDER CONSTANT FUEL PRESSURE EVEN WITH THE ENGINE OFF. BEFORE DISCONNECTING FUEL LINE AT FUEL RAIL, THIS PRESSURE MUST BE RELEASED. REFER TO THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE. NOTE: Use this test in conjunction with the Fuel Pump Capacity Test and Fuel Pressure Leak Down Test. Check Valve Operation: The electric fuel pump outlet contains a one-way check valve to prevent fuel flow back into the tank and to maintain fuel supply line pressure (engine warm) when pump is not operational. It is also used to keep the fuel supply line full of gasoline when pump is not operational. After the vehicle has cooled down, fuel pressure may drop to 0 psi (cold fluid contracts), but liquid gasoline will remain in fuel supply line between the check valve and fuel injectors. Fuel pressure that has dropped to 0 psi on a cooled down vehicle (engine off) is a normal condition. When the electric fuel pump is activated, fuel pressure should immediately rise to specification. All fuel systems are equipped with a fuel tank module mounted, combination fuel filter/fuel pressure regulator. The fuel pressure regulator is not controlled by engine vacuum. Procedure 1. Release fuel pressure. Refer to the Fuel System Pressure Release Procedure-Without Pressure Test Port. 2. Disconnect latch clip and fuel line at fuel rail. Refer to Quick-Connect Fittings for procedures. 3. Connect adapter tool number 6923 into the fuel rail (Fig. 10). Be sure adapter tool is fully seated into fuel rail. 4. Install latch clip to fuel rail. If latch clip can not be fully seated into fuel rail, check for adapter tool not fully seated to fuel rail. 5. Connect vehicle fuel line into adapter tool 6923 (Fig. 10). Be sure fuel line is fully seated into adapter tool 6923. 6. Remove protective cap at test port "T" on adapter tool number 6923. 7. Connect the 0-414 kPa (0-60 psi) fuel pressure gauge (from gauge set 5069) to the test port "T" (Fig. 10). 8. Start engine and note pressure gauge reading. Fuel pressure should be 339 kPa +/- 34 kPa (49.2 psi +/5 psi) at idle. 9. If engine runs but pressure is below 44.2 psi, check for a kinked fuel supply line somewhere between fuel rail and fuel pump module. If line is not kinked, replace fuel pump module assembly. Refer to Fuel Pump Module Removal/Installation. 10. If operating pressure is above 54.2 psi, electric fuel pump is OK, but fuel pressure regulator is defective. Replace fuel filter/fuel pressure regulator. Certain filter/regulators may be serviced separately and some require the replacement of the fuel pump module assembly. Refer to Fuel Filter/Fuel Pressure Regulator Removal/Installation for more information. 11. After performing pressure test, install fuel line into fuel rail. Install latch clip into fuel rail. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 1693 Fuel Pressure: Testing and Inspection Fuel Pump Capacity Test NOTE: Before performing this test, vent fuel pump pressure by performing the Fuel Pump Pressure Test. Use this test in conjunction with the Fuel Pressure Leak Down Test. 1. Release fuel system pressure. Refer to the Fuel Pressure Release Procedure. 2. Disconnect fuel supply line at fuel rail. Some engines may require air cleaner housing removal before line disconnection. 3. Connect appropriate Fuel Line Pressure Test Adapter Tool Hose (number 6631, 6923, 6541 or 6539) into disconnected fuel supply line. Insert other end of Adaptor Tool hose into a graduated container. 4. Remove fuel fill cap. 5. To activate fuel pump and pressurize system, obtain DRB scan tool and actuate ASD Fuel System Test. 6. A good fuel pump will deliver at least 1/4 liter of fuel in 7 seconds. Do not operate fuel pump for longer than 7 seconds with fuel line disconnected as fuel pump module reservoir may run empty. a. If capacity is lower than specification, but fuel pump can be heard operating through fuel fill cap opening, check for a kinked/damaged fuel supply line somewhere between fuel rail and fuel pump module. b. If line is not kinked/damaged, and fuel pressure is OK, but capacity is low, replace fuel filter/ fuel pressure regulator. The filter/regulator may be serviced separately on certain applications. Refer to Fuel Filter/Fuel Pressure Regulator Removal/Installation for additional information. c. If both fuel pressure and capacity are low, replace fuel pump module assembly Refer to Fuel Pump Module Removal/Installation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Minimum Air Flow Idle ......................................................................................................................... ......................................................... 500 to 900 rpm Note: Idle speed range achieved through Minimum Air Flow Idle Test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 1697 Idle Speed: Testing and Inspection The following test procedure has been developed to check throttle body calibrations for correct idle conditions. The procedure should be used to diagnose the throttle body for conditions that may cause idle problems. This procedure should be used only after normal diagnostic procedures have failed to produce results that indicate a throttle body related problem. Be sure to check for proper operation of the idle air control motor before performing this test. Fig. 73 Fixed Orifice Tool A special fixed orifice tool (number 6714) must be used for the following test. 1. Start the engine and bring to operating temperature. Be sure all accessories are off before performing this test. 2. Shut off the engine and remove the air cleaner element housing. Fig. 74 Install Orifice Tool 3. Disconnect the vacuum line at the PCV valve. 4. Install the 0.185 inch orifice tool (number 6714) into the disconnected vacuum line in place of the PCV valve. Fig. 75 Idle Purge Line Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 1698 5. Disconnect the idle purge vacuum line from fitting at throttle body This vacuum line is located on the front of throttle body next to the MAP sensor. Cap the fitting at throttle body after vacuum line has been removed. 6. Connect the DRB scan tool to the 16-way data link connector. This connector is located under the instrument panel to the left of the steering column. 7. Start the engine. 8. Using the DRB scan tool, scroll through the menus as follows: select-System, select-Engine, select-Fuel and Ignition, select-Actuator Tests, select Engine rpm and select-Minimum Air Flow. 9. The DRB scan tool will count down to stabilize the idle rpm and display the minimum air flow idle rpm. The idle rpm should be between 500 and 900 rpm. If the idle speed is outside of these specifications, replace the throttle body. 10. Disconnect the DRB scan tool from the vehicle. 11. Remove cap from idle purge fitting at throttle body and install vacuum line. 12. Remove orifice tool and connect vacuum line to PCV valve. 13. Install air cleaner element housing. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 1699 Idle Speed: Adjustments Idle speed is electronically controlled by the Powertrain Control Module (PCM) through the Idle Air Control (IAC) motor, and is not adjustable. CAUTION: This vehicle is equipped with a factory adjusted throttle plate position set screw. Never attempt to adjust idle speed using this screw, unless directed to do so in a service procedure. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > With Pressure Test Port Fuel Pressure Release: Service and Repair With Pressure Test Port WARNING: BECAUSE THE FUEL SYSTEM IS UNDER CONSTANT FUEL PRESSURE, IT MUST BE RELEASED BEFORE SERVICING ANY FUEL SYSTEM COMPONENT THIS DOES NOT APPLY TO THROTTLE BODY REMOVAL. NOTE: The fuel pressure test port is used on certain engines only. If equipped, the test port will be located on fuel rail. A sealing cap is screwed onto test port. - The fuel system is under constant fuel pressure (even with engine off). 1. Disconnect negative battery cable. 2. Remove fuel tank filler tube cap to release fuel tank pressure. 3. Remove protective cap from pressure test port on fuel rail. This is located on top of fuel rail. WARNING: DO NOT ALLOW FUEL TO SPILL ONTO ENGINE INTAKE OR EXHAUST MANIFOLDS. PLACE SHOP TOWELS UNDER AND AROUND PRESSURE PORT TO ABSORB FUEL WHEN PRESSURE IS RELEASED FROM FUEL RAIL. WARNING: WEAR PROPER EYE PROTECTION WHEN RELEASING FUEL SYSTEM PRESSURE. 4. Obtain fuel pressure gauge/hose assembly from fuel pressure gauge tool set 5069. Remove gauge from hose. 5. Place one end of hose (gauge end) into an approved gasoline container. 6. Place a shop towel under test port. 7. To release fuel pressure, screw other end of hose onto fuel pressure test port. 8. After fuel pressure has been released, remove hose from test port. 9. Install protective cap to fuel test port. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > With Pressure Test Port > Page 1705 Fuel Pressure Release: Service and Repair Without Pressure Test Port NOTE: Use the following procedure if the fuel rail is not equipped with a fuel pressure test port. 1. Remove the Fuel Pump relay from the Power Distribution Center (PDC). For location of the relay, refer to the label on the underside of the PDC cover. 2. Start and run engine until it stalls. 3. Attempt restarting engine until it will no longer run. 4. Turn ignition key to OFF position. CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within the fuel rail. Do not attempt to use the following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber. 5. Unplug connector from any injector. 6. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 7. Connect the other end of the jumper wire to the positive side of the battery 8. Connect one end of a second jumper wire to the remaining injector terminal. CAUTION: Supplying power to an injector for more than 4 seconds will permanently damage the injector. Do not leave the injector connected to power for more than 4 seconds. 9. Momentarily touch the other end of this jumper wire to the negative terminal of the battery for no more than 4 seconds. 10. Place a rag or towel below the fuel line at the quick connect to the rail. 11. Disconnect the quick connect fitting to the rail. Refer to Quick-Connect Fittings. 12. Return the fuel pump relay to the PDC. 13. One or more Diagnostic Trouble Codes (DTC's) may have been stored in the PCM memory due to fuel pump relay removal. The DRB scan tool must be used to erase a DTC. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Engine Firing Order - 3.9L Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks and Indicators > System Information > Locations Timing Marks and Indicators: Locations Align Timing Marks The timing marks are located on the timing cover, next to the vibration damper. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction Technical Service Bulletin # 18-48-98 Date: 981230 Ignition System - Cross Fire/Ignition Wire Induction NO: 18-48-98 GROUP: Vehicle Performance DATE: Dec. 30, 1998 SUBJECT: Ignition System Cross Fire/Secondary Ignition Wire Induction MODELS: 1994 - 1999 (AN) Dakota 1994 - 1999 (BR/BE)Ram Truck 1998 - 1999 (DN) Durango 1995 - 1998 (ZG) Grand Cherokee (International Market) 1994 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 3.9L, 5.2L, OR 5.9L ENGINE. AB MODELS WILL BE ADDED LATER (NEW PARTS REQUIRED). SYMPTOM/CONDITION: Some vehicles may exhibit one or more of the following: Spark knock complaints when the vehicle is under load. Various single cylinder misfire (1, 3, 7), especially 5 and/or 8. Surge in 4th gear with the Electronically Modulated Converter Clutch (EMCC) engaged (around 45 mph). Perceived torque converter EMCC engagement/disengagement around 45 mph. DIAGNOSIS: Using the Mopar Diagnostic System (MDS/MDS 2) or the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If other than mentioned Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present or if the above symptoms/conditions have been described by the customer, perform the Repair Procedure. NOTE: THIS REROUTING PROCEDURE SHOULD BE PERFORMED BEFORE ANY OTHER MISFIRE, SURGE, OR SPARK KNOCK REPAIRS ARE ATTEMPTED. PARTS REQUIRED: 3 56028186 Clip, Single Wire 2 06503441 Clip, Wire To Hose (5.2L & 5.9L) 1 04364375 Convolute, 10 ft Roll POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-12-15-92 - 3.9L (All) 0.2 Hrs. 08-12-15-93 (ZJ) 5.2/5.9L 0.2 Hrs. (AN/DN) 5.2/5.9L 0.3 Hrs. (BR/BE) 5.2/5.9L 0.4 Hrs. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1721 FAILURE CODE: 9X - Routed Improperly Repair Procedure This bulletin involves rerouting the coil wire for all engines listed and rerouting the 4, 5, 7, and 8 plug wires for the 5.2/5.9L applications to minimize induction effects. NOTE: IF WIRES MUST CROSS DURING THE REROUTE PROCEDURE, THEY MUST CROSS AT A 90° ANGLE. 5.2L and 5.9L Engine Procedures 1. Coil Wire Routing (Figure 1 and 2) A. Remove the coil wire from the distributor cap coil wire tower terminal. B. Remove the coil wire from the rear five-wire clip, the center three-wire clip, and the front one-wire clip located along the lower side of the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover. Use the studs of the valve cover retaining bolts (Figure 1). NOTE: SOME APPLICATIONS MAY ONLY HAVE STUD LOCATIONS FOR 3 OF THE ONE-WIRE CLIPS. D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths 203 mm (8 in.), 101.5 mm (4 in.), and 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the 203 mm (8 in.) and the 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1722 H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 2). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM AND/OR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. I. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. 2. No.8 Cylinder Plug Wire Routing (Figure 3) A. Remove the No.8 cylinder plug wire from the distributor cap tower terminal. B. Remove the No.8 cylinder plug wire from the five-wire clip located at the lower rear of the valve cover. C. Route the No.8 cylinder plug wire over the rear quarter of the right valve cover (Figure 3). D. Position the original piece convolute from the No.8 cylinder plug wire to prevent chafing at the right valve cover and with other engine components. E. Secure the No.8 cylinder plug wire and its convolute in place with the hose to wire clip p/n 06503441. The small end of the clip is positioned over the convolute. The large end of the clip is fastened to a heater hose (A/C line on ZJ models). NOTE: MAKE SURE THE NO.8 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE COIL WIRE AND THE NO.4 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. F. Install the No.8 cylinder plug wire to its distributor cap terminal. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1723 3. No.4 Cylinder Plug Wire Routing (Figure 4 and 5) A. Remove the No.4 cylinder plug wire from the distributor cap terminal. B. At the three-wire clip (located at the center of the lower side of the right valve cover), keep the two wires from crossing and chafing each other. Position the No.2 cylinder plug wire in the top wire slot and the No.4 cylinder plug wire in the bottom wire slot. Leave the middle wire slot empty (Figure 5). C. At the five-wire clip (located at the right rear lower side of the valve cover), keep the plug wires from crossing and chafing each other. Position the No.4 cylinder plug wire in a slot that will obtain the maximum amount of distance allowable from the No.8 cylinder plug wire (Figure 6). Remove any slack in the No.4 cylinder plug wire between the three-wire and the five-wire clips. NOTE: EARLIER MODEL FIVE-WIRE CLIPS LOOK SLIGHTLY DIFFERENT BUT THE SAME WIRING LAYOUT APPLIES. D. Route the No.4 cylinder plug wire behind the transmission dipstick tube and heater hoses. On ZJ models this may not be possible due to the location of the bulkhead. NOTE: MAKE SURE THAT THE NO.4 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH AWAY FROM THE NO.8 CYLINDER PLUG WIRE. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1724 E. Install the No.4 cylinder plug wire to its distributor cap terminal (Figure 7). 4. No.7 Cylinder Plug Wire Routing (Figure 8 and 9) A. Verify that the No.7 cylinder plug wire crosses over the distributor cap and leaves the distributor cap between the No.3 and the No.6 tower terminals (Figure 8). This is the original wire routing for 1998 and prior model years. B. For 1999 M.Y. vehicles the No.7 cylinder plug wire was shortened. Reroute the No.7 cylinder plug wire so that it crosses the distributor cap and leaves the distributor cap between the No.6 and the No.5 tower terminals (Figure 9). NOTE: MAKE SURE THE NO.7 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH, AWAY FROM THE NO.5 CYLINDER PLUG WIRE. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1725 5. No. 5 Cylinder Plug Wire Routing (Figure 10) A. Remove the No.5 cylinder plug wire from its distributor cap terminal. B. Remove the No.5 cylinder plug wire from the five-wire clip located at the lower rear of the left valve cover. C. Route the No.5 cylinder plug wire over the left valve cover and in front of the breather tube elbow. D. Position the original convolute from the No.5 cylinder plug wire to prevent chafing against the valve cover and any engine components. Secure the small end of the hose to wire clip p/n 06503441 over the convolute. Secure the large end of the hose to wire clip to the breather hose. NOTE: MAKE SURE THE NO.5 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE NO.7 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. 3.9L Engine Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1726 1. Coil Wire Routing (Figure 11 and 12) A. Remove the coil wire from the distributor cap tower terminal. B. Remove the coil wire from the right rear five-wire clip, the center three wire clip and the front one-wire clip on the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover studs (Figure 11). D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths. Two (2) at 101.5 mm (4 in.), and one (1) at 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the two 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 12). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM ANDIOR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction Technical Service Bulletin # 18-48-98 Date: 981230 Ignition System - Cross Fire/Ignition Wire Induction NO: 18-48-98 GROUP: Vehicle Performance DATE: Dec. 30, 1998 SUBJECT: Ignition System Cross Fire/Secondary Ignition Wire Induction MODELS: 1994 - 1999 (AN) Dakota 1994 - 1999 (BR/BE)Ram Truck 1998 - 1999 (DN) Durango 1995 - 1998 (ZG) Grand Cherokee (International Market) 1994 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 3.9L, 5.2L, OR 5.9L ENGINE. AB MODELS WILL BE ADDED LATER (NEW PARTS REQUIRED). SYMPTOM/CONDITION: Some vehicles may exhibit one or more of the following: Spark knock complaints when the vehicle is under load. Various single cylinder misfire (1, 3, 7), especially 5 and/or 8. Surge in 4th gear with the Electronically Modulated Converter Clutch (EMCC) engaged (around 45 mph). Perceived torque converter EMCC engagement/disengagement around 45 mph. DIAGNOSIS: Using the Mopar Diagnostic System (MDS/MDS 2) or the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If other than mentioned Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present or if the above symptoms/conditions have been described by the customer, perform the Repair Procedure. NOTE: THIS REROUTING PROCEDURE SHOULD BE PERFORMED BEFORE ANY OTHER MISFIRE, SURGE, OR SPARK KNOCK REPAIRS ARE ATTEMPTED. PARTS REQUIRED: 3 56028186 Clip, Single Wire 2 06503441 Clip, Wire To Hose (5.2L & 5.9L) 1 04364375 Convolute, 10 ft Roll POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-12-15-92 - 3.9L (All) 0.2 Hrs. 08-12-15-93 (ZJ) 5.2/5.9L 0.2 Hrs. (AN/DN) 5.2/5.9L 0.3 Hrs. (BR/BE) 5.2/5.9L 0.4 Hrs. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1732 FAILURE CODE: 9X - Routed Improperly Repair Procedure This bulletin involves rerouting the coil wire for all engines listed and rerouting the 4, 5, 7, and 8 plug wires for the 5.2/5.9L applications to minimize induction effects. NOTE: IF WIRES MUST CROSS DURING THE REROUTE PROCEDURE, THEY MUST CROSS AT A 90° ANGLE. 5.2L and 5.9L Engine Procedures 1. Coil Wire Routing (Figure 1 and 2) A. Remove the coil wire from the distributor cap coil wire tower terminal. B. Remove the coil wire from the rear five-wire clip, the center three-wire clip, and the front one-wire clip located along the lower side of the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover. Use the studs of the valve cover retaining bolts (Figure 1). NOTE: SOME APPLICATIONS MAY ONLY HAVE STUD LOCATIONS FOR 3 OF THE ONE-WIRE CLIPS. D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths 203 mm (8 in.), 101.5 mm (4 in.), and 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the 203 mm (8 in.) and the 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1733 H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 2). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM AND/OR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. I. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. 2. No.8 Cylinder Plug Wire Routing (Figure 3) A. Remove the No.8 cylinder plug wire from the distributor cap tower terminal. B. Remove the No.8 cylinder plug wire from the five-wire clip located at the lower rear of the valve cover. C. Route the No.8 cylinder plug wire over the rear quarter of the right valve cover (Figure 3). D. Position the original piece convolute from the No.8 cylinder plug wire to prevent chafing at the right valve cover and with other engine components. E. Secure the No.8 cylinder plug wire and its convolute in place with the hose to wire clip p/n 06503441. The small end of the clip is positioned over the convolute. The large end of the clip is fastened to a heater hose (A/C line on ZJ models). NOTE: MAKE SURE THE NO.8 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE COIL WIRE AND THE NO.4 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. F. Install the No.8 cylinder plug wire to its distributor cap terminal. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1734 3. No.4 Cylinder Plug Wire Routing (Figure 4 and 5) A. Remove the No.4 cylinder plug wire from the distributor cap terminal. B. At the three-wire clip (located at the center of the lower side of the right valve cover), keep the two wires from crossing and chafing each other. Position the No.2 cylinder plug wire in the top wire slot and the No.4 cylinder plug wire in the bottom wire slot. Leave the middle wire slot empty (Figure 5). C. At the five-wire clip (located at the right rear lower side of the valve cover), keep the plug wires from crossing and chafing each other. Position the No.4 cylinder plug wire in a slot that will obtain the maximum amount of distance allowable from the No.8 cylinder plug wire (Figure 6). Remove any slack in the No.4 cylinder plug wire between the three-wire and the five-wire clips. NOTE: EARLIER MODEL FIVE-WIRE CLIPS LOOK SLIGHTLY DIFFERENT BUT THE SAME WIRING LAYOUT APPLIES. D. Route the No.4 cylinder plug wire behind the transmission dipstick tube and heater hoses. On ZJ models this may not be possible due to the location of the bulkhead. NOTE: MAKE SURE THAT THE NO.4 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH AWAY FROM THE NO.8 CYLINDER PLUG WIRE. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1735 E. Install the No.4 cylinder plug wire to its distributor cap terminal (Figure 7). 4. No.7 Cylinder Plug Wire Routing (Figure 8 and 9) A. Verify that the No.7 cylinder plug wire crosses over the distributor cap and leaves the distributor cap between the No.3 and the No.6 tower terminals (Figure 8). This is the original wire routing for 1998 and prior model years. B. For 1999 M.Y. vehicles the No.7 cylinder plug wire was shortened. Reroute the No.7 cylinder plug wire so that it crosses the distributor cap and leaves the distributor cap between the No.6 and the No.5 tower terminals (Figure 9). NOTE: MAKE SURE THE NO.7 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH, AWAY FROM THE NO.5 CYLINDER PLUG WIRE. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1736 5. No. 5 Cylinder Plug Wire Routing (Figure 10) A. Remove the No.5 cylinder plug wire from its distributor cap terminal. B. Remove the No.5 cylinder plug wire from the five-wire clip located at the lower rear of the left valve cover. C. Route the No.5 cylinder plug wire over the left valve cover and in front of the breather tube elbow. D. Position the original convolute from the No.5 cylinder plug wire to prevent chafing against the valve cover and any engine components. Secure the small end of the hose to wire clip p/n 06503441 over the convolute. Secure the large end of the hose to wire clip to the breather hose. NOTE: MAKE SURE THE NO.5 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE NO.7 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. 3.9L Engine Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 1737 1. Coil Wire Routing (Figure 11 and 12) A. Remove the coil wire from the distributor cap tower terminal. B. Remove the coil wire from the right rear five-wire clip, the center three wire clip and the front one-wire clip on the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover studs (Figure 11). D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths. Two (2) at 101.5 mm (4 in.), and one (1) at 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the two 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 12). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM ANDIOR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 1738 Ignition Cable: Specifications Minimum ..................................................................................................................................................... 250 ohms per inch (3,000 ohms per foot) Maximum ............................................................................................................................................... 1,000 ohms per inch (12,000 ohms per foot) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 1739 Ignition Cable: Description and Operation DESCRIPTION Spark plug cables are sometimes referred to as secondary ignition wires. The resistive spark plug cables are of nonmetallic construction. OPERATION These cables transfer electrical current from the ignition coil(s) and/or distributor, to individual spark plugs at each cylinder. The cables provide suppression of radio frequency emissions from the ignition system. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 1740 Ignition Cable: Service and Repair Fig. 11 Cable Removal CAUTION: When disconnecting a high voltage cable from a spark plug or from the distributor cap, twist the rubber boot slightly (1/2 turn) to break it loose. Grasp the boot (not the cable) and pull it off with a steady, even force. When replacing the spark plug and coil cables, route the cables correctly and secure in the proper retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise. It could also cause cross ignition of the plugs or short circuit the cables to ground. When installing new cables, make sure a positive connection is made. A snap should be felt when a good connection is made between the plug cable and the distributor cap tower. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Cap > Component Information > Testing and Inspection Distributor Cap: Testing and Inspection Fig. 22 Cap Inspection - External - Typical (V6 Shown) Fig. 23 Cap Inspection - Internal - Typical (V6 Shown) Remove the distributor cap and wipe it clean with a dry lint free cloth. Visually inspect the cap for cracks, carbon paths, broken towers or damaged rotor button. Also check for white deposits on the inside (caused by condensation entering the cap through cracks). Replace any cap that displays charred or eroded terminals. NOTE: A small amount of erosion is expected from normal operation. Examine the terminal ends for evidence of mechanical interference with the rotor tip. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Testing and Inspection Ignition Rotor: Testing and Inspection Fig. 24 Rotor Inspection - Typical Visually inspect the rotor for cracks, evidence of corrosion, or the effects of arcing on the metal tip. Also check for evidence of mechanical interference with the cap. Some charring is normal on the end of the metal tip. The silicone-dielectric-varnish-compound applied to the rotor tip for radio interference noise suppression, will appear charred. This is normal. Do not remove the charred compound. Test the spring for insufficient tension. Replace a rotor that displays any of these adverse conditions. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Electrode Gap ...................................................................................................................................... ..................................................... 1.01 mm (0.040 in) Torque ............................................................ ............................................................................................................................................. 41 Nm (30 ft. lb.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1751 Spark Plug: Application and ID Plug Type ............................................................................................................................................ .................................................................... RC12LC4 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1752 Spark Plug: Description and Operation DESCRIPTION All engines use resistor type spark plugs. 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 recommended intervals. Spark plugs that have low milage may be cleaned and reused if not otherwise defective, carbon or oil fouled. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator Spark Plug: Testing and Inspection Broken, Cracked or Chipped 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 Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1755 Spark Plug: Testing and Inspection Brown to Gray/Tan Color - Normal Operating Condition Normal Operation And Carbon Fouling The few deposits present on the spark plug will probably be light tan or slightly gray in color. This is evident with most grades of commercial gasoline. There will not be evidence of electrode burning. Gap growth will not average more than approximately 0.025 mm (.001 in) per 1600 km (1000 miles) of operation. Spark plugs that have normal wear can usually be cleaned, have the electrodes filed, have the gap set and then be installed. Some fuel refiners in several areas of the United States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT causes the entire tip of the spark plug to be coated with a rust colored deposit. This rust color can be misdiagnosed as being caused by coolant in the combustion chamber. Spark plug performance is not affected by MMT deposits. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1756 Spark Plug: Testing and Inspection Dry, Fluffy Black Deposits - Cold or Carbon Fouling Normal Operation And Carbon Fouling Cold fouling is sometimes referred to as carbon fouling. The deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or defective spark plug cables. Cold (carbon) fouling of the entire set of spark plugs may be caused by a clogged air filter or repeated short operating times (short trips). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1757 Spark Plug: Testing and Inspection 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 Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1758 Spark Plug: Testing and Inspection Broken, Cracked or Chipped 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. Brown to Gray/Tan Color - Normal Operating Condition Normal Operation And Carbon Fouling The few deposits present on the spark plug will probably be light tan or slightly gray in color. This is evident with most grades of commercial gasoline. There will not be evidence of electrode burning. Gap growth will not average more than approximately 0.025 mm (.001 in) per 1600 km (1000 miles) of operation. Spark plugs that have normal wear can usually be cleaned, have the electrodes filed, have the gap set and then be installed. Some fuel refiners in several areas of the United States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT causes the entire tip of the spark plug to be coated with a rust colored deposit. This rust color can be misdiagnosed as being caused by coolant in the combustion chamber. Spark plug performance is not affected by MMT deposits. Dry, Fluffy Black Deposits - Cold or Carbon Fouling Normal Operation And Carbon Fouling Cold fouling is sometimes referred to as carbon fouling. The deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or defective spark plug cables. Cold (carbon) fouling of the entire set of spark plugs may be caused by a clogged air filter or repeated short operating times (short trips). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1759 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. 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. Overheating Spark Plug Overheating Overheating is indicated by a white or gray center electrode insulator that also appears blistered. The increase in electrode gap will be considerably in excess of 0.001 inch per 1000 miles of operation. This suggests that a plug with a cooler heat range rating should be used. Over advanced ignition Premature Electrode Wear - Preignition Damage Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1760 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.) 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. 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 Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 1761 Spark Plug: Service and Repair Fig. 31 Heat Shields Spark plug cable heat shields are pressed into the cylinder head to surround each cable boot and spark plug. If removal of the heat shield(s) is necessary, remove the spark plug cable and compress the sides of shield for removal. Each shield is slotted to allow for compression and removal. To install the shields, align shield to machined opening in cylinder head and tap into place with a block of wood. Fig. 11 Cable Removal PLUG REMOVAL 1. Always remove spark plug or ignition coil cables by grasping at the cable boot. Turn the cable boot 1/2 turn and pull straight back in a steady motion. Never pull directly on the cable. Internal damage to cable will result. 2. Prior to removing the spark plug, spray compressed air around the spark plug hole and the area around the spark plug. This will help prevent foreign material from entering the combustion chamber. 3. Remove the spark plug using a quality socket with a rubber or foam insert. 4. Inspect the spark plug condition. PLUG CLEANING The plugs may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file the center electrode flat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator and will cause plug misfire. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 1762 Fig. 44 Setting Spark Plug Gap - Typical PLUG GAP ADJUSTMENT Check the spark plug gap with a gap gauge tool. If the gap is not correct, adjust it by bending the ground electrode. Never attempt to adjust the gap by bending the center electrode. SPARK PLUG GAP 1.01 mm (0.040 in). PLUG INSTALLATION Special care should be taken when installing spark plugs into the cylinder head spark plug wells. Be sure the plugs do not drop into the plug wells as electrodes can be damaged. Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap or a cracked porcelain insulator. When replacing the spark plug and ignition coil cables, route the cables correctly and secure them in the appropriate retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise. It could cause cross ignition of the spark plugs or short circuit the cables to ground. 1. Start the spark plug into the cylinder head by hand to avoid cross threading. 2. Tighten spark plugs to 35-41 Nm (26-30 ft lb) torque. 3. Install spark plug cables over spark plugs. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression should not be less than 689 kPa (100 psi) and not vary more than 172 kPa (25 psi) from cylinder to cylinder. If cylinder(s) have abnormally low compression pressures, repeat procedure. - If the same cylinder(s) repeat an abnormally low reading, it could indicate the existence of a problem in the cylinder. NOTE: The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should NOT be disassembled to determine the cause of low compression unless some malfunction is present. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1766 Compression Check: Testing and Inspection NOTE: - 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. CAUTION: DO NOT overspeed the engine. a. Check engine oil level and add oil, if necessary. b. Drive the vehicle until engine reaches normal operating temperature. c. Select a route free from traffic and other forms of congestion, observe all traffic laws and briskly accelerate through the gears several times. The higher engine speed may help clean out valve seat deposits which can prevent accurate compression readings. d. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for abnormal firing indicators-fouled, hot, oily, etc. Record cylinder number of spark plug for future reference. e. Disconnect coil wire from distributor and secure to good ground to prevent a spark from starting a fire. f. Be sure throttle blades are fully open during the compression check. g. Insert compression gauge adapter into the No. 1 spark plug hole. Crank engine until maximum pressure is reached on gauge. Record this pressure as No.1 cylinder pressure. h. Repeat above step for all remaining cylinders. i. Compression should not be less than 689 kPa (100 psi) and not vary more than 172 kPa (25 psi) from cylinder to cylinder. j. If cylinder(s) have abnormally low compression pressures, repeat procedure. k. If the same cylinder(s) repeat an abnormally low reading, it could indicate the existence of a problem in the cylinder. NOTE: The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should NOT be disassembled to determine the cause of low compression unless some malfunction is present. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates this engine is equipped with hydraulic lifters or lash adjusters and therefore does not require adjustment. See "Rocker Arm: Service and Repair" for further information. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Water Pump Bolts Water Pump: Specifications Water Pump Mounting Bolts 30 ft.lb Water Pump Pulley 16 ft.lb Water Pump-to-Chain Case Cover Bolt 31 ft.lb Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Water Pump Bolts > Page 1774 Water Pump: Specifications Water Pump Pulley Bolts Mounting Bolts ..................................................................................................................................... .................................................... 27 Nm (20 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 1775 Water Pump: Locations The water pump is bolted directly to the engine timing chain case/cover. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 1776 Water Pump: Description and Operation GENERAL INFORMATION A centrifugal water pump circulates coolant through the water jackets, passages, intake manifold, radiator core, cooling system hoses and heater core. The pump is driven from the engine crankshaft by a drive belt. A gasket is used as a seal between the water pump and timing chain case/cover. IMPELLER The water pump impeller is pressed onto the rear of a shaft that rotates in a bearing pressed into the water pump body. The body has a small hole for ventilation. SEALS The water pump seals are lubricated by antifreeze in the coolant mixture. Additional lubrication is not necessary. FUNCTION CHECK A quick test to determine if pump is working is to check if heater warms properly. A defective water pump will not be able to circulate heated coolant through the long heater hose to the heater core. NOTE: The water pump on all models can be removed without discharging the air conditioning system (if equipped). WATER PUMP BYPASS HOSE A water pump bypass hose is used between the intake manifold and water pump on all engines. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 1777 Water Pump: Testing and Inspection VISUAL INSPECTION Replace water pump assembly if it has any of the following conditions: The body is cracked or damaged - Water leaks from the shaft seal. This is evident by traces of coolant below the vent hole - Loose or rough turning bearing. Also inspect thermal viscous fan drive - Impeller rubs either the pump body or timing chain case/cover Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Removal Water Pump: Service and Repair Removal NOTE: The water pump can be removed and installed without discharging the air conditioning system (if equipped). 1. Disconnect negative battery cable from battery. 2. Drain cooling system. 3. Do not waste reusable coolant. If solution is clean, drain coolant into a clean container for reuse. 4. Remove throttle cable at top of fan shroud. 5. Unsnap coolant overflow tank (up and out) from fan shroud and lay aside. Do not disconnect hose or drain coolant from tank. WARNING: Constant tension hose clamps are used on most cooling system hoses. When removing or installing, use only tools designed for servicing this type of clamp, such as special clamp tool (number 6094). Snap-on clamp tool (number HPC-20) may be used for larger clamps. always wear safety glasses when servicing constant tension clamps. CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only an original equipment clamp with matching number or letter 6. Remove upper radiator hose clamp and hose at radiator. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Removal > Page 1780 7. The thermal viscous fan drive is attached (threaded) to the water pump hub shaft. Remove fan/viscous fan drive assembly from water pump by turning mounting nut counterclockwise as viewed from front. Threads on viscous fan drive are RIGHT HAND. A Snap-On 36 MM Fan Wrench (number SP346 from Snap-On Cummins Diesel Tool Set number 2017DSP), or equivalents can be used. Place a bar or screwdriver between water pump pulley bolts to prevent pulley from rotating. Do not attempt to remove fan/viscous fan drive assembly from vehicle at this time. 8. If water pump is being replaced, do not unbolt fan blade assembly from thermal viscous fan drive. 9. Remove fan shroud attaching hardware (two bolts at bottom-two clips at top). 10. Remove fan shroud and fan blade/viscous fan drive assembly from vehicle as a complete unit. 11. After removing fan blade/viscous fan drive assembly, do not place thermal viscous fan drive in horizontal position. If stored horizontally, silicone fluid in viscous fan drive could drain into its bearing assembly and contaminate lubricant. 12. Do not remove water pump pulley bolts at this time. 13. Remove accessory drive belt as follows: The drive belt is equipped with a spring loaded automatic tensioner. Relax tension from belt by rotating tensioner clockwise (as viewed from front). When all belt tension has been relaxed, remove accessory drive belt. 14. Remove four water pump pulley-to-water pump hub bolts and remove pulley from vehicle. 15. Remove lower radiator hose clamp and remove lower hose at water pump. 16. Remove heater hose clamp and heater hose from heater hose coolant return tube. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Removal > Page 1781 17. Loosen heater hose coolant return tube mounting bolt and remove tube from water pump. Discard the old tube O-ring. 18. Remove seven water pump mounting bolts. CAUTION: Do not pry water pump at timing chain case/cover. The machined surfaces may be damaged resulting in leaks. 19. Loosen clamp at water pump end of bypass hose. Slip bypass hose from water pump while removing pump from vehicle. Discard old gasket. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Removal > Page 1782 Water Pump: Service and Repair Installation 1. Clean gasket mating surfaces. 2. Using a new gasket, install water pump to engine as follows: Guide water pump nipple into bypass hose as pump is being installed. Install water pump bolts. Tighten water pump mounting bolts to 40 Nm (30 ft. lbs.) torque. 3. Position bypass hose clamp to bypass hose. 4. Spin water pump to be sure that pump impeller does not rub against timing chain. 5. Install a new O-ring to the heater hose coolant return tube. Coat the new O-ring with antifreeze before installation. 6. Install coolant return tube and its mounting bolt to engine. Be sure the slot in tube bracket is bottomed to mounting bolt. This will properly position return tube. 7. Connect radiator lower hose to water pump. 8. Connect heater hose and hose clamp to coolant return tube. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Removal > Page 1783 9. Install water pump pulley. Tighten bolts to 27 Nm (20 ft. lbs.) torque. Place a bar or screwdriver between water pump pulley bolts to prevent pulley from rotating. 10. Relax tension from belt tensioner. Install drive belt. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Removal > Page 1784 CAUTION: When installing the serpentine accessory drive belt, the belt must be routed correctly. If not, engine may overheat due to Water pump rotating in wrong direction. Refer to illustration for correct belt routing. The correct belt with correct length must be used. 11. Position fan shroud and fan blade/viscous fan drive assembly to vehicle as a complete unit. 12. Install fan shroud. 13. Install fan blade/viscous fan drive assembly to water pump shaft. 14. Fill cooling system. 15. Connect negative battery cable. 16. Start and warm the engine. Check for leaks. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component Information > Service and Repair > With Air Conditioning Thermostat Bypass Hose: Service and Repair With Air Conditioning WARNING: The A/C system is under pressure even with engine off. Do not remove any refrigerant lines from A/C compressor. NOTE: If equipped with A/C, the generator and A/C compressor along with their common mounting bracket must be partially removed. Removing generator or A/C compressor from their mounting bracket is not necessary. Also, discharging A/C system is not necessary. REMOVAL 1. Disconnect negative battery cable from battery. 2. Partially drain cooling system. NOTE: Do not waste reusable coolant. If solution is clean, drain coolant into a clean container for reuse. 3. Remove upper radiator hose clamp and hose at radiator. 4. Unplug wiring harness from A/C compressor. 5. Remove air cleaner assembly. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component Information > Service and Repair > With Air Conditioning > Page 1790 6. Remove accessory drive belt as follows: The drive belt is equipped with a spring loaded automatic tensioner. Relax tension from belt by rotating tensioner clockwise (as viewed from front). When all belt tension has been relaxed, remove accessory drive belt. 7. The drive belt idler pulley must be removed to gain access to one of A/C compressor/generator bracket mounting bolts. Remove idler pulley bolt and remove idler pulley. 8. Remove oil dipstick tube mounting bolt at side of A/C-generator mounting bracket. 9. Disconnect throttle body control cables. Refer to Powertrain Management. 10. Remove heater hose clamp and heater hose from heater hose coolant return tube. 11. Remove heater hose coolant return tube mounting bolt and remove tube from engine. Discard the old tube O-ring. 12. Remove bracket-to-intake manifold bolts (number 1 and 2). 13. Remove six bracket bolts (number 3). 14. Lift and position generator and A/C compressor (along with their common mounting bracket) to gain access to bypass hose. A block of wood may be used to hold assembly in position. 15. Loosen and position both hose clamps to center of bypass hose. Remove hose from vehicle. INSTALLATION 1. Position bypass hose clamps to center of hose. 2. Install bypass hose to engine. 3. Secure both hose clamps. 4. Install generator-A/C mounting bracket assembly to engine. Tighten bolts (number 1 and 2) to 54 Nm (40 ft. lbs.) torque. Tighten bolts (number 3) to 40 Nm (30 ft. lbs.) torque. 5. Install a new O-ring to the heater hose coolant return tube. Coat the new O-ring with antifreeze before installation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component Information > Service and Repair > With Air Conditioning > Page 1791 6. Install coolant return tube and its mounting bolt to engine. 7. Connect throttle body control cables. 8. Install oil dipstick mounting bolt. 9. Install idler pulley. Tighten bolt to 54 Nm (40 ft. lbs.) torque. CAUTION: When installing serpentine accessory drive belt, the belt must be routed correctly. If not, engine may overheat due to water pump rotating in wrong direction. Refer to illustration for correct belt routing. The correct belt with correct length must be used. 10. Relax tension from belt tensioner. Install drive belt. 11. Install air cleaner assembly. 12. Install upper radiator hose to radiator. 13. Connect wiring harness to A/C compressor. 14. Fill cooling system. 15. Start and warm the engine. Check for leaks. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component Information > Service and Repair > With Air Conditioning > Page 1792 Thermostat Bypass Hose: Service and Repair Without Air Conditioning REMOVAL 1. Partially drain cooling system. NOTE: Do not waste reusable coolant. If the solution is clean, drain the coolant into a clean container for reuse. 2. Loosen both bypass hose clamps and position to the center of hose. WARNING: Constant tension hose clamps are used on most cooling system hoses. When removing or installing, use only tools designed for servicing this type of clamp, such as special clamp tool number 6094. snap-on clamp tool number HPC-20, or equivalents may be used for larger clamps. Always wear safety glasses when servicing constant tension clamps. CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only an original equipment clamp with matching number or letter. INSTALLATION 1. Position bypass hose clamps to the center of hose. 2. Install bypass hose to engine. 3. Secure both hose clamps. 4. Fill cooling system. 5. Start and warm the engine. Check for leaks. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Engine - Coolant Recommendations Coolant: Technical Service Bulletins Engine - Coolant Recommendations NO: 07-03-97 GROUP: Cooling DATE: May 9, 1997 SUBJECT: Engine Coolant Usage THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 07-05-93 DATED NOV. 26, 1993 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE 1993 TECHNICAL SERVICE BULLETIN BOOK (PUBLICATION NO. 81-699-94000). THE COMPLETE BULLETIN IS REVISED. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1997 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Pickup/Ram Cab & Chassis/Ramcharger/ Power Ram/Power Ram Cab & Chassis 1989 - 1993 (AG) Daytona 1989 (AH) Lancer/LeBaron GTS 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - 1997 (AN) Dakota 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 1997 (BR) Ram Truck 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1997 (FJ) Sebring/Avenger/Talon 1996 - 1997 (GS) Chrysler Voyager (European Market) 1995 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1989 - 1992 (MJ) Comanche 1996 - 1997 (NS) Town & Country/Caravan/Voyager 1995 - 1997 (PL) Neon 1997 (PR) Prowler 1992 - 1997 (SR) Viper/Viper Coupe 1997 (TJ) Wrangler 1989 - 1997 (XJ) Cherokee 1989 - 1995 (YJ) Wrangler 1993 - 1997 (ZJ) Grand Cherokee DISCUSSION: Some owners have expressed interest in using engine coolants made with propylene glycol instead of ethylene glycol due to its lower toxicity and resultant reduced hazards to children and animals. Based on recent test data, most owners should not experience significant effects on cooling system performance when using propylene glycol based coolant. The use of national brand propylene glycol based engine coolant that meets the same Chrysler ethylene glycol specification of MS-7170 (or equivalent ASTM D5216) is acceptable for Chrysler built vehicles. NOTE: ANTIFREEZE SOLD FOR PROTECTING PLUMBING ETC. (RV ANTIFREEZE) IS NOT A SUITABLE ENGINE COOLANT. However, owners should be discouraged from changing their engine coolant prior to the regularly scheduled maintenance period. Prematurely changing engine coolant unnecessarily adds to the risk of environmental exposure. Sufficient freeze protection for the region should be maintained. However, do not use more than a 55% solution (-35 F, -37 C). Use the chart that accompanies the propylene glycol coolant, since a higher concentration is required to obtain the same freeze points as ethylene glycol coolant. If the temperatures for your region fall below this, use ethylene glycol coolant. Under severe driving conditions (towing a trailer in hot weather etc.) there may be a slight loss in cooling performance. If this is noticed, the system should be changed back to ethylene glycol coolant. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Engine - Coolant Recommendations > Page 1797 The two types of coolant should not be mixed. The standard testers for measuring freeze protection will not provide an accurate reading when this occurs. If the cooling system is changed to propylene glycol, all the ethylene glycol coolant should be removed using an approved cooling system flush procedure. The freeze protection of propylene glycol cannot be measured with a standard cooling system hydrometer. A refractometer or hydrometer calibrated for propylene glycol is the preferred test tool. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant Capacity ................................................................................................................................. ............................................. 13.3 liters ( 14.0 quarts) NOTES: - Nominal refill capacities are shown. A variation may be observed from vehicle to vehicle due to manufacturing tolerances and refill procedures. - Capacities shown include vehicles with air conditioning and/or heavy-duty cooling systems. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 1800 Coolant: Fluid Type Specifications PREFERRED MIXTURE The required ethylene-glycol (antifreeze) and water mixture depends upon the climate and vehicle operating conditions. The recommended mixture of 60/50 ethylene-glycol and water will provide protection against freezing to -37°C (-35°F). 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 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 the specific heat of antifreeze is lower than that of water. UNACCEPTABLE MIXTURES 100 Percent Ethylene-Glycol 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 Formulations Propylene-glycol formulations do not meet Chrysler coolant specifications. Its 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 in Chrysler vehicles, which are 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 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. CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Service Precautions > Technician Safety Information Coolant: Technician Safety Information 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 running temperature, personal injury can result. Avoid radiator cooling fan when engine compartment related service is performed, personal injury can result. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Service Precautions > Technician Safety Information > Page 1803 Coolant: Vehicle Damage Warnings CAUTION: Do not use straight antifreeze as engine coolant, inadequate engine running temperatures can result. Do not operate vehicle without proper concentration of recommended ethylene glycol coolant, high running temperatures and cooling system corrosion can result. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Description and Operation > General Information Coolant: Description and Operation General Information 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 running temperature, personal injury can result. Avoid radiator cooling fan when engine compartment related service is performed, personal injury can result. CAUTION: Do not use straight antifreeze as engine coolant, inadequate engine running temperatures can result. Do not operate vehicle without proper concentration of recommended ethylene glycol coolant, high running temperatures and cooling system corrosion can result. DESCRIPTION The cooling system is designed around the coolant. Coolant flows through the engine water jacket absorbing heat produced during engine operation. PURPOSE The coolant carries the heat to radiator and heater core fins. Here it is transferred to the ambient air passing through the radiator and heater core fins. The coolant also removes heat from the automatic transmision. MIXTURE The cooling system factory fill is a mixture of 50% Ethylene Glycol based antifreeze and 50% water. Using a suitable hydrometer, measure antifreeze concentration in the radiator when the engine is cool. If the cooling system has recently been serviced, allow coolant to circulate for at least 20 minutes before taking hydrometer reading. Properly mixed coolant will protect the cooling system to -37°C (-35°F). If the freeze protection is above -28°C (-20°F), drain enough coolant from the cooling system to allow room to add antifreeze to achieve adequate protection. NOTE: Chrysler Corporation recommends Mopar Antifreeze/Coolant or a high quality, ethylene glycol base antifreeze/coolant, with a silicate inhibitor. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Description and Operation > General Information > Page 1806 Coolant: Description and Operation Coolant Performance PREFERRED MIXTURE The required ethylene-glycol (antifreeze) and water mixture depends upon the climate and vehicle operating conditions. The recommended mixture of 60/50 ethylene-glycol and water will provide protection against freezing to -37°C (-35°F). 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 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 the specific heat of antifreeze is lower than that of water. UNACCEPTABLE MIXTURES 100 Percent Ethylene-Glycol 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 Formulations Propylene-glycol formulations do not meet Chrysler coolant specifications. Its 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 in Chrysler vehicles, which are 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 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. CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Description and Operation > General Information > Page 1807 Coolant: Description and Operation Selection and Additives The presence of aluminum components in the cooling system requires strict corrosion protection. Maintain coolant at specified level with a mixture of ethylene-glycol based antifreeze and water. Chrysler Corporation recommends Mopar Antifreeze or equivalent. If coolant becomes contaminated or looses color, drain and flush cooling system and fill with correctly mixed solution. A 0.25 percent emulsifiable oil is added to the radiator at the factory to prevent solder corrosion. CAUTION: Do not use coolant additives that are claimed to improve engine cooling. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Description and Operation > Page 1808 Coolant: Service and Repair Refer to Cooling System, Service and Repair for applicable service procedures. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair Coolant Reservoir: Service and Repair NOTE: Should the reserve/overflow tank become coated with corrosion or emulsifiable oil, it can be cleaned with detergent and water. Rinse tank thoroughly before refilling cooling system. REMOVAL 1. Remove battery positive and negative cables and battery. 2. Remove upper radiator closure panel. 3. Remove overflow hose at reserve/overflow tank. 4. Remove three (3) coolant recovery bottle screws and remove coolant recovery bottle from vehicle. INSTALLATION 1. Install coolant recovery bottle and three (3) Screws. 2. Install overflow hose to tank. 3. Install upper radiator closure panel. 4. Install battery. 5. Add coolant. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Technical Service Bulletins > Engine Cooling Fan - Roaring Noise Explanation Fan Blade: Technical Service Bulletins Engine Cooling Fan - Roaring Noise Explanation NO: 07-05-98 GROUP: Cooling DATE: Sep. 4, 1998 SUBJECT: Engine Cooling Fan Noise MODELS: 1998 - 1999 (AB) Ram Van/Wagon 1997 - 1999 (AN) Dakota 1998 - 1999 (DN) Durango DISCUSSION: Some vehicles may exhibit an engine cooling fan "roar" noise. This noise is created by a large cooling fan that is required to provide optimum cooling for low vehicle speed operation in hot weather conditions and for heavy trailer towing. Since the large cooling fan is unnecessary in most operating conditions, these vehicles are also equipped with viscous fan drives that allow the fan to operate at variable speeds based upon temperature loads. The viscous fan drive will engage the fan for maximum cooling when temperatures are high and allow the fan to operate at slower speeds when temperatures are low. In addition, at engine start-up, the viscous fan drive engages the fan for maximum cooling until the fluid in the viscous clutch can dissipate out of the clutch drive grooves allowing the fan to operate at a slower speed. Because of the viscous fan drive, the noise may occur during high temperature conditions and for the first 1-2 minutes of operation. Due to the roar of the fan, customers may also complain of a perceived loss of power, automatic transmission slippage, or that the transmission is slaying into a low gear too long (delayed upshift). Customers concerned about this noise should be advised that this condition is normal and no repair attempts should be made. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Technical Service Bulletins > Page 1817 Fan Blade: Service and Repair The fan cannot be repaired. If the fan is damaged, it must be replaced. Inspect the fan as follows: 1. Remove fan blade and viscous fan drive assembly from engine. Refer to the preceding Removal procedure. 2. Remove fan blade assembly from viscous fan drive unit (four bolts). 3. Lay fan on a flat surface with leading edge facing down. With tip of blade touching flat surface, replace fan if clearance between opposite blade and surface is greater than 2.0 mm (0.090 inch). Rocking motion of opposite blades should not exceed 2.0 mm (0.090 inch). Test all blades in this manner. WARNING: Do not attempt to bend or straighten fan blades if not within specifications. 4. Inspect fan assembly for cracks, bends, loose rivets or broken welds. Replace fan if any damage is found. CAUTION: If the fan blade assembly is replaced because of mechanical damage, the water pump and thermal viscous fan drive should also be inspected. These components could have been damaged due to excessive vibration. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Viscous Fan Drive <--> [Fan Clutch] > Component Information > Technical Service Bulletins > Engine Cooling Fan - Roaring Noise Explanation Viscous Fan Drive: Technical Service Bulletins Engine Cooling Fan - Roaring Noise Explanation NO: 07-05-98 GROUP: Cooling DATE: Sep. 4, 1998 SUBJECT: Engine Cooling Fan Noise MODELS: 1998 - 1999 (AB) Ram Van/Wagon 1997 - 1999 (AN) Dakota 1998 - 1999 (DN) Durango DISCUSSION: Some vehicles may exhibit an engine cooling fan "roar" noise. This noise is created by a large cooling fan that is required to provide optimum cooling for low vehicle speed operation in hot weather conditions and for heavy trailer towing. Since the large cooling fan is unnecessary in most operating conditions, these vehicles are also equipped with viscous fan drives that allow the fan to operate at variable speeds based upon temperature loads. The viscous fan drive will engage the fan for maximum cooling when temperatures are high and allow the fan to operate at slower speeds when temperatures are low. In addition, at engine start-up, the viscous fan drive engages the fan for maximum cooling until the fluid in the viscous clutch can dissipate out of the clutch drive grooves allowing the fan to operate at a slower speed. Because of the viscous fan drive, the noise may occur during high temperature conditions and for the first 1-2 minutes of operation. Due to the roar of the fan, customers may also complain of a perceived loss of power, automatic transmission slippage, or that the transmission is slaying into a low gear too long (delayed upshift). Customers concerned about this noise should be advised that this condition is normal and no repair attempts should be made. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Viscous Fan Drive <--> [Fan Clutch] > Component Information > Technical Service Bulletins > Page 1822 Viscous Fan Drive: Description and Operation GENERAL INFORMATION The thermal viscous fan drive is a silicone-fluid-filled coupling used to connect the fan blades to the water pump shaft. The coupling allows the fan to be driven in a normal manner. This is done at low engine speeds while limiting the top speed of the fan to a predetermined maximum level at higher engine speeds. OPERATION A thermostatic bimetallic spring coil is located on the front face of the viscous fan drive unit (a typical viscous unit is shown. This spring coil reacts to the temperature of the radiator discharge air. It engages the viscous fan drive for higher fan speed if the air temperature from the radiator rises above a certain point. Until additional engine cooling is necessary, the fan will remain at a reduced rpm regardless of engine speed. Engagement Of Fan Only when sufficient heat is present, will the viscous fan drive engage. This is when the air flowing through the radiator core causes a reaction to the bimetallic coil. It then increases fan speed to provide the necessary additional engine cooling. Disengagement Of Fan Once the engine has cooled, the radiator discharge temperature will drop. The bimetallic coil again reacts and the fan speed is reduced to the previous disengaged speed. CAUTIONS: - Engines equipped with serpentine drive belts have reverse rotating fans and viscous fan drives. They are marked with the word REVERSE to designate their usage. Installation of the wrong fan or viscous fan drive can result in engine overheating. - If the viscous fan drive is replaced because of mechanical damage, the cooling fan blades should also be inspected. Inspect for fatigue cracks, loose blades, or loose rivets that could have resulted from excessive vibration. Replace fan blade assembly if any of these conditions are found. Also inspect water pump bearing and shaft assembly for any related damage due to a viscous fan drive malfunction. NOISE Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Viscous Fan Drive <--> [Fan Clutch] > Component Information > Technical Service Bulletins > Page 1823 It is normal for fan noise to be louder (roaring) when: The underhood temperature is above the engagement point for the viscous drive coupling. This may occur when ambient (outside air temperature) is very high. - Engine loads and temperatures are high such as when towing a trailer. - Cool silicone fluid within the fan drive unit is being redistributed back to its normal disengaged (warm) position. This can occur during the first 15 seconds to one minute after engine start-up on a cold engine. LEAKS Viscous fan drive operation is not affected by small oil stains near the drive bearing. If leakage appears excessive, replace the fan drive unit. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Viscous Fan Drive <--> [Fan Clutch] > Component Information > Technical Service Bulletins > Page 1824 Viscous Fan Drive: Testing and Inspection SPIN TEST If the fan assembly free-wheels without drag (the fan blades will revolve more than five turns when spun by hand), replace the fan drive. This spin test must be performed when the engine is cool. NOTE: For the following test, the cooling system must be in good condition. It also will ensure against excessively high coolant temperature. FUNCTION TEST CAUTION: Be sure that there is adequate fan blade clearance before drilling. 1. Drill a 3.18 mm (1/8 inch) diameter hole in the top center of the fan shroud. 2. Obtain a dial thermometer with an 8 inch stem (or equivalent). It should have a range of -18° to 105°C (0° to 220° F). Insert thermometer through the hole in the shroud. Be sure that there is adequate clearance from the fan blades. 3. Connect a tachometer and an engine ignition timing light (timing light is to be used as a strobe light). 4. Block the air flow through the radiator. Secure a sheet of plastic in front of the radiator (or air conditioner condenser). Use tape at the top to secure the plastic and be sure that the air flow is blocked. 5. Be sure that the air conditioner (if equipped) is turned off. WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT STAND IN A DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING. 6. Start the engine and operate at 2400 rpm. Within ten minutes the air temperature (indicated on the dial thermometer) should be up to 88° C (190° F). Fan drive engagement should have started to occur at between 74° to 82° C (165° to 180° F). Engagement is distinguishable by a definite increase in fan flow noise (roaring). The timing light also will indicate an increase in the speed of the fan. 7. When the air temperature reaches 88° C (190° F), remove the plastic sheet. Fan drive disengagement should have started to occur at between 57° to 79° C (135° to 175° F). A definite decrease of fan flow noise (roaring) should be noticed. If not, replace the defective viscous fan drive unit. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Viscous Fan Drive <--> [Fan Clutch] > Component Information > Technical Service Bulletins > Page 1825 Viscous Fan Drive: Service and Repair REMOVAL/INSTALLATION - Refer to Fan Blade for removal or installation. - Viscous Fan Drive Fluid Pump Out Requirement: After installing a new viscous fan drive, bring the engine speed up to approximately 2000 rpm and hold for approximately two minutes. This will ensure proper fluid distribution within the drive. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications DESCRIPTION .................................................................................................................................... .............................................................. TORQUE Engine Coolant Temperature Sensor ........................................................................................................................................................... 11 Nm (96 in lb) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1830 Fig 6 Engine Coolant Temperature Sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1831 ECT Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1832 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig 6 Engine Coolant Temperature Sensor DESCRIPTION The engine coolant temperature sensor is installed in the intake manifold next to the thermostat housing. OPERATION The sensor provides an input voltage to the powertrain control module (PCM) relating coolant temperature. The PCM uses this input along with inputs from other sensors to determine injector pulse width and ignition timing. As coolant temperature varies, the coolant temperature sensor resistance will change. This change in resistance results in a different input voltage to the PCM. 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. CIRCUIT OPERATION The engine coolant temperature (ECT) sensor provides an input to the Powertrain Control Module (PCM) on circuit K2. From circuit K2, the engine coolant temperature sensor draws up to 5 Volts from the PCM. The sensor is a variable resistor. As coolant temperature changes, the resistance in the sensor changes, causing a change in current draw. The K2 circuit connects to cavity A16 of the PCM. The PCM provides a ground for the engine coolant temperature sensor signal (circuit K2) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Testing Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Component Testing Fig 57 Engine Coolant Temperature Sensor - Typical Sensor Resistance Chart (OHMS) To perform a complete test of the engine coolant temperature sensor and its circuitry, refer to Powertrain Management/Computers and Controls/Testing and Inspection/Procedures/Diagnostic Charts. To test the sensor only, refer to the following: 1. Disconnect wire harness connector from coolant temperature sensor (Fig. 57). 2. Engines with air conditioning: - When removing the connector from sensor, do not pull directly on wiring harness. - Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). - Place the hook part of tool under the connector for removal. - The connector is snapped onto the sensor. - It is not equipped with a lock type tab. 3. Test the resistance of the sensor with a high input impedance (digital) volt-ohmmeter. - The resistance (as measured across the sensor terminals) should be as shown in the Coolant Temperature Sensor/Intake Air Temperature Sensor resistance chart. - Replace the sensor if it is not within the range of resistance specified in the chart. 4. Test continuity of the wire harness between the PCM wire harness connector and the coolant sensor connector terminals. - Diagrams/Electrical/Connector Views for terminal/cavity locations. - Repair the wire harness if an open circuit is indicated. 5. After tests are completed, connect electrical connector to sensor. - The sensor connector is symmetrical (not indexed). - It can be installed to the sensor in either direction. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Testing > Page 1835 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Crankshaft position sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Page 1836 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig. 66 Engine Coolant Temperature Sensor WARNING: Hot, pressurized coolant can cause injury by scalding. cooling system must be partially drained before removing the coolant temperature sensor. REMOVAL 1. Partially drain cooling system. 2. Remove air cleaner assembly 3. Disconnect electrical connector from sensor. 4. Engines with air conditioning: - When removing the connector from sensor, do not pull directly on wiring harness. - Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). - Place the hook part of tool under the connector for removal. - The connector is snapped onto the sensor. - It is not equipped with a lock type tab. 5. Remove sensor from intake manifold. INSTALLATION 1. Install sensor. 2. Tighten to 11 Nm (8 ft lb) torque. 3. Connect electrical connector to sensor. - The sensor connector is symmetrical (not indexed). - It can be installed to the sensor in either direction. 4. Install air cleaner assembly 5. Replace any lost engine coolant. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation Heater Core: Description and Operation The heater core is located in the heater-A/C housing, under the instrument panel. It is a heat exchanger made of rows of tubes and fins. Engine coolant is circulated through heater hoses to the heater core at all times. As the coolant flows through the heater core, heat removed from the engine is transferred to the heater core fins and tubes. Air directed through the heater core picks up the heat from the heater core fins. The blend air door allows control of the heater output air temperature by controlling how much of the air flowing through the heater-A/C housing is directed through the heater core. The blower motor speed controls the amount of air flowing through the heater-A/C housing. The heater core cannot be repaired and, if faulty or damaged. it must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation > Page 1840 Heater Core: Service and Repair Fig 64 Heater Core Removal/Installation WARNING: On vehicles equipped with Air-Bags, failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel assembly from the vehicle. Refer to: "Instrument Panel, Gauges and Warning Indicators : Instrument Panel : Service and Repair" See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair 3. Remove the heater-A/C housing.Refer to: "Housing Assembly HVAC : Service and Repair" See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair 4. Remove the heater-A/C housing cover. 5. Lift the heater core out of the heater-A/C housing. INSTALLATION 1. Insert the heater core into the bottom of the heater-A/C housing. 2. Install the heater-A/C housing cover. 3. Reinstall the heater-A/C housing. 4. Reinstall the instrument panel assembly in the vehicle. 5. Connect the battery negative cable. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation SYSTEM OPERATION The coolant temperature gauge gives an indication of the engine coolant temperature. The instrument cluster circuitry controls the gauge pointer position. The instrument cluster circuitry calculates the proper gauge pointer position based upon an engine coolant temperature message received from the Powertrain Control Module (PCM) on the Chrysler Collision Detection (CCD) data bus. The PCM uses an input from the engine coolant temperature sensor and internal programming to decide what engine coolant temperature message is required. The PCM then sends the proper message to the instrument cluster on the CCD data bus. If the PCM message indicates that coolant temperature is too high, the instrument cluster circuitry moves the gauge needle to the 260 °F graduation on the gauge face, turns on the Check Gauges lamp, and sends a chime tone request to the Central Timer Module (CTM). The engine coolant temperature sensor is installed in a threaded hole that penetrates a coolant passage of the engine. It is a thermistor-type sensor that changes its internal resistance with changes in engine coolant temperature. CIRCUIT OPERATION The engine coolant temperature gauge receives its information across the CCD Bus from the Central Timer Module (CTM). The engine coolant temperature sensor uses a variable resistor to send a signal to the Powertrain Control Module (PCM) indicating coolant temperature. The PCM then sends this information to the CTM across the CCD Bus. The CTM calculates the position of the engine coolant temperature gauge and based on the information received from the PCM it adjusts the position of the gauge pointer. This signal is sent over the CCD Bus to the instrument cluster. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Description and Operation > Page 1845 Temperature Gauge: Testing and Inspection (FOR ADDITONAL TESTING REFER TO BODY CONTROL MODULE) If the problem being diagnosed is related to coolant temperature gauge accuracy, be certain to confirm that the problem is with the gauge and not with cooling system performance. The actual engine coolant temperature should be checked with a test gauge or thermometer and compared to the gauge readings before you proceed with gauge diagnosis. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Diagnosis of the coolant temperature sensor and circuit, the Chrysler Collision Detection (CCD) data bus, and/or the Powertrain Control Module (PCM) should be performed with a DRB scan tool. For diagnosis of the coolant temperature gauge and the instrument cluster circuitry, see Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Instrument Cluster. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Description and Operation Temperature Warning Lamp/Indicator: Description and Operation SYSTEM OPERATION The transmission oil temperature warning lamp gives an indication when the Powertrain Control Module (PCM) has detected that the automatic transmission oil is overheated. One side of the lamp bulb receives battery voltage when the ignition switch is turned to the On position. The lamp ground is controlled by the instrument cluster circuitry based upon messages received from the PCM on the Chrysler Collision Detection (CCD) data bus. The PCM sends a lamp-on message for about two seconds when the ignition switch is turned to the On position as a bulb test. Following the bulb test, the PCM uses an input from the automatic transmission oil temperature sensor located within the transmission, along with its internal programming, to decide whether a condition exists that requires the transmission oil temperature warning lamp to be turned on. The PCM then sends the proper message to the instrument cluster on the CCD data bus to turn the lamp on or off. CIRCUIT OPERATION The transmission temperature lamp is used to alert the operator that the transmission oil temperature has exceeded a pre-determined level. Circuit T34 provides the input to the Powertrain Control Module (PCM). When the PCM determines the need for lamp illumination it sends a message over the CCD bus to the Body Control Module (BCM). The BCM processes this message and sends a message to the instrument cluster via the CCD bus for lamp illumination. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Description and Operation > Page 1849 Temperature Warning Lamp/Indicator: Testing and Inspection The diagnosis found here addresses an inoperative transmission oil temperature warning lamp condition. If the transmission oil temperature warning lamp comes on and stays on with the engine running, refer to Transmission for diagnosis of a transmission overheating condition. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. If the transmission oil temperature warning lamp fails to light during the bulb test (about two seconds after the ignition switch is turned to the On position), diagnosis of the Powertrain Control Module (PCM) and the Chrysler Collision Detection (CCD) data bus should be performed with a DRB scan tool. For diagnosis of the transmission oil temperature warning lamp and the instrument cluster circuitry, see Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Instrument Cluster. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Radiator Drain Plug > Component Information > Service and Repair Radiator Drain Plug: Service and Repair WARNING: Do not loosen radiator draincock with system hot and pressurized, serious burns from coolant can occur. REMOVAL 1. Unscrew draincock stem (counterclockwise rotation). When stem is completely unscrewed, pull it from radiator tank and draincock body. 2. Using a pair of needle nose pliers, compress draincock body and pull straight out of radiator. INSTALLATION 1. Install draincock stem loosely into body. The draincock assembly cannot be installed if stem is threaded into the body. 2. Push draincock assembly into opening in radiator tank. It will snap into place when fully seated. 3. Tighten draincock (clockwise) to 2.0 - 2.7 Nm (18 - 25 inch lbs.) torque. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Description and Operation Radiator Cap: Description and Operation GENERAL INFORMATION Radiators are equipped with a pressure cap, which releases pressure at some point within a range of 97 - 124 kPa (14 - 18 psi). The pressure relief point (in pounds) is engraved on top of cap. PURPOSE The cooling system will operate at pressures slightly above atmospheric pressure. This results in a higher coolant boiling point allowing increased radiator cooling capacity. The cap contains a spring-loaded pressure relief valve that opens when system pressure reaches release range of 97 124 kPa (14 - 18 psi). VENT VALVE A vent valve in the center of cap allows a small coolant flow through cap when coolant is below boiling temperature. The valve is completely closed when boiling point is reached. As the coolant cools, it contracts and creates a vacuum in the cooling system. This causes the vacuum valve to open and coolant in the reserve/overflow tank to be drawn through its connecting hose into radiator. If the vacuum valve is stuck shut, the radiator hoses will collapse on cool down. Clean the vent valve. GASKET A rubber gasket seals radiator filler neck to prevent leakage. This is done to keep system under pressure. It also maintains vacuum during coolant cool-down allowing coolant to return from reserve/ overflow tank. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Radiator Cap: Initial Inspection and Diagnostic Overview HOLDING CAP RIGHT SIDE UP Hold cap at eye level, right side up. The vent valve at bottom of cap should open. If rubber gasket has swollen and prevents vent valve from opening, replace cap. HOLDING CAP UPSIDE DOWN Hold cap at eye level, upside down. If any light can be seen between vent valve and rubber gasket, replace cap. REPLACEMENT CAP Do not use a replacement cap that has a spring to hold vent shut. A replacement cap must be the type designed for a coolant reserve/overflow system with a completely sealed diaphragm spring and a rubber gasket. This gasket is used to seal to radiator filler neck top surface. Use of proper cap will allow coolant return to radiator. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1859 Radiator Cap: Component Tests and General Diagnostics Radiator Cap - Pressure Testing 1. Remove cap from radiator. Be sure that sealing surfaces are clean. 2. Moisten rubber gasket with water and install cap on pressure tester 7700 or an equivalent. 3. Operate tester pump to bring pressure to 104 kPa (15 psi) on gauge. If pressure cap fails to hold pressure of at least 97 kPa (14 psi) replace cap. NOTE: The pressure cap may test properly while positioned on tool 7700 or equivalent. It may not hold pressure or vacuum when installed on radiator. If so, inspect radiator filler neck and cap's top gasket for damage. Also inspect for dirt or distortion that may prevent cap from sealing properly. CAUTION: Radiator pressure testing tools are very sensitive to small air leaks, which will not cause cooling system problems. A pressure cap that does not have a history of coolant loss should not be replaced just because it leaks slowly when tested with this tool. Add water to tool. Turn tool upside down and recheck pressure cap to confirm that cap needs replacement. Radiator Cap to Filler Neck Seal - Pressure Relief Check PROCEDURE The pressure cap upper gasket (seal) pressure relief can be checked by removing the overflow hose at the radiator filler neck nipple. Attach hose of pressure tester tool 7700 (or equivalent) to nipple. It will be necessary to disconnect hose from its adapter for filler neck. Pump air into radiator. The pressure cap upper gasket should relieve at 69 - 124 kPa (10 - 18 psi) and hold pressure at a minimum of 55 kPa (8 psi). WARNING: The warning words do not open hot on the pressure cap is a safety precaution. When hot, the cooling system builds up pressure. To prevent scalding or other injury, the pressure cap should not be removed while the system is hot and/or under pressure. REASONS FOR REMOVING PRESSURE CAP There is no need to remove the pressure cap at any time except for the following purposes: Check and adjust coolant freeze point - Refill system with new coolant - Conducting service procedures - Checking for leaks WARNING: If vehicle has been run recently, wait at least 15 minutes before removing radiator cap. With a rag, squeeze radiator upper hose to check if system is under pressure. Place a rag over cap and without pushing cap down, rotate it counter-clockwise to first stop. allow fluid to escape through the coolant reserve/overflow hose into reserve/ overflow tank. Squeeze radiator upper hose to determine when pressure has been released. When coolant and steam stop being pushed into tank and system pressure drops, remove radiator cap completely. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Description and Operation Radiator Hose: Description and Operation GENERAL INFORMATION Rubber hoses route coolant to and from the radiator, intake manifold and heater core. Radiator lower hoses are spring-reinforced to prevent collapse from water pump suction at moderate and high engine speeds. WARNING: Constant tension hose clamps are used on most cooling system hoses. When removing or installing, use only tools designed for servicing this type of clamp, such as special clamp tool (number 6094). Snap-on clamp tool (number HPC-20) may be used for larger clamps. Always wear safety glasses when servicing constant tension clamps. CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only an original equipment clamp with matching number or letter. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications DESCRIPTION .................................................................................................................................... .............................................................. TORQUE Engine Coolant Temperature Sensor ........................................................................................................................................................... 11 Nm (96 in lb) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1868 Fig 6 Engine Coolant Temperature Sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1869 ECT Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1870 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig 6 Engine Coolant Temperature Sensor DESCRIPTION The engine coolant temperature sensor is installed in the intake manifold next to the thermostat housing. OPERATION The sensor provides an input voltage to the powertrain control module (PCM) relating coolant temperature. The PCM uses this input along with inputs from other sensors to determine injector pulse width and ignition timing. As coolant temperature varies, the coolant temperature sensor resistance will change. This change in resistance results in a different input voltage to the PCM. 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. CIRCUIT OPERATION The engine coolant temperature (ECT) sensor provides an input to the Powertrain Control Module (PCM) on circuit K2. From circuit K2, the engine coolant temperature sensor draws up to 5 Volts from the PCM. The sensor is a variable resistor. As coolant temperature changes, the resistance in the sensor changes, causing a change in current draw. The K2 circuit connects to cavity A16 of the PCM. The PCM provides a ground for the engine coolant temperature sensor signal (circuit K2) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Testing Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Component Testing Fig 57 Engine Coolant Temperature Sensor - Typical Sensor Resistance Chart (OHMS) To perform a complete test of the engine coolant temperature sensor and its circuitry, refer to Powertrain Management/Computers and Controls/Testing and Inspection/Procedures/Diagnostic Charts. To test the sensor only, refer to the following: 1. Disconnect wire harness connector from coolant temperature sensor (Fig. 57). 2. Engines with air conditioning: - When removing the connector from sensor, do not pull directly on wiring harness. - Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). - Place the hook part of tool under the connector for removal. - The connector is snapped onto the sensor. - It is not equipped with a lock type tab. 3. Test the resistance of the sensor with a high input impedance (digital) volt-ohmmeter. - The resistance (as measured across the sensor terminals) should be as shown in the Coolant Temperature Sensor/Intake Air Temperature Sensor resistance chart. - Replace the sensor if it is not within the range of resistance specified in the chart. 4. Test continuity of the wire harness between the PCM wire harness connector and the coolant sensor connector terminals. - Diagrams/Electrical/Connector Views for terminal/cavity locations. - Repair the wire harness if an open circuit is indicated. 5. After tests are completed, connect electrical connector to sensor. - The sensor connector is symmetrical (not indexed). - It can be installed to the sensor in either direction. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Testing > Page 1873 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Crankshaft position sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Page 1874 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig. 66 Engine Coolant Temperature Sensor WARNING: Hot, pressurized coolant can cause injury by scalding. cooling system must be partially drained before removing the coolant temperature sensor. REMOVAL 1. Partially drain cooling system. 2. Remove air cleaner assembly 3. Disconnect electrical connector from sensor. 4. Engines with air conditioning: - When removing the connector from sensor, do not pull directly on wiring harness. - Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). - Place the hook part of tool under the connector for removal. - The connector is snapped onto the sensor. - It is not equipped with a lock type tab. 5. Remove sensor from intake manifold. INSTALLATION 1. Install sensor. 2. Tighten to 11 Nm (8 ft lb) torque. 3. Connect electrical connector to sensor. - The sensor connector is symmetrical (not indexed). - It can be installed to the sensor in either direction. 4. Install air cleaner assembly 5. Replace any lost engine coolant. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation SYSTEM OPERATION The coolant temperature gauge gives an indication of the engine coolant temperature. The instrument cluster circuitry controls the gauge pointer position. The instrument cluster circuitry calculates the proper gauge pointer position based upon an engine coolant temperature message received from the Powertrain Control Module (PCM) on the Chrysler Collision Detection (CCD) data bus. The PCM uses an input from the engine coolant temperature sensor and internal programming to decide what engine coolant temperature message is required. The PCM then sends the proper message to the instrument cluster on the CCD data bus. If the PCM message indicates that coolant temperature is too high, the instrument cluster circuitry moves the gauge needle to the 260 °F graduation on the gauge face, turns on the Check Gauges lamp, and sends a chime tone request to the Central Timer Module (CTM). The engine coolant temperature sensor is installed in a threaded hole that penetrates a coolant passage of the engine. It is a thermistor-type sensor that changes its internal resistance with changes in engine coolant temperature. CIRCUIT OPERATION The engine coolant temperature gauge receives its information across the CCD Bus from the Central Timer Module (CTM). The engine coolant temperature sensor uses a variable resistor to send a signal to the Powertrain Control Module (PCM) indicating coolant temperature. The PCM then sends this information to the CTM across the CCD Bus. The CTM calculates the position of the engine coolant temperature gauge and based on the information received from the PCM it adjusts the position of the gauge pointer. This signal is sent over the CCD Bus to the instrument cluster. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Description and Operation > Page 1878 Temperature Gauge: Testing and Inspection (FOR ADDITONAL TESTING REFER TO BODY CONTROL MODULE) If the problem being diagnosed is related to coolant temperature gauge accuracy, be certain to confirm that the problem is with the gauge and not with cooling system performance. The actual engine coolant temperature should be checked with a test gauge or thermometer and compared to the gauge readings before you proceed with gauge diagnosis. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Diagnosis of the coolant temperature sensor and circuit, the Chrysler Collision Detection (CCD) data bus, and/or the Powertrain Control Module (PCM) should be performed with a DRB scan tool. For diagnosis of the coolant temperature gauge and the instrument cluster circuitry, see Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Instrument Cluster. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Description and Operation Temperature Warning Lamp/Indicator: Description and Operation SYSTEM OPERATION The transmission oil temperature warning lamp gives an indication when the Powertrain Control Module (PCM) has detected that the automatic transmission oil is overheated. One side of the lamp bulb receives battery voltage when the ignition switch is turned to the On position. The lamp ground is controlled by the instrument cluster circuitry based upon messages received from the PCM on the Chrysler Collision Detection (CCD) data bus. The PCM sends a lamp-on message for about two seconds when the ignition switch is turned to the On position as a bulb test. Following the bulb test, the PCM uses an input from the automatic transmission oil temperature sensor located within the transmission, along with its internal programming, to decide whether a condition exists that requires the transmission oil temperature warning lamp to be turned on. The PCM then sends the proper message to the instrument cluster on the CCD data bus to turn the lamp on or off. CIRCUIT OPERATION The transmission temperature lamp is used to alert the operator that the transmission oil temperature has exceeded a pre-determined level. Circuit T34 provides the input to the Powertrain Control Module (PCM). When the PCM determines the need for lamp illumination it sends a message over the CCD bus to the Body Control Module (BCM). The BCM processes this message and sends a message to the instrument cluster via the CCD bus for lamp illumination. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Description and Operation > Page 1882 Temperature Warning Lamp/Indicator: Testing and Inspection The diagnosis found here addresses an inoperative transmission oil temperature warning lamp condition. If the transmission oil temperature warning lamp comes on and stays on with the engine running, refer to Transmission for diagnosis of a transmission overheating condition. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. If the transmission oil temperature warning lamp fails to light during the bulb test (about two seconds after the ignition switch is turned to the On position), diagnosis of the Powertrain Control Module (PCM) and the Chrysler Collision Detection (CCD) data bus should be performed with a DRB scan tool. For diagnosis of the transmission oil temperature warning lamp and the instrument cluster circuitry, see Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Instrument Cluster. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications Thermostat: Specifications THERMOSTAT TEMPERATURE OPERATING RANGE: INFORMATION NOT SUPPLIED BY MANUFACTURER. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 1886 Thermostat: Locations The thermostat on all engines is located beneath the thermostat housing at the front of the intake manifold. The thermostat has an air bleed notch. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 1887 Thermostat: Description and Operation CAUTION: Do not operate an engine without a thermostat, except for servicing or testing. GENERAL INFORMATION An arrow plus the word UP is stamped on the front flange next to the air bleed. The words TO RAD are stamped on one arm of the thermostat. They indicate the proper installed position. The same thermostat is used for winter and summer seasons. An engine should not be operated without a thermostat, except for servicing or testing. Operating without a thermostat causes longer engine warm-up time, unreliable warm-up performance, increased exhaust emissions and crankcase condensation that can result in sludge formation. DESIGN The engine cooling thermostats are a wax pellet driven, reverse poppet choke type. The wax pellet is located in a sealed container at the spring end of the thermostat. When heated, the pellet expands, overcoming closing spring tension and water pump pressure to force the valve to open. Coolant leakage into the pellet container will cause the thermostat to fail in the open position. Thermostats very rarely stick. Do not attempt to free a thermostat with a prying device. PURPOSE They are designed to provide the fastest warm up possible by preventing leakage through them and to guarantee a minimum engine operating temperature of 88° to 93°C (192° to 199°F). The thermostat controls the operating temperature of the engine by controlling the amount of coolant flow to the radiator. The thermostat is closed below 88°C (192°F). When the coolant reaches this temperature, the thermostat begins to open, allowing coolant flow to the radiator. This provides quick engine warm-up and overall temperature control. The thermostat is designed to provide a minimum engine operating temperature of 88° to 93°C (192° to 199°F). It should be fully open for maximum coolant flow during operation in hot ambient temperatures of approximately 104°C (220°F). Above 104°C (220°F), coolant temperature is controlled by the radiator, fan and ambient temperature. DIAGNOSTICS All models are equipped with On-Board Diagnostics for certain cooling system components. If the powertrain control module (PCM) detects low engine coolant temperature, it will record a Diagnostic Trouble Code (DTC) in the PCM memory. The DTC number for low coolant temperature is 17. Do not change a thermostat for lack of heat as indicated by the instrument panel gauge or heater performance unless a DTC number 17 is present. The DTC can also be accessed through the Diagnostic Readout Box (DRB) scan tool. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Service and Repair > Removal Thermostat: Service and Repair Removal WARNING: Do not loosen radiator draincock with system hot and pressurized serious burns from coolant can occur. GENERAL INFORMATION Do not waste reusable coolant. If solution is clean, drain coolant into a clean container for reuse. If thermostat is being replaced, be sure that replacement is specified thermostat for vehicle model and engine type. Factory installed thermostat housings on this engine is installed on a gasket with an anti-stick coating. This will aid in gasket removal and clean-up. PROCEDURE 1. Disconnect negative battery cable at battery. 2. Drain cooling system until coolant level is below thermostat. 3. Air Conditioned vehicles: Remove support bracket (generator mounting bracket-to-intake manifold) located near rear of generator. 4. On air conditioning equipped vehicles, the generator must be partially removed. a. Remove generator drive belt as follows: Drive belts on this engine is equipped with a spring loaded automatic belt tensioner. b. Attach a socket/wrench to pulley mounting bolt of automatic belt tensioner. c. Rotate tensioner assembly clockwise (as viewed from front) until tension has been relieved from belt. d. Remove belt from vehicle. e. Remove two generator mounting bolts. Do not remove any wiring at generator. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Service and Repair > Removal > Page 1890 f. Remove generator. Position generator to gain access for thermostat gasket removal. WARNING: Constant tension hose clamps are used on most cooling system hoses. When removing or installing, use only tools designed for servicing this type of clamp, such as special clamp tool (number 6094) snap-on clamp tool (number HPC-20) may be used for larger clamps. Always wear safety glasses when servicing constant tension clamps. CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only an original equipment with matching number or letter. 5. Remove upper radiator hose clamp and upper radiator hose at thermostat housing. 6. Position wiring harness (behind thermostat housing) to gain access to thermostat housing. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Service and Repair > Removal > Page 1891 7. Remove thermostat housing mounting bolts, thermostat housing, gasket and thermostat. Discard old gasket. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Service and Repair > Removal > Page 1892 Thermostat: Service and Repair Installation 1. Clean mating areas of intake manifold and thermostat housing. 2. Install thermostat (spring side down) into recessed machined groove on intake manifold. 3. Install gasket on intake manifold and over thermostat. 4. Position thermostat housing to intake manifold. Note the word FRONT stamped on housing. For adequate clearance, this must be placed towards front of vehicle. The housing is slightly angled forward after installation to intake manifold. 5. Install two housing-to-intake manifold bolts. Tighten bolts to 23 Nm (200 inch lbs.) torque. CAUTION: Housing must be tightened evenly and thermostat must be centered into recessed groove in intake manifold. If not, it may result in a cracked housing, damaged intake manifold threads or coolant leak. 6. Install upper radiator hose to thermostat housing. 7. Air Conditioned vehicles: a. Install generator. Tighten bolts to 41 Nm (30 ft. lbs.) torque. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Service and Repair > Removal > Page 1893 b. Install support bracket (generator mounting bracket-to-intake manifold). Tighten bolts to 54 Nm (40 ft. lbs.) torque. c. Position drive belt over all pulleys except idler pulley (located between generator and A/C compressor). d. Attach a socket/wrench to pulley mounting bolt of automatic belt tensioner. CAUTION: When installing the serpentine accessory drive belt, belt must be routed correctly. If not, engine may overheat due to water pump Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Service and Repair > Removal > Page 1894 rotating in wrong direction. Refer to illustration for correct engine belt routing. Or, refer to the Belt Routing Label located in the engine compartment. The correct belt with correct length must be used. e. Rotate socket/wrench clockwise. Place belt over idler pulley. Let tensioner rotate back into place. Remove wrench. Be sure belt is properly seated on all pulleys. 8. Fill cooling system. 9. Connect negative battery cable to battery. 10. Start and warm the engine. Check for leaks. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Specifications Thermostat Housing: Specifications Mounting Bolts ..................................................................................................................................... ............................................... 23 Nm (200 inch lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Water Pump Bolts Water Pump: Specifications Water Pump Mounting Bolts 30 ft.lb Water Pump Pulley 16 ft.lb Water Pump-to-Chain Case Cover Bolt 31 ft.lb Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Water Pump Bolts > Page 1902 Water Pump: Specifications Water Pump Pulley Bolts Mounting Bolts ..................................................................................................................................... .................................................... 27 Nm (20 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 1903 Water Pump: Locations The water pump is bolted directly to the engine timing chain case/cover. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 1904 Water Pump: Description and Operation GENERAL INFORMATION A centrifugal water pump circulates coolant through the water jackets, passages, intake manifold, radiator core, cooling system hoses and heater core. The pump is driven from the engine crankshaft by a drive belt. A gasket is used as a seal between the water pump and timing chain case/cover. IMPELLER The water pump impeller is pressed onto the rear of a shaft that rotates in a bearing pressed into the water pump body. The body has a small hole for ventilation. SEALS The water pump seals are lubricated by antifreeze in the coolant mixture. Additional lubrication is not necessary. FUNCTION CHECK A quick test to determine if pump is working is to check if heater warms properly. A defective water pump will not be able to circulate heated coolant through the long heater hose to the heater core. NOTE: The water pump on all models can be removed without discharging the air conditioning system (if equipped). WATER PUMP BYPASS HOSE A water pump bypass hose is used between the intake manifold and water pump on all engines. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 1905 Water Pump: Testing and Inspection VISUAL INSPECTION Replace water pump assembly if it has any of the following conditions: The body is cracked or damaged - Water leaks from the shaft seal. This is evident by traces of coolant below the vent hole - Loose or rough turning bearing. Also inspect thermal viscous fan drive - Impeller rubs either the pump body or timing chain case/cover Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Removal Water Pump: Service and Repair Removal NOTE: The water pump can be removed and installed without discharging the air conditioning system (if equipped). 1. Disconnect negative battery cable from battery. 2. Drain cooling system. 3. Do not waste reusable coolant. If solution is clean, drain coolant into a clean container for reuse. 4. Remove throttle cable at top of fan shroud. 5. Unsnap coolant overflow tank (up and out) from fan shroud and lay aside. Do not disconnect hose or drain coolant from tank. WARNING: Constant tension hose clamps are used on most cooling system hoses. When removing or installing, use only tools designed for servicing this type of clamp, such as special clamp tool (number 6094). Snap-on clamp tool (number HPC-20) may be used for larger clamps. always wear safety glasses when servicing constant tension clamps. CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only an original equipment clamp with matching number or letter 6. Remove upper radiator hose clamp and hose at radiator. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Removal > Page 1908 7. The thermal viscous fan drive is attached (threaded) to the water pump hub shaft. Remove fan/viscous fan drive assembly from water pump by turning mounting nut counterclockwise as viewed from front. Threads on viscous fan drive are RIGHT HAND. A Snap-On 36 MM Fan Wrench (number SP346 from Snap-On Cummins Diesel Tool Set number 2017DSP), or equivalents can be used. Place a bar or screwdriver between water pump pulley bolts to prevent pulley from rotating. Do not attempt to remove fan/viscous fan drive assembly from vehicle at this time. 8. If water pump is being replaced, do not unbolt fan blade assembly from thermal viscous fan drive. 9. Remove fan shroud attaching hardware (two bolts at bottom-two clips at top). 10. Remove fan shroud and fan blade/viscous fan drive assembly from vehicle as a complete unit. 11. After removing fan blade/viscous fan drive assembly, do not place thermal viscous fan drive in horizontal position. If stored horizontally, silicone fluid in viscous fan drive could drain into its bearing assembly and contaminate lubricant. 12. Do not remove water pump pulley bolts at this time. 13. Remove accessory drive belt as follows: The drive belt is equipped with a spring loaded automatic tensioner. Relax tension from belt by rotating tensioner clockwise (as viewed from front). When all belt tension has been relaxed, remove accessory drive belt. 14. Remove four water pump pulley-to-water pump hub bolts and remove pulley from vehicle. 15. Remove lower radiator hose clamp and remove lower hose at water pump. 16. Remove heater hose clamp and heater hose from heater hose coolant return tube. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Removal > Page 1909 17. Loosen heater hose coolant return tube mounting bolt and remove tube from water pump. Discard the old tube O-ring. 18. Remove seven water pump mounting bolts. CAUTION: Do not pry water pump at timing chain case/cover. The machined surfaces may be damaged resulting in leaks. 19. Loosen clamp at water pump end of bypass hose. Slip bypass hose from water pump while removing pump from vehicle. Discard old gasket. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Removal > Page 1910 Water Pump: Service and Repair Installation 1. Clean gasket mating surfaces. 2. Using a new gasket, install water pump to engine as follows: Guide water pump nipple into bypass hose as pump is being installed. Install water pump bolts. Tighten water pump mounting bolts to 40 Nm (30 ft. lbs.) torque. 3. Position bypass hose clamp to bypass hose. 4. Spin water pump to be sure that pump impeller does not rub against timing chain. 5. Install a new O-ring to the heater hose coolant return tube. Coat the new O-ring with antifreeze before installation. 6. Install coolant return tube and its mounting bolt to engine. Be sure the slot in tube bracket is bottomed to mounting bolt. This will properly position return tube. 7. Connect radiator lower hose to water pump. 8. Connect heater hose and hose clamp to coolant return tube. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Removal > Page 1911 9. Install water pump pulley. Tighten bolts to 27 Nm (20 ft. lbs.) torque. Place a bar or screwdriver between water pump pulley bolts to prevent pulley from rotating. 10. Relax tension from belt tensioner. Install drive belt. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Removal > Page 1912 CAUTION: When installing the serpentine accessory drive belt, the belt must be routed correctly. If not, engine may overheat due to Water pump rotating in wrong direction. Refer to illustration for correct belt routing. The correct belt with correct length must be used. 11. Position fan shroud and fan blade/viscous fan drive assembly to vehicle as a complete unit. 12. Install fan shroud. 13. Install fan blade/viscous fan drive assembly to water pump shaft. 14. Fill cooling system. 15. Connect negative battery cable. 16. Start and warm the engine. Check for leaks. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalyst Shield > Component Information > Description and Operation Catalyst Shield: Description and Operation Heat shields are needed to protect both the vehicle and the environment from the high temperatures developed by the catalytic converter. The catalytic converter releases additional heat into the exhaust system. Under severe operating conditions, the temperature increases in the area of the converter. Such conditions can exist when the engine misfires or otherwise does not operate at peak efficiency. NOTE: Avoid application of rust prevention compounds or undercoating materials to exhaust system floor pan heat shields. Light overspray near the edges is permitted. Application of coating will result in excessive floor pan temperatures and objectionable fumes. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalyst Shield > Component Information > Description and Operation > Page 1918 Catalyst Shield: Service and Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalyst Shield > Component Information > Description and Operation > Page 1919 REMOVAL 1. Raise and support the vehicle. 2. Remove the screws and nuts holding the heat shields to the frame and floorpan. 3. When removing muffler heat shield, the muffler front support bracket must be removed first. 4. Slide the shield out around the exhaust system. INSTALLATION 1. Position the heat shields to the floor pan or the frame and install the screws and nuts. 2. Tighten the nuts to 5 Nm (45 inch lbs.) torque. Tighten the screws to the rear frame heat shield to 9 Nm (80 inch lbs.) torque. Tighten the other screws to 10 Nm (90 inch lbs.) torque. 3. Lower the vehicle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Crossover Pipe > Component Information > Specifications Exhaust Crossover Pipe: Specifications To Manifold Nuts ................................................................................................................................. .................................................... 32 Nm (25 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Crossover Pipe > Component Information > Specifications > Page 1923 Exhaust Crossover Pipe: Service and Repair REMOVAL 1. Raise and support the vehicle. 2. Saturate the bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration. 3. Disconnect the oxygen sensor. 4. Remove the exhaust manifold-to-exhaust pipe nuts. 5. Disconnect the exhaust pipe from the catalytic converter front flange. 6. Remove the exhaust pipe. INSTALLATION 1. Connect the exhaust pipe to the exhaust manifold. Tighten the nuts to 32 Nm (25 ft. lbs.) torque. 2. Align and connect the exhaust pipe to the catalytic converter flange. Install exhaust clamp and tighten clamp nuts to 47 Nm (35 ft. lbs.) torque. 3. Connect oxygen sensor connector. 4. Lower the vehicle. 5. Start the engine and inspect for exhaust leaks and exhaust system contact with the body panels. Adjust the alignment, if needed. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications To Head Bolts/Nuts ............................................................................................................................. ..................................................... 34 Nm (25 ft. lbs.) To Exhaust Pipe ............................................... ......................................................................................................................................... 26 Nm (19 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 1927 Exhaust Manifold: Description and Operation The exhaust manifolds are equipped with ball flange outlets to assure a tight seal and strain free connections. Exhaust manifolds are LOG type with balanced flow. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Removal and Installation Exhaust Manifold: Service and Repair Removal and Installation REMOVAL 1. Disconnect the negative cable from the battery. 2. Raise the vehicle. 3. Remove the bolts and nuts attaching the exhaust pipe to the exhaust manifold. 4. Lower the vehicle. 5. Remove bolts, nuts and washers attaching manifold to cylinder head. 6. Remove manifold from the cylinder head. CAUTION: If the studs came out with the nuts when removing the exhaust manifold, install new studs. INSTALLATION 1. Position the exhaust manifolds on the two studs located on the cylinder head. Install conical washers and nuts on these studs. 2. Install new bolt and washer assemblies in the remaining holes. Start at the center arm and work outward. Tighten the bolts and nuts to 24 Nm (18 ft. lbs.) torque. 3. Raise the vehicle. 4. Assemble the exhaust pipe to the exhaust manifold and secure with bolts, nuts and washers. Tighten these nuts to 27 Nm (20 ft. lbs.) torque. 5. Lower the vehicle. 6. Connect the negative cable to the battery. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Removal and Installation > Page 1930 Exhaust Manifold: Service and Repair Cleaning and Inspection CLEANING Clean mating surfaces on cylinder head and manifold, wash with solvent and blow dry with compressed air. Inspect manifold for cracks. INSPECTION Inspect mating surfaces of manifold for flatness with a straight edge. Seal surfaces must be flat within 0.1 mm (0.004 inch) overall. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Specifications Exhaust Pipe: Specifications Hanger Bolt .......................................................................................................................................... ............................................... 23 Nm (200 inch lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Pipe Replacement Exhaust Pipe: Service and Repair Exhaust Pipe Replacement REMOVAL 1. Raise and support the vehicle. 2. Saturate the clamp nuts with heat valve lubricant. Allow 5 minutes for penetration. 3. Remove the front and rear clamp nuts 4. It may be necessary to loosen other sections of the exhaust system to remove the extension pipe. INSTALLATION 1. Position the extension pipe in the muffler or and the catalytic converter flange. 2. If other sections of the exhaust system-where loosened in removal, follow appropriate tightening procedures. 3. Install the clamps and nuts. Tighten the nuts to 47 Nm (35 ft. lbs.) torque. 4. Lower the vehicle. 5. Start the engine and inspect for exhaust leaks and exhaust system contact with the body panels. Adjust the alignment, if needed. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Pipe Replacement > Page 1936 Exhaust Pipe: Service and Repair Tailpipe Replacement REMOVAL 1. Raise and support the vehicle. 2. Saturate the clamp nuts with heat valve lubricant. Allow 5 minutes for penetration. 3. Remove muffler to tailpipe exhaust clamp. 4. Remove the tailpipe: from the front and rear insulators. 5. Remove the tailpipe. INSTALLATION 1. Position the tailpipe into the muffler. Install the nuts onto the clamp bolt finger tight. 2. Install the tailpipe into the insulators. 3. Position tailpipe and tighten the muffler rear clamp nuts to 47 Nm (35 ft. lbs.) torque. 4. Lower the vehicle. 5. Start the engine and inspect for exhaust leaks and exhaust system contact with the body panels. Adjust the alignment, if needed. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Specifications Exhaust Pipe/Muffler Hanger: Specifications Mounting Nuts ..................................................................................................................................... ..................................................... 47 Nm (35 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Specifications Heat Shield: Specifications Nuts ..................................................................................................................................................... .................................................... 5 Nm (45 inch lbs.) Screws ............................................................. ...................................................................................................................................... 10 Nm (90 inch lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Specifications > Page 1943 Heat Shield: Description and Operation Heat shields are needed to protect both the vehicle and the environment from the high temperatures developed by the catalytic converter. The catalytic converter releases additional heat into the exhaust system. Under severe operating conditions, the temperature increases in the area of the converter. Such conditions can exist when the engine misfires or otherwise does not operate at peak efficiency. NOTE: Avoid application of rust prevention compounds or undercoating materials to exhaust system floor pan heat shields. Light overspray near the edges is permitted. Application of coating will result in excessive floor pan temperatures and objectionable fumes. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Specifications > Page 1944 Heat Shield: Service and Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Specifications > Page 1945 REMOVAL 1. Raise and support the vehicle. 2. Remove the screws and nuts holding the heat shields to the frame and floorpan. 3. When removing muffler heat shield, the muffler front support bracket must be removed first. 4. Slide the shield out around the exhaust system. INSTALLATION 1. Position the heat shields to the floor pan or the frame and install the screws and nuts. 2. Tighten the nuts to 5 Nm (45 inch lbs.) torque. Tighten the screws to the rear frame heat shield to 9 Nm (80 inch lbs.) torque. Tighten the other screws to 10 Nm (90 inch lbs.) torque. 3. Lower the vehicle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair Muffler: Service and Repair REMOVAL 1. Raise and support the vehicle. 2. Saturate the clamp nuts with heat valve lubricant. Allow 5 minutes for penetration. 3. Remove the muffler clamp nuts from the front hanger and the rear muffler to tailpipe connection. 4. Disconnect the muffler from the tailpipe. The tailpipe should be supported when the muffler is disconnected. 5. Remove the muffler from the extension pipe or catalytic converter flange. INSTALLATION 1. If the upper front muffler hanger was removed, install the bolts into the frame. Tighten the bolts to 23 Nm (200 inch lbs.) torque. The insulators slip over the ends of the upper and lower muffler hangers. 2. Install the muffler into the extension pipe or catalytic converter flange. Install the clamp and tighten the nuts finger tight. 3. Install the tailpipe into the rear of the muffler. 4. Tighten the clamp nuts on the front and rear muffler hangers to 47 Nm (35 ft. lbs.) torque. 5. Lower the vehicle. 6. Start the engine and inspect for exhaust leaks and exhaust system contact with the body panels. Adjust the alignment, if needed. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Locations > Data Link Connector DLC Location Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Locations > Data Link Connector > Page 1956 Module Locations Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Locations > Data Link Connector > Page 1957 Module Locations Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Locations > Data Link Connector > Page 1958 Module Locations Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions Central Timer Module ( CTM ) High Option: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1961 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 Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1962 Electrostatic Discharge Symbol All Electrostatic Discharge (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, especially 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. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1963 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1964 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1965 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1966 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1967 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1968 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1969 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1970 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. 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. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1971 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1972 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1973 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1974 Central Timer Module ( CTM ) High Option: Diagnostic Aids 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 in 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 and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1975 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. 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 every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. 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 fuse circuit. 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 the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1976 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools 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 - This instrument is 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 vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. 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 non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1977 Central Timer Module ( CTM ) High Option: Connector Views Data Link Connector Pinout ABCM Connector Pinout Passenger Airbag Connector Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1978 Drivers Airbag Squib Connector Pinout Clockspring 2-Way Connector Pinout Central Timer Module (CTM) Connector "A" Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1979 Central Timer Module (CTM) Connector "B" Pinout Left Instrument Cluster Connector "A" (Black) Pinout Right Instrument Cluster Connector "B" (Gray) Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1980 Overhead Console Compass/Mini-Trip Computer Pinout Ambient Temperature Sensor Connector Pinout Door Jamb Switch Connector Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1981 Door Disarm Switch Connector Pinout Power Door Lock Switch Connections Door Lock Actuator Connector Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1982 Key-In Ignition Connector Pinout Multifunction Switch Connector Pinout Windshield Wiper Motor Connector Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1983 Central Timer Module ( CTM ) High Option: Electrical Diagrams Airbag System Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1984 Chrysler Collision Detection (CCD) Bus System Compass/Mini-Trip Computer System Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1985 Central Timer Module Block Diagram Power Lock System Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1986 Windshield Wiper System Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Service Precautions > Technician Safety Information Central Timer Module ( CTM ) High Option: Technician Safety Information Technician Safety Information DANGER!!! Engines produce carbon monoxide that is odorless, causes slower reaction time, and can lead to serious injury. When the engine is operating, keep service areas WELL VENTILATED or attach the vehicle exhaust system to the shop exhaust removal system. Set the parking brake and block the wheels before testing or repairing the vehicle. It is especially important to block the wheels on front-wheel drive vehicles; the parking brake does not hold the drive wheels. When servicing a vehicle, always wear eye protection, and remove any metal jewelry such as watchbands or bracelets that might make an inadvertent electrical contact. When diagnosing a body system problem, it is important to follow approved procedures where applicable. Following these procedures is very important to the safety of individuals performing diagnostic tests. 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. Servicing Sub-Assemblies SERVICING SUB-ASSEMBLIES Some components of the body system are intended to be serviced in 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 Service and Repair procedures should be serviced. DRB III Safety Information DRBIII SAFETY INFORMATION WARNING: Exceeding the limits of the DRB 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 DRB 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 function for the measurement. Do not try voltage or current measurements that may exceed the rated capacity. DRB III Safety Limits - Do not exceed the limits shown in the table below: - Voltage between any terminal and ground must not exceed 500v DC or 500v peak AC. - Use caution when measuring voltage above 25v DC or 25v AC. - The circuit being tested must be protected by a 10A fuse or circuit breaker. - Use the low current shunt to measure circuits up to 10A. Use the high current clamp to measure circuits exceeding 10A. - 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Service Precautions > Technician Safety Information > Page 1989 - 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 DRB away from spark plug or coil wires to avoid measuring error from outside interference. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Service Precautions > Technician Safety Information > Page 1990 Central Timer Module ( CTM ) High Option: Vehicle Damage Warnings Vehicle Damage Warnings 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. Road Testing A Complaint Vehicle ROAD TESTING A COMPLAINT VEHICLE 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 screen while in motion. Do not hang the DRB from the rear view mirror or operate it yourself. Have an assistant available to operate the DRB. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Service Precautions > Page 1991 Central Timer Module ( CTM ) High Option: Application and ID GLOSSARY OF ACRONYMS ACM ..................................................................................................................................................... ....................................... Airbag Control Module CAB ........................................................................ ................................................................................................................ Controller Anti-lock Brake CCD ................................................................................................................................... Chrysler Collision Detection (Vehicle Communications Bus) CMTC ................................................................. ................................................................................................................ Compass/mini-trip Computer CTM .................................................................................................................................... .......................................................... Central Timer Module DAB ....................................................... ...................................................................................................................................................... Driver Airbag DLC ............................................................................................................................... ................................................................... Data Link Connector DTC ............................................... ............................................................................................................................................ Diagnostic Trouble Code MIC ............................................................................................................................... ................................................... Mechanical Instrument Cluster PAB ................................................ ........................................................................................................................................................ Passenger Airbag PCM ....................................................................................................................... ................................................................ Powertrain Control Module PDC ........................................ .................................................................................................................................................. Power Distribution Center RKE ...................................................................................................................... ......................................................................... Remote Keyless Entry SQUIB ................................................................................................................................... Also Called Initiator (Located In Rear Of Airbag Module) VTSS ............................................................................ ..................................................................................................... Vehicle Theft Security System Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System Central Timer Module ( CTM ) High Option: Description and Operation Airbag System Airbag System Description AIRBAG SYSTEM The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front end collision. The system is most effective when used in conjunction with the seat belt system. The airbag control module (ACM) is an electronic module that monitors the airbag system for proper operation, stores Diagnostic Trouble Code (DTCs), controls the airbag warning lamp, monitors the pressure in the passenger airbag module 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 the diagnostic information DTCs to the technician through the DRB III via the CCD bus. Some circuits are tested continuously; others are checked only under certain circumstances. The warning lamp is driven with messages relayed to the Mechanical Instrument Cluster (MIC) from the ACM via the CCD bus. The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be observed by the customer. Whenever the ignition key is turned to the run or start" position, the airbag control module performs a lamp check by turning the AIRBAG warning lamp on for 6-8 seconds. If the lamp remains off, it means that the ACM has checked the system and found it to be free of discernible malfunctions. If the lamp remains on, there could be an active fault in the system or the circuit that operates the lamp may be shorted to ground. If the lamp comes on and stays on for a period longer than 6-8 seconds, then goes off, there is usually an intermittent problem in the system. Perform the WARNING LAMP CIRCUIT OPEN procedure in this book to find the cause of any customer complaint regarding the AIRBAG warning lamp, such as: Warning Lamp Does Not Illuminate - Warning Lamp Stays Illuminated WARNING! The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must first disconnect and isolate the battery negative (ground) cable. Then wait two minutes for the system capacitor to discharge before further system service. This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Never strike or kick the airbag control module, as it can damage the impact sensor or affect its calibration. If an airbag control module is accidentally dropped during service, the module must be scrapped and replaced with a new unit. Airbag Diagnostic Trouble Codes AIRBAG DIAGNOSTIC TROUBLE CODES Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Always begin by reading the diagnostic trouble codes using the DRB. This procedure begins with AIRBAG TEST 1A - Identifying Airbag System Problems. This will direct you to the specific test(s) that must be performed. Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures within this manual, diagnostic trouble codes are used as a diagnostic tool. ACTIVE CODES The codes become 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 are automatically erased 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 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 1994 "Loss of Ignition Run Only" code which is an active code only. A "stored" code indicates that there was an active code present at some time. However, the code currently may not be present as an active code, although another code could be. When a trouble code occurs, the airbag warning lamp illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. If a malfunction is detected a diagnostic trouble code is stored and will remain stored as long as the malfunction exists. When and if the malfunction ceases to exist, and ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of that same malfunction, the diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. If no obvious problems are found, erase stored codes, and with the ignition "on" wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 1995 Central Timer Module ( CTM ) High Option: Description and Operation Interior Lighting INTERIOR LIGHTING The courtesy lights are controlled by the CTM. The door switches are inputs to the CTM and the courtesy lights are outputs. The glove box lamp and the ash receiver lamp (if equipped) are not controlled by the CTM. They are hardwired to individual switches and fuses. The ignition key halo lamp is controlled by the CTM and will remain on for thirty seconds after the door is closed. The Highline CTM also provides for an illuminated entry option. If the CTM detects an unlock signal from the RKE transmitter, a door disarm switch input or the door jamb switch input, the interior courtesy lights will be turned on. The illuminated entry function is cancelled if the CTM senses an ignition "on" condition or the "lock" command from a valid key fob. If a door is left open or the dome lamp switch is left in the "on" position for more than fifteen minutes, the CTM will extinguish the lamps to avoid discharging the battery. If the lamps are turned on by rotation of the headlamp panel dimmer switch, the CTM will not be able to turn them off. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 1996 Central Timer Module ( CTM ) High Option: Description and Operation Central Timer Module INTRODUCTION Central Timer Module The Central Timer Module (CTM) is used to supply the vehicles occupants with visual and audible information, control various vehicle functions, and provide a centralized power distribution for the passenger compartment. To both provide and receive vehicle information the BCM is interfaced to the CCD Bus. Power for the CTM is supplied from three sources. Circuit F12 supplies power to the CTM in the START and RUN position. This circuit is protected by a 10 Amp fuse located in the junction block. Power is also supplied to the CTM on circuit F35. This circuit is HOT at all times and protected by a 20 Amp fuse located in the junction block. In the RUN position circuit V6 provides battery power to the CTM. This circuit is protected by a 20 Amp fuse located in the junction block. Ground for the ECM is provided by circuits Z1 and Z2. CCD Bus interface is accomplished on circuits D1 and D2. The D1 circuit is used for Bus (+), and D2 is for Bus (-). SYSTEM OPERATION Central Timer Module Two versions of the Central Timer Module (CTM) are available on this vehicle, a base version and a high-line version. The base version of the CTM is used on base models of the vehicle. The base version of the CTM combines the functions of a chime/buzzer module, an intermittent wipe module, and an ignition lamp time delay relay in a single unit. The high-line version of the CTM is used on highline vehicles. The high-line CTM provides all of the functions of the base version CTM, but also is used to control and integrate many of the additional electronic functions and features included on the high- line models. The high-line version of the CTM contains a central processing unit and interfaces with other modules in the vehicle on the Chrysler Collision Detection (CCD) data bus network. The CCD data bus network allows the sharing of sensor information. This helps to reduce wire harness complexity, reduce internal controller hardware, and reduce component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. The power lock and Remote Keyless Entry (RKE) systems are two of the systems that the high-line CTM controls. The high-line CTM receives hard-wired inputs from the power lock switches, CCD message inputs from the Powertrain Control Module (PCM) and Airbag Control Module (ACM), and coded radio signal inputs from the RKE transmitters. In response to those inputs, the internal programming of the CTM sends the proper outputs to control the power lock motors, the horn relay, and the courtesy lamps. Some of the features and functions of the power lock and Remote Keyless Entry (RKE) systems made possible because of the communication of the CTM on the CCD data bus network include: - A door-lock inhibit feature which prevents the power lock system from being energized with a power door lock switch if the key is in the ignition and/or the headlamps are on. However, the locks can still be operated manually with a key or energized with the RKE transmitter. - An enhanced accident response feature will prevent the doors from locking, then unlock both doors after receiving a CCD message from the ACM indicating a frontal impact requiring airbag deployment. This feature will also turn on the courtesy lamps ten seconds after receiving the ACM deployment message, if the CCD vehicle speed message from the PCM indicates the vehicle is not moving. Of course, these responses are dependent upon functional battery power and wiring circuitry following the impact. - Rolling door locks is a programmable feature of the power lock system. This feature will automatically lock all of the doors after the vehicle reaches a speed of about 24 kilometers-per-hour (15 miles-per-hour) or greater. This feature will also lock the doors if a door is opened, then closed again at any speed above 24 kilometers-per-hour (15 miles-per-hour). This feature can be enabled or disabled using the DRB scan tool and the proper Diagnostic Procedures. - A programmable feature of the RKE system is the enabling or disabling of the horn chirp following the RKE Lock function. This feature can be enabled or disabled using the DRB scan tool and the proper Diagnostic Procedures. The horn relay is one of the outputs that the high-line CTM can control. The high-line CTM is programmed to energize or de-energize the horn relay in response to certain inputs from the Vehicle Theft Security System (VTSS) and the Remote Keyless Entry (RKE) system. One of the features that the high-line CTM supports and controls is the Vehicle Theft Security System (VTSS). In the VTSS, the CTM receives hard-wired inputs from the door jamb, door lock cylinder, and ignition switches. The programming in the CTM allows it to process the information from these inputs and send control outputs to energize or de-energize the headlamp relay, horn relay, and the Security lamp. The CTM also sends CCD data bus messages to the Powertrain Control Module (PCM) to control the engine no-run feature of the VTSS The CTM also contains the receiver and control logic for the power lock and Remote Keyless Entry (RKE) systems, which are integrated into the arming, disarming, and triggering functions of the VTSS. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 1997 Both versions of the CTM are mounted under the passenger side end of the instrument panel, behind the instrument panel top cover and outboard of the glove box opening. For diagnosis of the base version of the CTM, refer to Wiper and Washer Systems or Chime/Buzzer Warning Systems. For diagnosis of the high-line version of the CTM or the CCD data bus, a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 1998 Central Timer Module ( CTM ) High Option: Description and Operation Chime System CHIME SYSTEM The chime system is built into the CTM. The system also supports an external chime request from the instrument cluster. This feature allows the instrument cluster to request a chime from the CTM for gauge problems and tell-tale warnings. There are two chime rates, Low; 50 chimes per minute for reminders and High; 180 chimes per minute for serious conditions that require immediate attention. The high rate chime sounds when the key is left in the ignition and the doors are open or the headlights are left on. The low rate chime sounds for any of the other conditions. There is a variable rate feature that allows the chime to sound continuously for key-in and headlamp warning as long as the door is open. The seat belt warning chime is activated for six seconds, and all other chime conditions will activate the chime once at the time the warning light on the cluster is illuminated. The chime will sound for the following conditions: - Ignition oft, key in ignition, driver's door open - Ignition oft, headlamps on, driver's door open - Seat belt warning - Check engine lamp illuminated (after prove-out) - Airbag lamp illuminated (after prove-out) - Anti-lock lamp illuminated (after prove-out if equipped) - Check gauges lamp illuminated - Low fuel - Low washer fluid - Engine temp critical - Engine oil press too low CIRCUIT OPERATION Seat Belt Warning Chime The seat belt chime is used to indicate to the operator that the seat belt is not fastened when the ignition switch is in the RUN position. The seat belt switch is normally OPEN with the seat belt buckled. Circuit G10 is connected between the Central Timer Module (CTM) and the switch. Ground for the switch is provided on circuit Z1. Exterior Lamp-On Warning Chime The exterior lamp ON chime is used to indicate to the operator that the lamps are ON with the drivers door OPEN and the key removed from the ignition. The Central Timer Module (CTM) uses information from circuit G26 to determine if the lamps are ON, and circuit G16 for drivers door ajar. Key-In Ignition Warning Chime The Key-In chime is used to indicate to the operator that the key is in the ignition with the driver's door OPEN. If the key is in the ignition, a ground path is completed from the G26 circuit at the Central Timer Module (CTM), through the CLOSED switch, to the Z1 circuit. The Z1 circuit is the ground circuit. When the driver's door is open the normally OPEN door ajar switch CLOSES completing a path to ground on circuit G16. The CTM processes this information and turns on the chime. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 1999 Central Timer Module ( CTM ) High Option: Description and Operation Airbag System Description AIRBAG SYSTEM The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front end collision. The system is most effective when used in conjunction with the seat belt system. The airbag control module (ACM) is an electronic module that monitors the airbag system for proper operation, stores Diagnostic Trouble Code (DTCs), controls the airbag warning lamp, monitors the pressure in the passenger airbag module 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 the diagnostic information DTCs to the technician through the DRB III via the CCD bus. Some circuits are tested continuously; others are checked only under certain circumstances. The warning lamp is driven with messages relayed to the Mechanical Instrument Cluster (MIC) from the ACM via the CCD bus. The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be observed by the customer. Whenever the ignition key is turned to the run or start" position, the airbag control module performs a lamp check by turning the AIRBAG warning lamp on for 6-8 seconds. If the lamp remains off, it means that the ACM has checked the system and found it to be free of discernible malfunctions. If the lamp remains on, there could be an active fault in the system or the circuit that operates the lamp may be shorted to ground. If the lamp comes on and stays on for a period longer than 6-8 seconds, then goes off, there is usually an intermittent problem in the system. Perform the WARNING LAMP CIRCUIT OPEN procedure in this book to find the cause of any customer complaint regarding the AIRBAG warning lamp, such as: Warning Lamp Does Not Illuminate - Warning Lamp Stays Illuminated WARNING! The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must first disconnect and isolate the battery negative (ground) cable. Then wait two minutes for the system capacitor to discharge before further system service. This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Never strike or kick the airbag control module, as it can damage the impact sensor or affect its calibration. If an airbag control module is accidentally dropped during service, the module must be scrapped and replaced with a new unit. Airbag Diagnostic Trouble Codes AIRBAG DIAGNOSTIC TROUBLE CODES Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Always begin by reading the diagnostic trouble codes using the DRB. This procedure begins with AIRBAG TEST 1A - Identifying Airbag System Problems. This will direct you to the specific test(s) that must be performed. Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures within this manual, diagnostic trouble codes are used as a diagnostic tool. ACTIVE CODES The codes become 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 are automatically erased 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 2000 A "stored" code indicates that there was an active code present at some time. However, the code currently may not be present as an active code, although another code could be. When a trouble code occurs, the airbag warning lamp illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. If a malfunction is detected a diagnostic trouble code is stored and will remain stored as long as the malfunction exists. When and if the malfunction ceases to exist, and ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of that same malfunction, the diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. If no obvious problems are found, erase stored codes, and with the ignition "on" wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Interior Lighting INTERIOR LIGHTING The courtesy lights are controlled by the CTM. The door switches are inputs to the CTM and the courtesy lights are outputs. The glove box lamp and the ash receiver lamp (if equipped) are not controlled by the CTM. They are hardwired to individual switches and fuses. The ignition key halo lamp is controlled by the CTM and will remain on for thirty seconds after the door is closed. The Highline CTM also provides for an illuminated entry option. If the CTM detects an unlock signal from the RKE transmitter, a door disarm switch input or the door jamb switch input, the interior courtesy lights will be turned on. The illuminated entry function is cancelled if the CTM senses an ignition "on" condition or the "lock" command from a valid key fob. If a door is left open or the dome lamp switch is left in the "on" position for more than fifteen minutes, the CTM will extinguish the lamps to avoid discharging the battery. If the lamps are turned on by rotation of the headlamp panel dimmer switch, the CTM will not be able to turn them off. Central Timer Module INTRODUCTION Central Timer Module The Central Timer Module (CTM) is used to supply the vehicles occupants with visual and audible information, control various vehicle functions, and provide a centralized power distribution for the passenger compartment. To both provide and receive vehicle information the BCM is interfaced to the CCD Bus. Power for the CTM is supplied from three sources. Circuit F12 supplies power to the CTM in the START and RUN position. This circuit is protected by a 10 Amp fuse located in the junction block. Power is also supplied to the CTM on circuit F35. This circuit is HOT at all times and protected by a 20 Amp fuse located in the junction block. In the RUN position circuit V6 provides battery power to the CTM. This circuit is protected by a 20 Amp fuse located in the junction block. Ground for the ECM is provided by circuits Z1 and Z2. CCD Bus interface is accomplished on circuits D1 and D2. The D1 circuit is used for Bus (+), and D2 is for Bus (-). SYSTEM OPERATION Central Timer Module Two versions of the Central Timer Module (CTM) are available on this vehicle, a base version and a high-line version. The base version of the CTM is used on base models of the vehicle. The base version of the CTM combines the functions of a chime/buzzer module, an intermittent wipe module, and an ignition lamp time delay relay in a single unit. The high-line version of the CTM is used on highline vehicles. The high-line CTM provides all of the functions of the base version CTM, but also is used to control and integrate many of the additional electronic functions and features included on the high- line models. The high-line version of the CTM contains a central processing unit and interfaces with other modules in the vehicle on the Chrysler Collision Detection (CCD) data bus network. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 2001 The CCD data bus network allows the sharing of sensor information. This helps to reduce wire harness complexity, reduce internal controller hardware, and reduce component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. The power lock and Remote Keyless Entry (RKE) systems are two of the systems that the high-line CTM controls. The high-line CTM receives hard-wired inputs from the power lock switches, CCD message inputs from the Powertrain Control Module (PCM) and Airbag Control Module (ACM), and coded radio signal inputs from the RKE transmitters. In response to those inputs, the internal programming of the CTM sends the proper outputs to control the power lock motors, the horn relay, and the courtesy lamps. Some of the features and functions of the power lock and Remote Keyless Entry (RKE) systems made possible because of the communication of the CTM on the CCD data bus network include: - A door-lock inhibit feature which prevents the power lock system from being energized with a power door lock switch if the key is in the ignition and/or the headlamps are on. However, the locks can still be operated manually with a key or energized with the RKE transmitter. - An enhanced accident response feature will prevent the doors from locking, then unlock both doors after receiving a CCD message from the ACM indicating a frontal impact requiring airbag deployment. This feature will also turn on the courtesy lamps ten seconds after receiving the ACM deployment message, if the CCD vehicle speed message from the PCM indicates the vehicle is not moving. Of course, these responses are dependent upon functional battery power and wiring circuitry following the impact. - Rolling door locks is a programmable feature of the power lock system. This feature will automatically lock all of the doors after the vehicle reaches a speed of about 24 kilometers-per-hour (15 miles-per-hour) or greater. This feature will also lock the doors if a door is opened, then closed again at any speed above 24 kilometers-per-hour (15 miles-per-hour). This feature can be enabled or disabled using the DRB scan tool and the proper Diagnostic Procedures. - A programmable feature of the RKE system is the enabling or disabling of the horn chirp following the RKE Lock function. This feature can be enabled or disabled using the DRB scan tool and the proper Diagnostic Procedures. The horn relay is one of the outputs that the high-line CTM can control. The high-line CTM is programmed to energize or de-energize the horn relay in response to certain inputs from the Vehicle Theft Security System (VTSS) and the Remote Keyless Entry (RKE) system. One of the features that the high-line CTM supports and controls is the Vehicle Theft Security System (VTSS). In the VTSS, the CTM receives hard-wired inputs from the door jamb, door lock cylinder, and ignition switches. The programming in the CTM allows it to process the information from these inputs and send control outputs to energize or de-energize the headlamp relay, horn relay, and the Security lamp. The CTM also sends CCD data bus messages to the Powertrain Control Module (PCM) to control the engine no-run feature of the VTSS The CTM also contains the receiver and control logic for the power lock and Remote Keyless Entry (RKE) systems, which are integrated into the arming, disarming, and triggering functions of the VTSS. Both versions of the CTM are mounted under the passenger side end of the instrument panel, behind the instrument panel top cover and outboard of the glove box opening. For diagnosis of the base version of the CTM, refer to Wiper and Washer Systems or Chime/Buzzer Warning Systems. For diagnosis of the high-line version of the CTM or the CCD data bus, a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. Chime System CHIME SYSTEM The chime system is built into the CTM. The system also supports an external chime request from the instrument cluster. This feature allows the instrument cluster to request a chime from the CTM for gauge problems and tell-tale warnings. There are two chime rates, Low; 50 chimes per minute for reminders and High; 180 chimes per minute for serious conditions that require immediate attention. The high rate chime sounds when the key is left in the ignition and the doors are open or the headlights are left on. The low rate chime sounds for any of the other conditions. There is a variable rate feature that allows the chime to sound continuously for key-in and headlamp warning as long as the door is open. The seat belt warning chime is activated for six seconds, and all other chime conditions will activate the chime once at the time the warning light on the cluster is illuminated. The chime will sound for the following conditions: - Ignition oft, key in ignition, driver's door open - Ignition oft, headlamps on, driver's door open - Seat belt warning - Check engine lamp illuminated (after prove-out) - Airbag lamp illuminated (after prove-out) - Anti-lock lamp illuminated (after prove-out if equipped) - Check gauges lamp illuminated - Low fuel - Low washer fluid - Engine temp critical - Engine oil press too low Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 2002 CIRCUIT OPERATION Seat Belt Warning Chime The seat belt chime is used to indicate to the operator that the seat belt is not fastened when the ignition switch is in the RUN position. The seat belt switch is normally OPEN with the seat belt buckled. Circuit G10 is connected between the Central Timer Module (CTM) and the switch. Ground for the switch is provided on circuit Z1. Exterior Lamp-On Warning Chime The exterior lamp ON chime is used to indicate to the operator that the lamps are ON with the drivers door OPEN and the key removed from the ignition. The Central Timer Module (CTM) uses information from circuit G26 to determine if the lamps are ON, and circuit G16 for drivers door ajar. Key-In Ignition Warning Chime The Key-In chime is used to indicate to the operator that the key is in the ignition with the driver's door OPEN. If the key is in the ignition, a ground path is completed from the G26 circuit at the Central Timer Module (CTM), through the CLOSED switch, to the Z1 circuit. The Z1 circuit is the ground circuit. When the driver's door is open the normally OPEN door ajar switch CLOSES completing a path to ground on circuit G16. The CTM processes this information and turns on the chime. Compass Mini-Trip Computer (CMTC) SYSTEM OPERATION A mini trip computer is available on this model to provide several electronic functions and features. The trip computer contains a central processing unit and interfaces with other modules in the vehicle on the Chrysler Collision Detection (CCD) data bus network. The CCD data bus network allows the sharing of sensor information. This helps to reduce wire harness complexity, reduce internal controller hardware, and reduce component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. Some of the functions and features that the trip computer supports and/or controls, include the following display options: Compass and temperature - Trip odometer (ODO) - Average fuel economy (AVG ECO) - Instant fuel economy (ECO) - Distance to empty (DTE) - Elapsed time (ET) - Blank display Momentarily depressing and releasing the Step button when the ignition switch is in the On position will cause the overhead console display to step sequentially through the listed display options. Momentarily depressing and releasing the U.S./Metric button toggles the display between U.S. and Metric measurements. For more information on the trip computer features and functions, refer to the owner 5 manual in the vehicle glove box. The push button (Step and U.S./Metric) switches and the compass flux-gate unit are integral to the trip computer, compass, and thermometer display module unit. The ambient temperature sensor is hard-wired to the module. Data input for all other trip computer functions is received through CCD data bus messages. The trip computer uses its internal programming and all of these inputs to calculate and display the requested data. If the data displayed is incorrect, perform the self-diagnostic tests as described. If these tests prove inconclusive, the use of a DRB scan tool and the proper Diagnostic Procedures are recommended for further testing of the trip computer and the CCD data bus. The trip computer, compass, and thermometer display module cannot be repaired, and are only available for service as a unit. If faulty or damaged, the complete module must be replaced. COMPASS MINI-TRIP COMPUTER (CMTC) This system, located in the overhead console, displays information on outside temperature, compass direction and trip information. Compass And Temperature Display This display provides the outside temperature and one of eight compass readings to indicate the direction the vehicle is facing. Trip Odometer (ODO) Shows the distance travelled since the last reset. Average Fuel Economy (AVE ECO) Shows the average fuel economy in MPG (miles per gallon) or L/100Km since the last reset. Instantaneous Fuel Economy Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 2003 Shows the fuel economy for the last few seconds in MPG or L/100Km. Distance to Empty (DTE) Shows the estimated distance that can be travelled with the fuel remaining in the tank. This is calibrated using the MPG for the last few minutes. Elapsed Time (ET) Shows the accumulated ignition on time since the last reset. Step Button Press this button to cycle through all the mini-trip computer displays. US/M Button Press this button to convert all vehicle displays from US to metric to US. To Reset the Display Press the Step and US/M buttons simultaneously for at least two seconds and all resettable conditions will be rest. This will occur only if a resettable function (AVG ECO, ECO, ET) is currently being displayed. Automatic Compass Calibration This compass is self-calibrating which eliminates the need to manually set the compass. When the vehicle is new, the compass may appear erratic and the CAL symbol will be displayed. After completing three 360° turns in an area free from large metal or metallic objects, the CAL symbol will turn off and the compass will function normally. Compass Variance Compass Variance is the difference between Magnetic North and Geographic North. In some areas of the country, the difference between Magnetic and Geographic North is great enough to cause the compass to give false readings. If this occurs, the compass variance must be set. Enhanced Accident Response (Highline CTM only) If the Airbag Control Module (ACM) deploys the airbags, a message is transmitted over the CCD bus to the CTM module to unlock the doors. The interior lights will be turned on when the vehicle speed message on the CCD bus indicates 0 mph or the message is not present. In addition to unlocking the doors, the door lock feature will be disabled for a predetermined amount of time following the deployment. Once the ignition key has been cycled to the "off" position, normal operation will resume. Disclaimers DISCLAIMERS All information, illustrations, and specifications contained in this database are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice. Glossary of Terms/Acronyms GLOSSARY OF ACRONYMS ACM ..................................................................................................................................................... ....................................... Airbag Control Module CAB ........................................................................ ................................................................................................................ Controller Anti-lock Brake CCD ................................................................................................................................... Chrysler Collision Detection (Vehicle Communications Bus) CMTC ................................................................. ................................................................................................................ Compass/mini-trip Computer CTM .................................................................................................................................... .......................................................... Central Timer Module DAB ....................................................... ...................................................................................................................................................... Driver Airbag DLC ............................................................................................................................... ................................................................... Data Link Connector DTC ............................................... ............................................................................................................................................ Diagnostic Trouble Code MIC ............................................................................................................................... ................................................... Mechanical Instrument Cluster PAB ................................................ ........................................................................................................................................................ Passenger Airbag PCM ....................................................................................................................... ................................................................ Powertrain Control Module PDC ........................................ .................................................................................................................................................. Power Distribution Center RKE ...................................................................................................................... ......................................................................... Remote Keyless Entry SQUIB ................................................................................................................................... Also Called Initiator (Located In Rear Of Airbag Module) VTSS ............................................................................ ..................................................................................................... Vehicle Theft Security System Introduction SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION The body system consists of four modules that communicate over the (CCD) bus (Chrysler Collision Detection multiplex system). There are two additional modules, the Powertrain Control Module (PCM) and the Controller Anti-lock Brake (CAB) that are not part of the body system, but do utilize the CCD bus for communication. The CAB also utilizes the bus for diagnostics. The PCM sends and receives messages on the CCD bus, Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 2004 however diagnostics are performed through the Serial Communication Interface or (SCI), the same as last year. All of the information about the functioning of all the systems is organized, controlled, and communicated by the CCD bus. Through the CCD bus, information about the operation of vehicle components and circuits is relayed quickly to the appropriate module(s). All modules receive all the information transmitted on the bus even though a module may not require all information to perform it's function. It will only respond to messages "addressed" to it through a binary coding process. This method of data transmission significantly reduces the complexity of the wiring in the vehicle and the size of the wiring harnesses. Mechanical Instrument Cluster (MIC) MECHANICAL INSTRUMENT CLUSTER (MIC) The MIC is available in 4 different versions. Two of the versions are Canadian clusters. There is a Highline and a low line cluster available. The difference between Highline and low line is the addition of a tachometer in the Highline. In order to accomplish this, the fuel level gauge is reduced in size and the oil pressure gauge is relocated. The cluster positions it's gauges with bus messages received from the Powertrain Control Module (PCM). The odometer is a Liquid Crystal Display (LCD). The cluster will provide bus bias and the PCM provides termination. The MIC has an internal self-test routine that can be accessed by pushing and holding the trip odometer and rotating the key to the on position. The cluster will then place all the gauges at their calibration points and will light all the CCD driven tell-tales. It will also light all the segments of the LCD display for a visual verification check. All of the red warning symbols are non-replaceable LED's, amber tell-tales are serviceable incandescent bulbs. The MIC is not addressable with the DRB. All diagnostics are performed with the on-board sequence described above. If there are faults found during the diagnostic routine, the cluster will report them on the LCD odometer display. For further information about the diagnostic routine and the explanation of faults, please refer to Powertrain Management/Computers and Control Systems/Testing and Inspection/. Power Door Lock System POWER DOOR LOCKS The CTM controls the door lock actuator assemblies to handle locking and unlocking with the key fob or interior switch. There is also a door lock inhibit feature that prevents power locking of the doors if the ignition is off and the key is in the ignition. Automatic or "rolling locks" are included as a DRB programmable feature. If the vehicle is moving approximately 15 mph and approximately 10 degrees of throttle opening is seen by the PCM, (the PCM will send this info to the CTM via the CCD bus) indicating acceleration, the CTM will cycle the lock actuators. Remote Keyless Entry (RKE) /Vehicle Theft Security System (VTSS) INTRODUCTION Remote Keyless Entry System The Remote Keyless Entry (RKE) system is a radio frequency system that allows the use of a remote transmitter to control the power lock and illuminated entry systems. If the vehicle is so equipped, the RKE transmitter can also control the vehicle theft alarm system. The RKE system consists of the remote key fob transmitter and a receiver with program logic, which is integral to the high-line version of the Central Timer Module (CTM). The RKE system can retain the vehicle access codes of up to four transmitters. The transmitter codes are retained in memory, even if the battery is disconnected. If a transmitter is faulty or lost, new transmitter vehicle access codes can be programmed into the system using a DRE scan tool and the proper Diagnostic Procedures. The high line Central Timer Module (CTM) provides for Remote Keyless Entry (RKE) and the Vehicle Theft Security System (VTSS). The base CTM is not able to provide these functions. The presence of either of these options dictates that the vehicle be equipped with a Highline CTM. The VTSS system monitors the door jamb switches and ignition switch to detect unauthorized entry into the vehicle. Once the vehicle is "armed", any one of these inputs can cause the VTSS system to be tripped. Once tripped, the horn and lights will pulse for 3 minutes and if an attempt is made to start the engine, it will start and stall. If the trigger condition is still present, the lights will continue to flash for an additional 15 minutes. After 15 minutes the system will stop pulsing the lights and return to the "armed" state. The cause of the last 4 alarm triggers is stored by the CTM and may be retrieved by the DRB. The system may be disarmed by either an unlock command from a valid RKE key fob or by using a key in either door. Both front door key cylinders are equipped with disarm switches. There is also a VTSS lamp on the dash that provides information to the driver about the state of the vehicle theft system. The RKE system is placed in the programming mode by the DRB. The system will stores up to four key fob codes. Through the DRB, programming of one key fob without deleting the others is possible. If the key fob is stolen, all the fob codes stored previously may be erased to provide the owner of the vehicle with an extra sense of security. Wiper System SPEED SENSITIVE INTERMITTENT WIPERS The Dakota trucks equipped with a Highline Central Timer Module (CTM) will utilize speed sensitive intermittent wipers. Only a Highline CTM will be able to support this feature. A base CTM will provide for intermittent wipers without the speed sensitive feature. The low and high speeds Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 2005 are controlled through the wiper stalk switch. The intermittent portion of the wiper control is handled by the CTM through the intermittent wiper relay. When the module detects a decrease in delay time as selected by the driver, an immediate wipe of the windshield takes place and the new delay interval is implemented. This feature is present only on the Highline CTM. hen the vehicle is moving at speeds at or below 10 mph, the delay time ranges from 1 to 36 seconds. When the speed rises above 10 mph, the delay times are cut in half for a range of 1/2 to 18 seconds. The speed signal is provided to the CTM from the PCM over the CCD bus. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Central Timer Module ( CTM ) High Option: Initial Inspection and Diagnostic Overview VEHICLE COMMUNICATION The Chrysler Collision Detection multiplex system (CCD bus) consists of a twisted pair of wires. These wires run from one module to another. They receive and deliver coded information between the modules. The information is coded to identify the message as well as the importance of the message. When there are multiple messages trying to access the CCD bus at one time, the code determines the message that has higher priority, and is then allowed to access the bus first. The two wires of the twisted pair that make up the CCD multiplex system are called "bus+" (bus plus) and "bus-" (bus minus) respectively. Each wire has a measurable voltage level of roughly 2.5 volts. In order to maintain the 2.5 volts on each line and provide a means of transportation for the coded messages, there is a "voltage divider network" located in the module that supplies bus bias or voltage. Along with the module that supplies bias, some modules provide termination. Bias is the voltage necessary to make the bus operational. At least one point of termination is necessary, some systems use more than one. Some modules are capable of biasing and terminating the bus by themselves. Termination in the circuitry (a 120 ohm resistor placed across the bus) is required to complete the voltage divider network and also provides some electromagnetic protection for the bus. In this vehicle, the bias is supplied by the instrument cluster and termination is provided by the Powertrain Control Module (PCM). Without termination, voltage on the bus goes to approximately 5 volts on one wire and 0 volts on the other wire. In this application, the instrument cluster supplies bus bias and termination and the PCM supplies an additional point of termination. NOTE: Communication over the bus is essential to the proper operation of the vehicle's on-board diagnostic systems and the DRB. Problems with the operation of the bus or DRB must be corrected before proceeding with diagnostic testing. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2008 Central Timer Module ( CTM ) High Option: Component Tests and General Diagnostics DIAGNOSTICS The Central Timer Module (CTM) is fully addressable with DRB III and it is the recommended method for diagnosis. The CTM reports 6 Diagnostic Trouble Codes. All of the inputs to the CTM can be read with DRB and the outputs can be actuated. If the inputs are OK and the outputs can be cycled with the DRB, the problem is "USUALLY" the Central Timer Module. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2009 Central Timer Module ( CTM ) High Option: Scan Tool Testing and Procedures DRB III Does Not Power Up (Blank Screen) DRB III ERROR MESSAGES AND BLANK SCREEN Under normal operation, the DRB will display one of only two error messages: - User-Requested WARM Boot - User-Requested COLD Boot If the DRB should display any other error message, record the entire display and call the MDS Hotline, or call for information and assistance at 1-800-825-8737. This is a sample of such an error message display: VER: 2.14 date: 26 Jul93 file: key_itf.cc date: Jul 26 1993 line: 548 err. Ox1 User-Requested COLD boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. DRB III DOES NOT POWER UP (BLANK SCREEN) 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. If all connection are proper between the DRB and the Vehicle or other devices, and the vehicle battery is fully charged, an inoperative DRB may be the result of faulty cable of vehicle wiring. Perform Vehicle Communication TEST 1A. DRB III Safety Limits WARNING: Never exceed DRBIII safety limits! Display Is Not Visible DISPLAY IS NOT VISIBLE Low temperatures will effect the visibility of the display. Adjust the contrast to compensate for this condition. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Adjustments > Setting the Compass Central Timer Module ( CTM ) High Option: Adjustments Setting the Compass SETTING THE COMPASS The compass/mini-trip module is self-calibrated and requires no adjustment. The word CAL will be displayed to indicate that the compass is in the fast calibrating mode. CAL will turn off after the vehicle has gone in three complete circles without stopping, in an area free of magnetic disturbance. If the module displays the temperature while the compass is blank or shows a false reading, the vehicle must be demagnetized. If the compass still goes blank after the vehicle is demagnetized, the compass/mini-trip module must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Adjustments > Setting the Compass > Page 2012 Central Timer Module ( CTM ) High Option: Adjustments Setting the Variance SETTING THE VARIANCE Setting The Variance Variance is the difference between magnetic north and geographic north. To determine the variance for the area you are in, refer to the zone map provided. The number shown for your area is the variance number for your area. 1. Set the Compass/Mini-Trip Console (CMTC) to compass/temperature mode. 2. Press and hold down the reset button for 5 seconds. NOTE: If the buttons are held for 10 seconds instead of 5, the CMTC will set the variance to 8 and enter the fast calibration mode. 3. The VAR light will come on and the last variance setting will be displayed. 4. Press the STEP button to set the zone number. 5. Press the US/M button and resume normal operation. NOTE: Do not attach any magnetic device such as a magnetic CB antenna to the vehicle. This can cause the compass to give false readings. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Service and Repair > Maintenance and Service Information Central Timer Module ( CTM ) High Option: Service and Repair Maintenance and Service Information MAINTENANCE AND SERVICE INFORMATION When replacing a blown fuse, it is important to use only a fuse having the correct amperage rating. The use of a fuse with a rating other than indicated may result in a dangerous electrical system overload. If a properly rated fuse continues to blow, it indicates a problem in the circuit that must be corrected. When replacing any bulbs, do not touch the new bulb with your fingers. Oil contamination will severely shorten bulb life. If the bulb comes in contact with an oily surface, clean the bulb with rubbing alcohol. WARNING: Failure to have the airbag system properly serviced by an authorized dealer may lead to possible injury in the event of an accident. Aside from the maintenance required in response to the airbag lamp conditions, an inspection of the mechanical and electrical components of the system is included in the regular maintenance service recommended for every 3 years or 30,000 miles. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Service and Repair > Maintenance and Service Information > Page 2015 Central Timer Module ( CTM ) High Option: Service and Repair Setting the Compass SETTING THE COMPASS The compass/mini-trip module is self-calibrated and requires no adjustment. The word CAL will be displayed to indicate that the compass is in the fast calibrating mode. CAL will turn off after the vehicle has gone in three complete circles without stopping, in an area free of magnetic disturbance. If the module displays the temperature while the compass is blank or shows a false reading, the vehicle must be demagnetized. If the compass still goes blank after the vehicle is demagnetized, the compass/mini-trip module must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Service and Repair > Maintenance and Service Information > Page 2016 Central Timer Module ( CTM ) High Option: Service and Repair Setting the Variance SETTING THE VARIANCE Setting The Variance Variance is the difference between magnetic north and geographic north. To determine the variance for the area you are in, refer to the zone map provided. The number shown for your area is the variance number for your area. 1. Set the Compass/Mini-Trip Console (CMTC) to compass/temperature mode. 2. Press and hold down the reset button for 5 seconds. NOTE: If the buttons are held for 10 seconds instead of 5, the CMTC will set the variance to 8 and enter the fast calibration mode. 3. The VAR light will come on and the last variance setting will be displayed. 4. Press the STEP button to set the zone number. 5. Press the US/M button and resume normal operation. NOTE: Do not attach any magnetic device such as a magnetic CB antenna to the vehicle. This can cause the compass to give false readings. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Service and Repair > Page 2017 Central Timer Module ( CTM ) High Option: Tools and Equipment REQUIRED TOOLS AND EQUIPMENT DRB III (diagnostic read-out box) Jumper Wires Ohmmeter Voltmeter Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 18-13-97A > Jun > 97 > PCM - Cold Engine Idle Fluctuation Powertrain Control Module: Customer Interest PCM - Cold Engine Idle Fluctuation NO: 18-13-97 Rev.A GROUP: Vehicle Performance DATE: Jun. 13, 1997 SUBJECT: Cold Engine Idle Fluctuation THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-13-97 DATED MAR. 14, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL CHANGES ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES PART NUMBER AND MODEL ADDITIONS. MODELS: **1997 (AB) Ram Van/Wagon ** 1997 (AN) Dakota **1997 (BR) Ram Truck** NOTE: THIS BULLETIN APPLIES TO 1997 VEHICLES WITH A 3.9L ENGINE BUILT PRIOR TO THE FOLLOWING DATES: (AB) JUN. 2, 1997 (MDH 0602XX), (AN) FEB. 19, 1997 (MDH 0219XX) (BR) JUN. 2, 1997 (MDH 0602XX). SYMPTOM/CONDITION: The vehicle may exhibit an idle fluctuation following a cold engine start. This condition is most noticeable while the transmission selector is in either the park or neutral position. The incidence for idle fluctuation increases with lower engine start temperatures and is less likely to occur in a warm engine. DIAGNOSIS: Verify that the vehicle engine and powertrain control module are close to ambient temperature. Set the vehicle parking brake, place the transmission selector in Park or Neutral, and start the engine. Without giving the engine any throttle assist, allow time for the fuel system to enter "closed loop" fuel control and warm to normal operating temperatures. The engine idle speed should gradually decrease as the engine warms. If the engine exhibits idle fluctuation during engine warm-up, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves replacing the Powertrain Control Module (PCM) with revised parts. 1. Following service manual procedures, replace the PCM. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 18-13-97A > Jun > 97 > PCM - Cold Engine Idle Fluctuation > Page 2026 2. Type the necessary information on the Authorized Modification Label p/n 04275086. Attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-03-92 0.7 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 18-21-98 > Jun > 98 > Powertrain Control Module - Service Precaution Powertrain Control Module: All Technical Service Bulletins Powertrain Control Module - Service Precaution NO: 18-21-98 GROUP: Vehicle Performance DATE: Jun. 5, 1998 SUBJECT: Powertrain Control Module (PCM) Service Caution MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1997 - 1998 (TJ) Wrangler 1996-1998 (XJ) Cherokee 1996-1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (European Market) DISCUSSION: Whenever any connector on the PCM is disconnected, the ignition switch must be in the "OFF" position for a minimum of 5 seconds before connector removal. It has been found under certain key "ON" or momentary key "OFF" conditions, when the black connector is unplugged, the PCM may attempt to write information to the EEPROM processor within the PCM. Sometimes this inadvertent write will set the target charging voltage to 0 (zero) volts. The result will prevent the charging system from charging the battery. If this occurs, the only correction is PCM replacement. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 18-13-97A > Jun > 97 > PCM - Cold Engine Idle Fluctuation Powertrain Control Module: All Technical Service Bulletins PCM - Cold Engine Idle Fluctuation NO: 18-13-97 Rev.A GROUP: Vehicle Performance DATE: Jun. 13, 1997 SUBJECT: Cold Engine Idle Fluctuation THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-13-97 DATED MAR. 14, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL CHANGES ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES PART NUMBER AND MODEL ADDITIONS. MODELS: **1997 (AB) Ram Van/Wagon ** 1997 (AN) Dakota **1997 (BR) Ram Truck** NOTE: THIS BULLETIN APPLIES TO 1997 VEHICLES WITH A 3.9L ENGINE BUILT PRIOR TO THE FOLLOWING DATES: (AB) JUN. 2, 1997 (MDH 0602XX), (AN) FEB. 19, 1997 (MDH 0219XX) (BR) JUN. 2, 1997 (MDH 0602XX). SYMPTOM/CONDITION: The vehicle may exhibit an idle fluctuation following a cold engine start. This condition is most noticeable while the transmission selector is in either the park or neutral position. The incidence for idle fluctuation increases with lower engine start temperatures and is less likely to occur in a warm engine. DIAGNOSIS: Verify that the vehicle engine and powertrain control module are close to ambient temperature. Set the vehicle parking brake, place the transmission selector in Park or Neutral, and start the engine. Without giving the engine any throttle assist, allow time for the fuel system to enter "closed loop" fuel control and warm to normal operating temperatures. The engine idle speed should gradually decrease as the engine warms. If the engine exhibits idle fluctuation during engine warm-up, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves replacing the Powertrain Control Module (PCM) with revised parts. 1. Following service manual procedures, replace the PCM. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 18-13-97A > Jun > 97 > PCM - Cold Engine Idle Fluctuation > Page 2036 2. Type the necessary information on the Authorized Modification Label p/n 04275086. Attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-03-92 0.7 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 080197 > Feb > 97 > PCM - Wire Harness Connector Repair Package Technical Service Bulletin # 080197 Date: 970203 Discussion NO: 08-01-97 GROUP: Electrical EFFECTIVE DATE: Feb. 3, 1997 SUBJECT: JTEC Powertrain Control Module Wiring Harness Connector Repair Packages MODELS: 1996 - 1997 (AB) Ram Van 1996 - 1997 (AN) Dakota 1996 - 1997 (BR) Ram Truck 1996 - 1997 (SR) Viper/Viper GTS 1997 (TJ) Wrangler 1996-1997 (XJ) Cherokee 1996-1997 (ZJ) Grand Cherokee 1996 - 1997 (ZG) Grand Cherokee (International Markets) DISCUSSION: The following Jeep/Truck Engine Controller (JTEC) Powertrain Control Module (PCM) electrical connector and terminal repair components are available to aid in powertrain electrical wiring repairs. These components allow repairs of individual wiring circuits without the need to replace the entire engine harness. If you have determined that a powertrain customer complaint could be related to a poor electrical connection, the PCM connectors should be inspected. The following diagnosis and inspection can be utilized to determine the condition of the PCM connectors and their terminals. Diagnosis Inspection of the connector begins with a thorough inspection of the insulator. 1. Record the radio station presets. 2. Disconnect and isolate the battery negative cable (both batteries should be disconnected if the vehicle is equipped with a 5.9L Cummins Diesel). 3. Disconnect the connector from the PCM. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 080197 > Feb > 97 > PCM - Wire Harness Connector Repair Package > Page 2041 4. Inspect the connector lock tab on the side of the insulator (Figure 1) for damage and replace the insulator if damaged is identified. 5. Gently pull on the wires of the connector one at a time. The initial and final locks will need to be inspected if the wire pulls out of the insulator. 6. Push in the single lock tab on the side of the insulator (Figure 2). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 080197 > Feb > 97 > PCM - Wire Harness Connector Repair Package > Page 2042 7. Then, insert the probe of special tool 6934 (Figure 3) into the back of the insulator cavity. 8. Grasp the wire and tool 6934 and slowly remove the wire and terminal from the insulator (Figure 4). Then, remove the strain relief and wire seal (Figure 1). 9. Inspect the initial and final locks of the insulator (Figure 1) for damage. Replace the insulator if there are any signs of damage. 10. Inspect all wire terminals for corrosion. If corrosion is evident, replace the terminal ends and the insulator. 11. To verify how secure the cavity of the terminal fits onto the PCM pins, insert and remove the wire end terminal onto the mating pin of the PGM. Then, rotate the terminal 90°, 180°, and 270° while inserting and removing the terminal from the pin. If any connection is loose, replace the wire end terminal. 12. Inspect and replace the PCM connector cover or connector plug if the locking tabs are damaged. Perform the following Repair Procedure if damage or wear is identified in any component of the insulator or terminals (including corrosion on the terminal). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 080197 > Feb > 97 > PCM - Wire Harness Connector Repair Package > Page 2043 PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves replacing either the insulator or terminals of the PCM connectors. Insulator Replacement NOTE: THIS PROCEDURE ASSUMES THAT THE WIRE END TERMINALS WERE ALREADY REMOVED WHEN THE DIAGNOSIS WAS PERFORMED. 1. Utilizing the appropriate insulator (see Parts Required list), install the wire and terminal into the appropriate cavities of the insulator. Refer to the appropriate Service Manual, Group 8W-80, for proper terminal-to-cavity locations in the connector. Fully seat all terminals into the insulator. 2. Push in the two lock tabs on the side of the connector (Figure 5). 3. Install the connector into the proper cavity of the PCM. 4. Connect the battery negative cable (both batteries should be connected if the vehicle is equipped with a 5.9L Cummins Diesel). 5. Reset the clock and reprogram the radio stations to the presets recorded in step 1 of the Diagnosis. Wire End Terminal Replacement NOTE: THIS PROCEDURE ASSUMES THAT THE DAMAGED OR CORRODED WIRE END TERMINAL WAS ALREADY REMOVED WHEN THE DIAGNOSIS WAS PERFORMED. 1. The wire of the terminal end that needs repaired will need to be cut and discarded. Measure approximately three inches down the wire from the end of the terminal and cut the wire. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 080197 > Feb > 97 > PCM - Wire Harness Connector Repair Package > Page 2044 2. Cut one of the wires with terminal ends from package P/N 04882087 in half. This action will allow for two repairs if necessary. 3. Remove approximately one inch of insulation from the wires that are being spliced together. 4. Place a piece of heat shrink tubing over one of the wires. Make sure the tubing will be long enough to cover and seal the entire repair. 5. Spread the strands of the wire apart on each part of the exposed wire (Example 1) (Figure 6). 6. Push the ends of the two wires together until the strands of wire are close to the insulation (Example 2) (Figure 6). 7. Twist the wires together (Example 3) (Figure 6). 8. Solder the connection together using rosin core type solder only. Do not use acid core solder. 9. Center the heat shrink tubing over the joint and heat the tubing using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 10. Secure the wires to the existing harness to prevent chafing or damage to the insulation. 11. Install the wire terminal end into the appropriate cavity of the insulator. Fully seat all terminals into the insulator. 12. Push in the single lock tab on the side of the connector (Figure 5). 13. Install the connector into the proper cavity of the PCM. 14. Connect the battery negative cable (both batteries should be connected if the vehicle is equipped with a 5.9L Cummins Diesel). 15. Reset the clock and reprogram the radio stations to the presets recorded in step 1 of the Diagnosis. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 18-21-98 > Jun > 98 > Powertrain Control Module - Service Precaution Powertrain Control Module: All Technical Service Bulletins Powertrain Control Module - Service Precaution NO: 18-21-98 GROUP: Vehicle Performance DATE: Jun. 5, 1998 SUBJECT: Powertrain Control Module (PCM) Service Caution MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1997 - 1998 (TJ) Wrangler 1996-1998 (XJ) Cherokee 1996-1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (European Market) DISCUSSION: Whenever any connector on the PCM is disconnected, the ignition switch must be in the "OFF" position for a minimum of 5 seconds before connector removal. It has been found under certain key "ON" or momentary key "OFF" conditions, when the black connector is unplugged, the PCM may attempt to write information to the EEPROM processor within the PCM. Sometimes this inadvertent write will set the target charging voltage to 0 (zero) volts. The result will prevent the charging system from charging the battery. If this occurs, the only correction is PCM replacement. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 080197 > Feb > 97 > PCM - Wire Harness Connector Repair Package Technical Service Bulletin # 080197 Date: 970203 Discussion NO: 08-01-97 GROUP: Electrical EFFECTIVE DATE: Feb. 3, 1997 SUBJECT: JTEC Powertrain Control Module Wiring Harness Connector Repair Packages MODELS: 1996 - 1997 (AB) Ram Van 1996 - 1997 (AN) Dakota 1996 - 1997 (BR) Ram Truck 1996 - 1997 (SR) Viper/Viper GTS 1997 (TJ) Wrangler 1996-1997 (XJ) Cherokee 1996-1997 (ZJ) Grand Cherokee 1996 - 1997 (ZG) Grand Cherokee (International Markets) DISCUSSION: The following Jeep/Truck Engine Controller (JTEC) Powertrain Control Module (PCM) electrical connector and terminal repair components are available to aid in powertrain electrical wiring repairs. These components allow repairs of individual wiring circuits without the need to replace the entire engine harness. If you have determined that a powertrain customer complaint could be related to a poor electrical connection, the PCM connectors should be inspected. The following diagnosis and inspection can be utilized to determine the condition of the PCM connectors and their terminals. Diagnosis Inspection of the connector begins with a thorough inspection of the insulator. 1. Record the radio station presets. 2. Disconnect and isolate the battery negative cable (both batteries should be disconnected if the vehicle is equipped with a 5.9L Cummins Diesel). 3. Disconnect the connector from the PCM. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 080197 > Feb > 97 > PCM - Wire Harness Connector Repair Package > Page 2054 4. Inspect the connector lock tab on the side of the insulator (Figure 1) for damage and replace the insulator if damaged is identified. 5. Gently pull on the wires of the connector one at a time. The initial and final locks will need to be inspected if the wire pulls out of the insulator. 6. Push in the single lock tab on the side of the insulator (Figure 2). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 080197 > Feb > 97 > PCM - Wire Harness Connector Repair Package > Page 2055 7. Then, insert the probe of special tool 6934 (Figure 3) into the back of the insulator cavity. 8. Grasp the wire and tool 6934 and slowly remove the wire and terminal from the insulator (Figure 4). Then, remove the strain relief and wire seal (Figure 1). 9. Inspect the initial and final locks of the insulator (Figure 1) for damage. Replace the insulator if there are any signs of damage. 10. Inspect all wire terminals for corrosion. If corrosion is evident, replace the terminal ends and the insulator. 11. To verify how secure the cavity of the terminal fits onto the PCM pins, insert and remove the wire end terminal onto the mating pin of the PGM. Then, rotate the terminal 90°, 180°, and 270° while inserting and removing the terminal from the pin. If any connection is loose, replace the wire end terminal. 12. Inspect and replace the PCM connector cover or connector plug if the locking tabs are damaged. Perform the following Repair Procedure if damage or wear is identified in any component of the insulator or terminals (including corrosion on the terminal). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 080197 > Feb > 97 > PCM - Wire Harness Connector Repair Package > Page 2056 PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves replacing either the insulator or terminals of the PCM connectors. Insulator Replacement NOTE: THIS PROCEDURE ASSUMES THAT THE WIRE END TERMINALS WERE ALREADY REMOVED WHEN THE DIAGNOSIS WAS PERFORMED. 1. Utilizing the appropriate insulator (see Parts Required list), install the wire and terminal into the appropriate cavities of the insulator. Refer to the appropriate Service Manual, Group 8W-80, for proper terminal-to-cavity locations in the connector. Fully seat all terminals into the insulator. 2. Push in the two lock tabs on the side of the connector (Figure 5). 3. Install the connector into the proper cavity of the PCM. 4. Connect the battery negative cable (both batteries should be connected if the vehicle is equipped with a 5.9L Cummins Diesel). 5. Reset the clock and reprogram the radio stations to the presets recorded in step 1 of the Diagnosis. Wire End Terminal Replacement NOTE: THIS PROCEDURE ASSUMES THAT THE DAMAGED OR CORRODED WIRE END TERMINAL WAS ALREADY REMOVED WHEN THE DIAGNOSIS WAS PERFORMED. 1. The wire of the terminal end that needs repaired will need to be cut and discarded. Measure approximately three inches down the wire from the end of the terminal and cut the wire. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 080197 > Feb > 97 > PCM - Wire Harness Connector Repair Package > Page 2057 2. Cut one of the wires with terminal ends from package P/N 04882087 in half. This action will allow for two repairs if necessary. 3. Remove approximately one inch of insulation from the wires that are being spliced together. 4. Place a piece of heat shrink tubing over one of the wires. Make sure the tubing will be long enough to cover and seal the entire repair. 5. Spread the strands of the wire apart on each part of the exposed wire (Example 1) (Figure 6). 6. Push the ends of the two wires together until the strands of wire are close to the insulation (Example 2) (Figure 6). 7. Twist the wires together (Example 3) (Figure 6). 8. Solder the connection together using rosin core type solder only. Do not use acid core solder. 9. Center the heat shrink tubing over the joint and heat the tubing using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 10. Secure the wires to the existing harness to prevent chafing or damage to the insulation. 11. Install the wire terminal end into the appropriate cavity of the insulator. Fully seat all terminals into the insulator. 12. Push in the single lock tab on the side of the connector (Figure 5). 13. Install the connector into the proper cavity of the PCM. 14. Connect the battery negative cable (both batteries should be connected if the vehicle is equipped with a 5.9L Cummins Diesel). 15. Reset the clock and reprogram the radio stations to the presets recorded in step 1 of the Diagnosis. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 2058 Powertrain Control Module: Specifications DESCRIPTION .................................................................................................................................... .............................................................. TORQUE Powertrain Control Module Mounting Screws ..................................................................................................................................... 3-5 Nm (30-40 in lb) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 2059 Powertrain Control Module: Locations Powertrain Control Module (PCM) The Powertrain Control Module (PCM) is mounted in the engine compartment. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2062 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 Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2063 Electrostatic Discharge Symbol All Electrostatic Discharge (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, especially 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. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2064 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2065 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2066 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2067 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2068 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2069 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2070 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2071 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. 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. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2072 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2073 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2074 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2075 Powertrain Control Module: Diagnostic Aids 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 in 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 and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2076 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. 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 every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. 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 fuse circuit. 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 the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2077 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools 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 - This instrument is 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 vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. 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 non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2078 PCM Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Five Volt Sensor Supply-Primary Powertrain Control Module: Description and Operation Five Volt Sensor Supply-Primary Supplies the required 5 volt power source to the crankshaft position sensor, camshaft position sensor, Manifold Absolute Pressure (MAP) sensor and throttle position sensor. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Five Volt Sensor Supply-Primary > Page 2081 Powertrain Control Module: Description and Operation Five Volt Sensor Supply-Secondary Supplies the required 5 volt power source to the transmission pressure sensor and the vehicle speed sensor. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Five Volt Sensor Supply-Primary > Page 2082 Powertrain Control Module: Description and Operation Power Grounds The power ground is used to control ground circuits for the following powertrain control module (PCM) loads: Generator field winding - Fuel injectors - Ignition coil - Certain relays/solenoids Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Five Volt Sensor Supply-Primary > Page 2083 Powertrain Control Module: Description and Operation Sensor Return-PCM Input Sensor Return provides a low noise ground reference for all system sensors. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Five Volt Sensor Supply-Primary > Page 2084 Powertrain Control Module: Description and Operation Five Volt Sensor Supply-Primary Supplies the required 5 volt power source to the crankshaft position sensor, camshaft position sensor, Manifold Absolute Pressure (MAP) sensor and throttle position sensor. Five Volt Sensor Supply-Secondary Supplies the required 5 volt power source to the transmission pressure sensor and the vehicle speed sensor. Power Grounds The power ground is used to control ground circuits for the following powertrain control module (PCM) loads: Generator field winding - Fuel injectors - Ignition coil - Certain relays/solenoids Sensor Return-PCM Input Sensor Return provides a low noise ground reference for all system sensors. Signal Ground-PCM Input Signal ground provides a low noise ground to the data link connector. System Description Fig 1 Powertrain Control Module (PCM) SYSTEM DIAGNOSIS The Powertrain Control Module (PCM) can test many of its own input and output circuits. If the PCM senses a fault in a major system, it stores a Diagnostic Trouble Code (DTC) in its memory. Technicians can display stored DTC's with different methods. One way is using the DRB scan tool. Another way is using the malfunction indicator (check engine) lamp. On certain models the vehicle odometer can be used to display the numeric DTC. POWERTRAIN CONTROL MODULE (PCM) The powertrain control module (PCM) (Fig. 1) operates the fuel system. The PCM was formerly referred to as the SBEC or engine controller. The PCM is a pre-programmed, dual microprocessor digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, certain transmission features, speed control, air conditioning compressor clutch engagement and idle speed. The PCM can adapt its programming to meet changing operating conditions. The PCM receives input signals from various switches and sensors. Based on these inputs, the PCM regulates various engine and vehicle operations through different system components. These components are referred to as Powertrain Control Module (PCM) Outputs. The sensors and switches that provide inputs to the PCM are considered Powertrain Control Module (PCM) Inputs. The PCM adjusts ignition timing based upon inputs it receives from sensors that react to: engine rpm, manifold absolute pressure, engine coolant temperature, throttle position, transmission gear selection (automatic transmission), vehicle speed and the brake switch. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Five Volt Sensor Supply-Primary > Page 2085 The PCM adjusts idle speed based on inputs it receives from sensors that react to: throttle position, vehicle speed, transmission gear selection, engine coolant temperature and from inputs it receives from the air conditioning clutch switch and brake switch. Based on inputs that it receives, the PCM adjusts ignition coil dwell. The PCM also adjusts the generator charge rate through control of the generator field and provides speed control operation. PCM INPUTS: - A/C request (if equipped with factory A/C) - A/C select (if equipped with factory A/C) - Auto shutdown (ASD) sense - Battery temperature - Battery voltage - Brake switch - CCD bus (+) circuits - CCD bus (-) circuits - Camshaft position sensor signal - Crankshaft position sensor - Data link connection for DRB scan tool - Engine coolant temperature sensor - Fuel level - Generator (battery voltage) output - Ignition circuit sense (ignition switch in on/of/ crank/run position) - Intake manifold air temperature sensor - Leak detection pump (switch) sense (if equipped) - Manifold absolute pressure (MAP) sensor - Oil pressure - Output shaft speed sensor - Overdrive/override switch - Oxygen sensors - Park/neutral switch (auto. trans. only) - Power ground - Sensor return - Signal ground - Speed control multiplexed single wire input - Throttle position sensor - Transmission governor pressure sensor - Transmission temperature sensor - Vehicle speed sensor PCM OUTPUTS: - A/C clutch relay - Auto shutdown (ASD) relay - CCD bus (+) circuits - CCD bus (-) circuits - Data link connection for DRB scan tool - EGR valve control solenoid (if equipped) - EVAP canister purge solenoid - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel injectors - Fuel pump relay - Generator field driver (-) - Generator field driver (+) - Generator lamp (if equipped) - Idle air control (IAC) motor - Ignition coil - Leak detection pump - Malfunction indicator lamp (Check engine lamp) -- Driven through CCD circuits. - Overdrive indicator lamp (if equipped) - Speed control vacuum solenoid - Speed control vent solenoid - Tachometer (if equipped). Driven through CCD circuits. - Transmission convertor clutch circuit - Transmission 3-4 shift solenoid - Transmission relay Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Five Volt Sensor Supply-Primary > Page 2086 - Transmission temperature lamp (if equipped) - Transmission variable force solenoid The powertrain control module (PCM) contains a voltage convertor. This converts battery voltage to a regulated 5.0 volts. It is used to power the crankshaft position sensor, camshaft position sensor and vehicle speed sensor. The PCM also provides a five (5) volt supply for the manifold absolute pressure (MAP) sensor and throttle position sensor (TPS). SPEED CONTROL SYSTEM OPERATION The speed control electronic control circuitry is integrated into the Powertrain Control Module (PCM). The PCM is located in the engine compartment. The PCM speed control functions are monitored by the On-Board Diagnostics (OBD). All OBD-sensed systems are monitored by the PCM. Each monitored circuit is assigned a Diagnostic Trouble Code (DTC). The PCM will store a DTC in electronic memory for certain failures it detects. See Starting and Charging/Charging System/Testing and Inspection/Procedures/On-Board Diagnostic Test For Speed Control System for more information. The PCM cannot be repaired and must be replaced if faulty. CIRCUIT OPERATION Battery Feed Circuit A14 from the Power Distribution Center (PDC) supplies battery voltage to cavity A22 of the Powertrain Control Module (PCM). A 30 amp fuse in cavity 1 of the PDC protects circuit A14. Ignition Feed Circuit F18 provides an input to the Powertrain Control Module (PCM). This circuit is HOT in the START and RUN position and protected by a 10 amp fuse located in the junction block. Power for the fuse is supplied by circuit A21 from the ignition switch. Transmission Control The Powertrain Control Module (PCM) controls operation of the converter clutch, overdrive clutch, and governor pressure solenoid. The control module determines transmission shift points based on input signals from the transmission thermistor, transmission output shaft speed sensor, crankshaft position sensor, vehicle speed sensor, throttle position sensor, and battery temperature sensor. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Powertrain Control Module: Initial Inspection and Diagnostic Overview Battery Feed - Check the 20 amp fuse located in cavity 1 of the PDC Ignition Feed - Check the 10 amp fuse located in the junction block Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Testing and Inspection > Page 2089 Powertrain Control Module: Service and Repair Powertrain Control Module (PCM) REMOVAL 1. Disconnect the negative battery cable at battery. 2. Carefully unplug the three 32-way connectors from PCM. 3. Remove three Powertrain Control Module (PCM) mounting bolts and remove PCM from vehicle. INSTALLATION 1. Install PCM and mounting bolts to vehicle. 2. Tighten bolts to 3-5 Nm (30-40 in lb). 3. Check pin connectors in the PCM and the three 32-way connectors for corrosion or damage. Repair as necessary 4. Install three 32-way connectors. 5. Install battery cable. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates Automatic Shut Down (ASD) Relay: Technical Service Bulletins Engine Controls/Emissions/A/T Manual Updates NUMBER: 26-06-98 GROUP: Miscellaneous DATE: June, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 2.5L, 3.9L, 5.2L, 5.9L 8.0L SFI/CNG/Diesel Diagnostic Manual - Publication Number 81-699-96041 DESCRIPTION OF CHANGES Revision to the diagnostic trouble codes Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2094 56 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2095 57 Revisions to the Throttle Position Sensor test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2096 162 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2097 166 Revisions to the Evap. Purge Flow Monitor tests Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2098 374 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2099 375 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2100 377 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2101 379 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2102 379A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2103 379B Revision to the EGR system Failure tests Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2104 432 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2105 433 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2106 434 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2107 435 Revision to the torque convertor clutch - no drop at lock up test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2108 465 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2109 467 Revision to the no temp rise seen at intake heater test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2110 514 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2111 515 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2112 516 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2113 517 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2114 518 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2115 519 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2116 520 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2117 521 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2118 521A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2119 521B Revision to the 12 volt supply relay test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2120 571 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Page 2121 Automatic Shut Down (ASD) Relay: Locations Power Distribution Center Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Page 2122 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Page 2123 Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Page 2124 Automatic Shut Down (ASD) Relay: Description and Operation CIRCUIT OPERATION Automatic Shut Down (ASD) Relay Circuit A16 from the Power Distribution Center (PDC) supplies battery voltage to the contact side of the Automatic Shut Down (ASD) relay. In the START or RUN position, the ignition switch connects circuit F18 from the 10 amp fuse in the junction block to the coil side of the ASD relay. The Powertrain Control Module (PCM) provides the ground path for the coil side of the relay on circuit K51. Circuit K51 connects to cavity C3 of the PCM. When the ASD relay energizes, it connects circuit A16 and circuit A142. Circuit A142 splices to supply voltage to the fuel injectors, ignition coil, and heated oxygen sensors. Circuit A142 also splices to cavity C12 of the PCM. This input tells the PCM the ASD relay has energized. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Relay Tests Automatic Shut Down (ASD) Relay: Testing and Inspection Relay Tests Fig 91 ASD And Fuel Pump Relay Terminals ASD and Fuel Pump Relay Test The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relay. The terminals on the bottom of each relay are numbered (Fig. 91). RELAY OPERATION Terminal 30: Connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. Terminal 85: The PCM grounds the coil side of the relay through this terminal. Terminal 86: Supplies voltage to the coil side of the relay. Terminal 87A: 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. Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TESTING 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 between 70 - 80 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. CAUTION: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter should now show continuity between relay terminals 87 and 30. - The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. - If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Relay Tests > Page 2127 Automatic Shut Down (ASD) Relay: Testing and Inspection Helpful Information - Check the 30 amp fuse located in the PDC - Check the 10 amp fuse located in the junction block Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Page 2128 Automatic Shut Down (ASD) Relay: Service and Repair Power Distribution Center NOTE: The Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). The PDC is located in the engine compartment. Refer to label on PDC cover for relay location. REMOVAL 1. Remove the PDC cover. 2. Remove the relay by lifting straight up. INSTALLATION 1. Check condition of relay terminals at PDC for corrosion or damage. - Also check the heights of relay terminal pins at PDC. Pin height should be same for all pins. - Repair as necessary before installing relay. 2. Push the relay into the connector. 3. Install the relay cover. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Description and Operation Fuel Pump Control Unit: Description and Operation CIRCUIT OPERATION The in-tank fuel pump module contains the fuel pump motor and fuel level sensor. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Power Distribution Center Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2136 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2137 Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2138 Fuel Pump Relay: Description and Operation CIRCUIT OPERATION Circuit A14 from the Power Distribution Center (PDC) supplies battery voltage to the contact side of the fuel pump relay. In the START or RUN position, the ignition switch connects circuit F18 from the 10 amp fuse in the junction block to the coil side of the fuel pump relay. The Powertrain Control Module (PCM) provides the ground path for the coil side of the relay on circuit K151. Circuit K151 connects to cavity C19 of the PCM. When the fuel pump relay energizes, it connects circuit A14 and circuit A61. Circuit A61 supplies voltage to the fuel pump module. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Helpful Information Fuel Pump Relay: Testing and Inspection Helpful Information - Check the 20 amp fuse located in the PDC Check the 10 amp fuse located in the junction block Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Helpful Information > Page 2141 Fuel Pump Relay: Testing and Inspection Relay Tests Fig 91 ASD And Fuel Pump Relay Terminals ASD and Fuel Pump Relay Test The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relay. The terminals on the bottom of each relay are numbered (Fig. 91). RELAY OPERATION Terminal 30: Connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. Terminal 85: The PCM grounds the coil side of the relay through this terminal. Terminal 86: Supplies voltage to the coil side of the relay. Terminal 87A: 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. Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TESTING 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 between 70 - 80 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. CAUTION: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter should now show continuity between relay terminals 87 and 30. - The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. - If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Page 2142 Fuel Pump Relay: Service and Repair Fig 67 Power Distribution Center (PDC) Location The fuel pump relay is located in the Power Distribution Center (PDC) (Fig. 67). 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 Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates Automatic Shut Down (ASD) Relay: Technical Service Bulletins Engine Controls/Emissions/A/T Manual Updates NUMBER: 26-06-98 GROUP: Miscellaneous DATE: June, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 2.5L, 3.9L, 5.2L, 5.9L 8.0L SFI/CNG/Diesel Diagnostic Manual - Publication Number 81-699-96041 DESCRIPTION OF CHANGES Revision to the diagnostic trouble codes Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2147 56 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2148 57 Revisions to the Throttle Position Sensor test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2149 162 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2150 166 Revisions to the Evap. Purge Flow Monitor tests Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2151 374 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2152 375 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2153 377 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2154 379 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2155 379A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2156 379B Revision to the EGR system Failure tests Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2157 432 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2158 433 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2159 434 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2160 435 Revision to the torque convertor clutch - no drop at lock up test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2161 465 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2162 467 Revision to the no temp rise seen at intake heater test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2163 514 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2164 515 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2165 516 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2166 517 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2167 518 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2168 519 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2169 520 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2170 521 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2171 521A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2172 521B Revision to the 12 volt supply relay test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2173 571 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Page 2174 Automatic Shut Down (ASD) Relay: Locations Power Distribution Center Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Page 2175 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Page 2176 Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Page 2177 Automatic Shut Down (ASD) Relay: Description and Operation CIRCUIT OPERATION Automatic Shut Down (ASD) Relay Circuit A16 from the Power Distribution Center (PDC) supplies battery voltage to the contact side of the Automatic Shut Down (ASD) relay. In the START or RUN position, the ignition switch connects circuit F18 from the 10 amp fuse in the junction block to the coil side of the ASD relay. The Powertrain Control Module (PCM) provides the ground path for the coil side of the relay on circuit K51. Circuit K51 connects to cavity C3 of the PCM. When the ASD relay energizes, it connects circuit A16 and circuit A142. Circuit A142 splices to supply voltage to the fuel injectors, ignition coil, and heated oxygen sensors. Circuit A142 also splices to cavity C12 of the PCM. This input tells the PCM the ASD relay has energized. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Relay Tests Automatic Shut Down (ASD) Relay: Testing and Inspection Relay Tests Fig 91 ASD And Fuel Pump Relay Terminals ASD and Fuel Pump Relay Test The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relay. The terminals on the bottom of each relay are numbered (Fig. 91). RELAY OPERATION Terminal 30: Connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. Terminal 85: The PCM grounds the coil side of the relay through this terminal. Terminal 86: Supplies voltage to the coil side of the relay. Terminal 87A: 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. Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TESTING 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 between 70 - 80 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. CAUTION: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter should now show continuity between relay terminals 87 and 30. - The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. - If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Relay Tests > Page 2180 Automatic Shut Down (ASD) Relay: Testing and Inspection Helpful Information - Check the 30 amp fuse located in the PDC - Check the 10 amp fuse located in the junction block Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Page 2181 Automatic Shut Down (ASD) Relay: Service and Repair Power Distribution Center NOTE: The Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). The PDC is located in the engine compartment. Refer to label on PDC cover for relay location. REMOVAL 1. Remove the PDC cover. 2. Remove the relay by lifting straight up. INSTALLATION 1. Check condition of relay terminals at PDC for corrosion or damage. - Also check the heights of relay terminal pins at PDC. Pin height should be same for all pins. - Repair as necessary before installing relay. 2. Push the relay into the connector. 3. Install the relay cover. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations > Page 2187 MAP Connector Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Battery Temp. Sensor Location Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2191 Battery Temp. Sensor Connector Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2192 Battery Temperature Sensor: Service Precautions WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN . Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2193 Battery Temperature Sensor: Description and Operation SYSTEM OPERATION The battery temperature sensor 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. CIRCUIT OPERATION The Powertrain Control Module (PCM) determines battery temperature on circuit K118. Circuit K118 connects the PCM to the battery temperature sensor. Circuit K4 provides ground for the sensor. Circuit K118 connects to cavity C15 of the PCM. Circuit K4 connects to cavity A4. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Testing Battery Temperature Sensor: Testing and Inspection Testing To perform a complete test of this sensor and its circuitry, refer to the appropriate Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Charts Procedures. To test the sensor only, refer to the following: Battery Temperature Sensor 1. The sensor is located under the battery and is attached to the battery tray. A two-wire pigtail harness is attached directly to the sensor. The opposite end of this harness connects the sensor to the engine wiring harness. 2. Disconnect the two-wire pigtail harness from the engine harness. 3. Attach ohmmeter leads to the wire terminals of the pigtail harness. 4. At room temperature of 25 °C (75 - 80 °F), an ohmmeter reading of 9,000 (9K) to 11,000 (11K) ohms should be observed. 5. If reading is above or below the specification, replace the sensor. 6. Refer to the Removal and Installation for procedures. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Page 2196 Battery Temperature Sensor: Service and Repair Battery Temperature Sensor The battery temperature sensor is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray. The sensor is located under the battery on drivers side of vehicle. REMOVAL 1. Remove battery. 2. Disconnect sensor pigtail harness from engine wire harness. 3. Pry sensor straight up from battery tray mounting hole. INSTALLATION 1. Feed pigtail harness through mounting hole in top of battery tray and press sensor into top of tray (snaps in). 2. Connect pigtail harness. 3. Install battery. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Component Locations Camshaft Position Sensor: Component Locations Camshaft Position Sensor The Camshaft Position (CMP) Sensor is mounted in the distributor housing. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 2201 Distributor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2202 CPS Connector Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2203 Camshaft Position Sensor: Description and Operation LOCATION The camshaft position sensor is located in the distributor on all engines. DESCRIPTION The sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft. The pulse ring rotates 180 degrees through the sync signal generator. Its signal is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. OPERATION When the leading edge of the pulse ring (shutter) enters the sync signal generator, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a sync signal of approximately 5 volts. When the trailing edge of the pulse ring (shutter) leaves the sync signal generator, the change of the magnetic field causes the sync signal voltage to switch low to 0 volts. CIRCUIT OPERATION The camshaft position sensor is located internal to the distributor on all engine applications. The Powertrain Control Module (PCM) supplies 5 Volts to the camshaft position sensor on circuit K6. Circuit K6 connects to cavity A17 of the PCM. The PCM receives the camshaft position sensor signal on circuit K44. Circuit K44 connects to cavity A18 of the PCM. The PCM provides a ground for the camshaft position sensor (circuit K44) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2204 Camshaft Position Sensor: Testing and Inspection Circuit K6 splices to supply 5 Volts to the crankshaft position sensor, manifold absolute pressure sensor, and throttle position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Crankshaft position sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2205 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor NOTE: Distributor removal is not necessary to remove camshaft position sensor. REMOVAL 1. Remove air cleaner assembly 2. Disconnect negative cable from battery 3. Remove distributor cap from distributor (two screws). 4. Disconnect camshaft position sensor wiring harness from main engine wiring harness. 5. Remove distributor rotor from distributor shaft. 6. Lift the camshaft position sensor assembly from the distributor housing. INSTALLATION 1. Install camshaft position sensor to distributor. Align sensor into notch on distributor housing. 2. Connect wiring harness. 3. Install rotor 4. Install distributor cap. Tighten mounting screws. 5. Install air cleaner assembly. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications DESCRIPTION .................................................................................................................................... .............................................................. TORQUE Engine Coolant Temperature Sensor ........................................................................................................................................................... 11 Nm (96 in lb) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2209 Fig 6 Engine Coolant Temperature Sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2210 ECT Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2211 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig 6 Engine Coolant Temperature Sensor DESCRIPTION The engine coolant temperature sensor is installed in the intake manifold next to the thermostat housing. OPERATION The sensor provides an input voltage to the powertrain control module (PCM) relating coolant temperature. The PCM uses this input along with inputs from other sensors to determine injector pulse width and ignition timing. As coolant temperature varies, the coolant temperature sensor resistance will change. This change in resistance results in a different input voltage to the PCM. 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. CIRCUIT OPERATION The engine coolant temperature (ECT) sensor provides an input to the Powertrain Control Module (PCM) on circuit K2. From circuit K2, the engine coolant temperature sensor draws up to 5 Volts from the PCM. The sensor is a variable resistor. As coolant temperature changes, the resistance in the sensor changes, causing a change in current draw. The K2 circuit connects to cavity A16 of the PCM. The PCM provides a ground for the engine coolant temperature sensor signal (circuit K2) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Testing Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Component Testing Fig 57 Engine Coolant Temperature Sensor - Typical Sensor Resistance Chart (OHMS) To perform a complete test of the engine coolant temperature sensor and its circuitry, refer to Powertrain Management/Computers and Controls/Testing and Inspection/Procedures/Diagnostic Charts. To test the sensor only, refer to the following: 1. Disconnect wire harness connector from coolant temperature sensor (Fig. 57). 2. Engines with air conditioning: - When removing the connector from sensor, do not pull directly on wiring harness. - Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). - Place the hook part of tool under the connector for removal. - The connector is snapped onto the sensor. - It is not equipped with a lock type tab. 3. Test the resistance of the sensor with a high input impedance (digital) volt-ohmmeter. - The resistance (as measured across the sensor terminals) should be as shown in the Coolant Temperature Sensor/Intake Air Temperature Sensor resistance chart. - Replace the sensor if it is not within the range of resistance specified in the chart. 4. Test continuity of the wire harness between the PCM wire harness connector and the coolant sensor connector terminals. - Diagrams/Electrical/Connector Views for terminal/cavity locations. - Repair the wire harness if an open circuit is indicated. 5. After tests are completed, connect electrical connector to sensor. - The sensor connector is symmetrical (not indexed). - It can be installed to the sensor in either direction. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Testing > Page 2214 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Crankshaft position sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Page 2215 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig. 66 Engine Coolant Temperature Sensor WARNING: Hot, pressurized coolant can cause injury by scalding. cooling system must be partially drained before removing the coolant temperature sensor. REMOVAL 1. Partially drain cooling system. 2. Remove air cleaner assembly 3. Disconnect electrical connector from sensor. 4. Engines with air conditioning: - When removing the connector from sensor, do not pull directly on wiring harness. - Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). - Place the hook part of tool under the connector for removal. - The connector is snapped onto the sensor. - It is not equipped with a lock type tab. 5. Remove sensor from intake manifold. INSTALLATION 1. Install sensor. 2. Tighten to 11 Nm (8 ft lb) torque. 3. Connect electrical connector to sensor. - The sensor connector is symmetrical (not indexed). - It can be installed to the sensor in either direction. 4. Install air cleaner assembly 5. Replace any lost engine coolant. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications DESCRIPTION .................................................................................................................................... .............................................................. TORQUE Crankshaft Position Sensor ................................................................................................................. .......................................................... 8 Nm (70 in lb) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2219 Crankshaft Position Sensor: Locations Crankshaft Position Sensor The sensor is located on the top of cylinder block near the rear of right cylinder head. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2220 CKP Connector Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2221 Crankshaft Position Sensor: Description and Operation Fig. 4 Sensor Operation DESCRIPTION The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. The flywheel/drive plate has groups of notches at its outer edge. there are three sets of double notches and three sets of single notches. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. OPERATION Engine speed and crankshaft position are provided through the 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. CIRCUIT OPERATION The Powertrain Control Module (PCM) supplies 5 Volts to the crankshaft position sensor on circuit K6. Circuit K6 connects to cavity A17 of the PCM. The PCM receives the crankshaft position sensor signal on circuit K24. Circuit K24 connects to cavity A8 of the PCM. The PCM provides a ground for the crankshaft position sensor (circuit K24) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector. NOTE: The engine will not operate if the PCM does not receive a crankshaft position sensor input. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2222 Crankshaft Position Sensor: Testing and Inspection Circuit K6 splices to supply 5 Volts to the camshaft position sensor, manifold absolute pressure sensor, and throttle position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2223 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor NOTE: The sensor is bolted to the top of the cylinder block near the rear of right cylinder head. The sensor is accessed by removing the right front fender liner. REMOVAL 1. Remove right front tire and right front wheelhouse liner. 2. Disconnect crankshaft position sensor pigtail harness from main wiring harness. 3. Remove two sensor (recessed hex head) mounting bolts. 4. Remove sensor from engine. INSTALLATION 1. Position crankshaft position sensor to engine. 2. Install mounting bolts and tighten to 8 Nm (70 in lb) torque. 3. Connect main harness electrical connector to sensor. 4. Install right front tire and right front wheelhouse liner. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation The fuel level sensor (fuel gauge sending unit) sends a signal to the PCM to indicate fuel level. The purpose of this feature is to prevent a false setting of misfire and fuel system monitor trouble codes if the fuel level is less than approximately 15 percent of its rated capacity It is also used to send a signal for fuel gauge operation via the CCD bus circuits. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications Intake Air Temperature Sensor: Specifications DESCRIPTION .................................................................................................................................... .............................................................. TORQUE Intake Manifold Air Temp. Sensor ............................................................................................................................................................. 28 Nm (20 ft lb) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2230 Fig 59 Intake Manifold Air Temperature Sensor - Typical Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2231 IAT Connector Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2232 Intake Air Temperature Sensor: Description and Operation Fig 8 Intake Manifold Air Temperature Sensor PURPOSE The sensor provides an input voltage to the powertrain control module (PCM) indicating intake manifold air temperature. The input is used along with inputs from other sensors to determine injector pulse width. OPERATION As the temperature of the air-fuel stream in the manifold varies, the sensor resistance changes. This results in a different input voltage to the PCM. CIRCUIT OPERATION The intake air temperature sensor provides an input to the Powertrain Control Module (PCM) on circuit K21. Circuit K21 connects to cavity A15 of the PCM. From circuit K21, the intake air temperature sensor draws voltage from the PCM. The sensor is a variable resistor. As intake air temperature changes, the resistance in the sensor changes, causing a change in current draw. The PCM provides a ground for the intake air temperature sensor signal (circuit K21) through circuit K4. Circuit K4 connects to cavity A4 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Sensor Test Intake Air Temperature Sensor: Testing and Inspection Sensor Test Fig 59 Intake Manifold Air Temperature Sensor - Typical Sensor Resistance Chart (OHMS) To perform a complete test of the intake manifold air temperature sensor and its circuitry, refer to Powertrain Management/Computers and Controls/Testing and Inspection/Diagnostic Charts. To test the sensor only, refer to the following; 1. Disconnect the wire harness connector from the intake manifold air temperature sensor (Fig. 59). 2. Test the resistance of the sensor with an input impedance (digital) volt-ohmmeter. - The resistance (as measured across the sensor terminals) should be as shown in the Sensor Resistance Chart. - Replace the sensor if it is not within the range of resistance specified in the chart. 3. Test the resistance of the wire harness. - Do this between the PCM wire harness connector A-15 and the sensor connector terminal. - Also check between PCM connector A-4 to the sensor connector terminal. - Repair the wire harness as necessary if the resistance is greater than 1 ohm. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Sensor Test > Page 2235 Intake Air Temperature Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Crankshaft position sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Page 2236 Intake Air Temperature Sensor: Service and Repair Fig 88 Intake Manifold Air Temperature Sensor - Typical The intake manifold air temperature sensor is located in the front/side of the intake manifold (Fig. 88). REMOVAL 1. Remove air duct at throttle body. 2. Disconnect electrical connector at sensor (Fig. 88). 3. Remove sensor from intake manifold. INSTALLATION 1. Install sensor to intake manifold. Tighten to 28 Nm (20 ft lb) torque. 2. Install electrical connector. 3. Install air duct at throttle body. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications Manifold Pressure/Vacuum Sensor: Specifications DESCRIPTION .................................................................................................................................... .............................................................. TORQUE MAP Sensor Mounting Screws ............................................................................................................ ......................................................... 3 Nm (25 in lb) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2240 Manifold Pressure/Vacuum Sensor: Locations Fig 10 MAP And Throttle Position Sensor Location - Typical The MAP sensor is mounted into the right side of the intake manifold. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2241 Manifold Pressure/Vacuum Sensor: Description and Operation Fig 10 MAP And Throttle Position Sensor Location - Typical DESCRIPTION The Manifold Absolute Pressure (MAP) sensor reacts to absolute pressure in the intake manifold. It provides an input voltage to the powertrain control module (PCM). The MAP sensor is mounted into the right side of the intake manifold. OPERATION As engine load changes, manifold pressure varies. The change in manifold pressure causes MAP sensor voltage to change. The change in MAP sensor voltage results in a different input voltage to the PCM. The input voltage level supplies the PCM with information about ambient barometric pressure during engine start-up (cranking) and engine load while the engine is running. The PCM uses this input along with inputs from other sensors to adjust air-fuel mixture. CIRCUIT OPERATION From the Powertrain Control Module (PCM), circuit K6 supplies 5 Volts to the Manifold Absolute Pressure (MAP) sensor Circuit K6 connects to cavity A17 of the PCM. Circuit K1 delivers the MAP signal to the PCM. Circuit K1 connects to cavity A27 of the PCM. The PCM provides a ground for the MAP sensor signal (circuit K1) through circuit K4. Circuit K4 connects to cavity A4 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Helpful Information Manifold Pressure/Vacuum Sensor: Testing and Inspection Helpful Information Circuit K6 splices to supply 5 Volts to the Throttle Position Sensor (TPS), camshaft position sensor, and crankshaft position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Crankshaft position sensor - Intake air temperature sensor - Throttle position sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2244 Manifold Pressure/Vacuum Sensor: Testing and Inspection Component Test Fig 49 MAP Sensor - Typical NOTE: To perform a complete test of MAP sensor (Fig. 49) and its circuitry, refer to Powertrain Management/Computers and Controls/Testing and Inspection/Diagnostic Charts. To test the MAP sensor only, refer to the following: Fig 50 Rubber L-Shaped Fitting - MAP Sensor-to-Throttle Body 1. Inspect the rubber L-shaped fitting from the MAP sensor to the throttle body (Fig. 50). Repair as necessary. CAUTION: When testing the MAP sensor, be sure that the harness wires are not damaged by the test meter probes. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2245 Fig 51 MAP Sensor Connector Terminals - Typical 2. Test the MAP sensor output voltage at the MAP sensor connector between terminals A and B (Fig. 51). With the ignition switch ON and the engine OFF output voltage should be 4-to-5 volts. The voltage should drop to 1.5-to-2.1 volts with a hot, neutral idle speed condition. 3. Test powertrain control module (PCM) cavity A-27 for the same voltage described above to verify the wire harness condition. Repair as necessary 4. Test MAP sensor supply voltage at sensor connector between terminals A and C (Fig. 51) with the ignition ON. - The voltage should be approximately 5 volts (+/- 0.5V). - Five volts (+/- 0.5V) should also be at cavity A-17 of the PCM wire harness connector. - Repair or replace the wire harness as necessary. 5. Test the MAP sensor ground circuit at sensor connector terminal A (Fig. 51) and PCM connector A-4. - Repair the wire harness if necessary Refer to Diagrams/Electrical/Connector Views for cavity locations. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Page 2246 Manifold Pressure/Vacuum Sensor: Service and Repair Fig 77 MAP Sensor Location Fig 78 MAP Sensor L-Shaped Rubber Fitting The MAP sensor is located on the front of the throttle body (Fig. 77). An L-shaped rubber fitting is used to connect the MAP sensor to throttle body (Fig. 78). REMOVAL 1. Remove air duct at throttle body 2. Remove two MAP sensor mounting bolts (screws) (Fig. 77). 3. While removing MAP sensor, slide the vacuum rubber L-shaped fitting (Fig. 78) from the throttle body 4. Remove rubber L-shaped fitting from MAP sensor. INSTALLATION 1. Install rubber L-shaped fitting to MAP sensor. 2. Position sensor to throttle body while guiding rubber fitting over throttle body vacuum nipple. 3. Install MAP sensor mounting bolts (screws). Tighten screws to 3 Nm (25 in lb) torque 4. Install air duct at throttle body. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Description and Operation Oil Pressure Sensor: Description and Operation Sends a signal from the oil pressure sending unit to the Powertrain Control Module (PCM) relating to engine oil pressure. CIRCUIT OPERATION The engine oil pressure sensor is a variable resistor. As engine oil pressure changes the resistance on circuit G60 changes. The G60 circuit connects to cavity B23 of the Powertrain Control Module (PCM) connector. Ground for the sensor is supplied on circuit K4. This circuit connects to cavity A4 of the PCM connector. This circuit is the ground circuit for many of the components in the fuel/ignition system. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Oxygen Sensor .................................................................................................................................... ......................................................... 30 Nm (22 ft lb) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations Oxygen Sensor: Locations Oxygen Sensor Bank Locations Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 2255 Oxygen Sensor: Locations Oxygen Sensor Location Fig 82 Upstream Oxygen Sensor Locations Fig 83 Downstream Oxygen Sensor Location The upstream and downstream Oxygen (02S) sensors are located at the inlet and outlet ends of the catalytic converter. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 2256 Oxygen Sensor Configuration Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2257 Oxygen Sensor: Diagrams Pinout Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2258 Oxygen Sensor: Application and ID Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2259 Oxygen Sensor: Description and Operation OXYGEN SENSOR (O2S)-PCM INPUT Two heated O2S sensors are used. The sensors produce voltages from 0 to 1 volt, depending upon the oxygen content of the exhaust gas in the exhaust manifold. When a large amount of oxygen is present (caused by a lean air/fuel mixture), the sensors produces a low voltage. When there is a lesser amount present (rich air/fuel mixture) it produces a higher voltage. By monitoring the oxygen content and converting it to electrical voltage, the sensors act as a rich-lean switch. In Closed Loop operation, the PCM monitors the O2S sensor input (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. The oxygen sensors are equipped with a heating element that keeps the sensors at proper operating temperature during all operating modes. 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. The Automatic Shutdown (ASD) relay supplies battery voltage to both the upstream and downstream heated oxygen sensors. The oxygen sensors are equipped with a heating element. The heating elements reduce the time required for the sensors to reach operating temperature. UPSTREAM HEATED OXYGEN SENSOR The upstream O2S sensor is located near the inlet end of the catalytic converter. It 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 the air/fuel ratio by adjusting injector pulse width. DOWNSTREAM HEATED OXYGEN SENSOR The downstream heated oxygen sensor is located near the outlet end of the catalytic converter The downstream heated oxygen sensor input is used to detect catalytic convertor deterioration. As the convertor deteriorates, the input from the downstream sensor begins to match the upstream sensor input except for a slight time delay By comparing the downstream heated oxygen sensor input to the input from the upstream sensor, the PCM calculates catalytic convertor efficiency. When the catalytic converter efficiency drops below emission standards, the PCM stores a diagnostic trouble code and illuminates the Malfunction Indicator Lamp (MIL). For more information, refer to Emission Control Systems. CIRCUIT OPERATION When the Automatic Shut Down (ASD) relay contacts CLOSE, they connect circuits A16 and A142. Circuit A142 splices to supply voltage to the heated oxygen sensors. Circuit K141 delivers the signal from the center heated oxygen sensor to the PCM. Circuit K141 connects to cavity A24 of the Powertrain Control Module (PCM). Circuit K341 delivers the signal from the rear sensor and connects to cavity A25 of the PCM. Circuit K241 delivers the signal from the right heated oxygen sensor to the PCM. Circuit K241 connects to cavity A26 of the Powertrain Control Module (PCM). Circuit K441 delivers the signal from the left sensor and connects to cavity A25 of the PCM. The PCM provides a ground for the heated oxygen sensor signals (circuits K141 and K341) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector. Circuit Z1 provides a ground for the heater circuit in the sensors. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Helpful Information Oxygen Sensor: Testing and Inspection Helpful Information Circuit A142 splices to supply voltage to the fuel injectors and ignition coil. Circuit K4 splices to supply ground for the signals from the following: - Camshaft position sensor - Crankshaft position sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2262 Oxygen Sensor: Testing and Inspection Sensor Heating Element Test Fig 82 Upstream Oxygen Sensor Locations Fig 83 Downstream Oxygen Sensor Location The upstream O2S sensor is located in the exhaust downpipe. The downstream sensor is located near outlet end of catalytic converter. Refer to (Fig. 82) or (Fig. 83). WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. REMOVAL 1. Raise and support the vehicle. 2. Disconnect the wire connector from the O2S sensor. CAUTION: When disconnecting the sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove the O2S sensor. Snap-On oxygen sensor wrench (number YA 8875) may be used for removal and installation. NOTE: Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to the threads of a new oxygen sensor. INSTALLATION 1. Install the 02S sensor. Tighten to 30 Nm (22 ft lb) torque. 2. Connect the O2S sensor wire connector. 3. Lower the vehicle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Page 2263 Oxygen Sensor: Service and Repair Fig 82 Upstream Oxygen Sensor Locations Fig 83 Downstream Oxygen Sensor Location NOTE: The upstream and downstream Oxygen (02S) sensors are located at the inlet and outlet ends of the catalytic converter. REMOVAL WARNING: The exhaust manifold, exhaust pipes and catalytic converter become very hot during engine operation. Allow engine to cool before removing oxygen sensor. 1. Raise and support the vehicle. 2. Disconnect the wire connector from the 02S sensor. CAUTION: When disconnecting the sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove the O2S sensor. Snap-On oxygen sensor wrench (number YA 8875) may be used for removal and installation. INSTALLATION Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to the threads of a new oxygen sensor. 1. Install the 02S sensor. Tighten to 30 Nm (22 ft lb) torque. 2. Connect the 02S sensor wire connector. 3. Lower the vehicle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Power Steering - Pressure Switch Torque Revisions Power Steering Pressure Switch: Technical Service Bulletins Power Steering - Pressure Switch Torque Revisions NUMBER: 26-10-96B GROUP: Miscellaneous DATE: October, 1996 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 Dakota - Publication Number 81-270-7146 DESCRIPTION OF CHANGES Revised power steering pressure switch torque (124-195 In. Lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Power Steering - Pressure Switch Torque Revisions > Page 2268 14-65 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Power Steering - Pressure Switch Torque Revisions > Page 2269 14-66 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Page 2270 Power Steering Pressure Switch: Specifications The content of this article reflects changes called for in TSB 26-10-96. Power Steering Pressure Switch ................................................................................................................................................ 14-22 Nm (124-195 in.lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates Throttle Position Sensor: Technical Service Bulletins Engine Controls/Emissions/A/T - Manual Updates NUMBER: 26-06-98 GROUP: Miscellaneous DATE: June, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 2.5L, 3.9L, 5.2L, 5.9L 8.0L SFI/CNG/Diesel Diagnostic Manual - Publication Number 81-699-96041 DESCRIPTION OF CHANGES Revision to the diagnostic trouble codes Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2275 56 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2276 57 Revisions to the Throttle Position Sensor test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2277 162 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2278 166 Revisions to the Evap. Purge Flow Monitor tests Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2279 374 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2280 375 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2281 377 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2282 379 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2283 379A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2284 379B Revision to the EGR system Failure tests Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2285 432 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2286 433 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2287 434 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2288 435 Revision to the torque convertor clutch - no drop at lock up test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2289 465 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2290 467 Revision to the no temp rise seen at intake heater test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2291 514 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2292 515 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2293 516 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2294 517 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2295 518 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2296 519 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2297 520 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2298 521 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2299 521A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2300 521B Revision to the 12 volt supply relay test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2301 571 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2302 Throttle Position Sensor: Technical Service Bulletins Fuel/Engine Controls - Injector Circuit/TPS Revisions NUMBER: 26-05-98F GROUP: Miscellaneous DATE: May, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 2.5L, 3.9L, 5.2L, 5.9L Truck Powertrain Diagnostic Manual - Publication Number 81-699-96041 DESCRIPTION OF CHANGES Revision to the injector connector diagram Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2303 224 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2304 225 Revision to the throttle position sensor test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2305 164 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2306 165 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2307 168 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2308 169 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2309 169A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2310 169B Revision to the TPS voltage test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2311 422 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2312 423 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2313 Throttle Position Sensor: Specifications DESCRIPTION .................................................................................................................................... .............................................................. TORQUE Throttle Position Sensor Mounting Screws ................................................................................................................................................... 7 Nm (60 in lb) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2314 Throttle Position Sensor: Locations Fig. 15 MAP And Throttle Position Sensor Location - Typical The TPS is mounted on the throttle body. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2315 Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2316 Throttle Position Sensor: Description and Operation DESCRIPTION The Throttle Position Sensor (TPS) is a variable resistor that provides the powertrain control module (PCM) with an input signal (voltage) that represents throttle blade position. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the resistance of the TPS changes. OPERATION 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 1 volt at minimum throttle opening (idle), to 4 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. This input signal is also used to determine overdrive and converter clutch shift schedule and to select the proper governor curve. Fig. 15 MAP And Throttle Position Sensor Location - Typical LOCATION The TPS is mounted on the throttle body. CIRCUIT OPERATION From the Powertrain Control Module (PCM), circuit K6 supplies 5 Volts to the Throttle Position Sensor (TPS). Circuit K6 connects to cavity A17 of the PCM. Circuit K22 delivers the TPS signal to the PCM. Circuit K22 connects to cavity A23 of the PCM. The PCM provides a ground for the TPS signal (circuit K22) through circuit K4. Circuit K4 connects to cavity A4 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Component Test Throttle Position Sensor: Testing and Inspection Component Test Fig 62 TPS To perform a complete test of the TPS and its circuitry, refer to Powertrain Management/Computers and Controls/Testing and Inspection/Diagnostic Charts. To test the TPS only, refer to the following: The TPS (Fig. 62) can be tested with a digital voltmeter. The center electrical terminal of the TPS is the output terminal. With the ignition key in the ON position, check the TPS output voltage at the center terminal wire of the connector. Check this at idle (throttle plate closed) and at wide open throttle (WOT). At idle, TPS output voltage should be greater than 0.350 millivolts but less than 900 millivolts. At wide open throttle, TPS output voltage must be less than 4.5 volts. The output voltage should increase gradually as the throttle plate is slowly opened from idle to WOT. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Component Test > Page 2319 Throttle Position Sensor: Testing and Inspection Helpful Information Circuit K6 splices to supply 5 Volts to the manifold absolute pressure sensor, crankshaft position sensor and camshaft position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Crankshaft position sensor - Intake air temperature sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Page 2320 Throttle Position Sensor: Service and Repair Fig 71 TPS Mounting Bolts Fig 72 Installation - Typical REMOVAL 1. Remove air duct at throttle body. 2. Disconnect TPS electrical connector. 3. Remove two TPS mounting bolts (Fig. 71). 4. Remove TPS from throttle body. NOTES: - The throttle shaft end of the throttle body slides into a socket in the TPS (Fig. 72). - The TPS must be installed so that it can be rotated a few degrees. - If the sensor will not rotate, install the sensor with the throttle shaft on the other side of the socket tangs. - The TPS will be under slight tension when rotated. INSTALLATION 1. Install the TPS and two retaining bolts. 2. Tighten bolts to 7 Nm (60 in lb) torque. 3. Manually operate the throttle control lever by hand to check for any binding of the TPS. 4. Connect TPS electrical connector to TPS. 5. Install air duct at throttle body. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2324 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. 4. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 5. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 6. Test continuity of new switch with 12V test lamp. 7. Connect switch wires and lower vehicle. 8. Top off transmission fluid level. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications Vehicle Speed Sensor: Specifications DESCRIPTION .................................................................................................................................... .............................................................. TORQUE Vehicle Speed Sensor Mounting Bolt ......................................................................................................................................................... 2.2 Nm (20 in lb) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 2328 Vehicle Speed Sensor: Locations Fig 13 Vehicle Speed Sensor Location - 2WD - Typical Fig 14 Vehicle Speed Sensor Location - 4WD - Typical Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2331 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 Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2332 Electrostatic Discharge Symbol All Electrostatic Discharge (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, especially 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. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2333 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2334 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2335 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2336 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2337 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2338 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2339 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2340 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. 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. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2341 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2342 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2343 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2344 Vehicle Speed Sensor: Diagnostic Aids 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 in 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 and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2345 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. 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 every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. 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 fuse circuit. 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 the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2346 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools 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 - This instrument is 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 vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. 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 non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2347 Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Circuit Operation Vehicle Speed Sensor: Description and Operation Circuit Operation CIRCUIT OPERATION The Powertrain Control Module (PCM) supplies 5 Volts to the vehicle speed sensor on circuit K7. Circuit K7 connects B31 of the PCM. Circuit G7 from the vehicle speed sensor provides an input signal to the PCM. The G7 circuit connects to cavity B27 of the PCM. The PCM provides a ground for the vehicle speed sensor signal (circuit G7) through circuit K4. Circuit K4 connects to cavity A4 of the PCM. HELPFUL INFORMATION Circuit K4 also provides ground for the signals from the following: Heated oxygen sensors - Crankshaft position sensor - Camshaft position sensor - Engine coolant temperature sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Circuit Operation > Page 2350 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor Operation Fig 13 Vehicle Speed Sensor Location - 2WD - Typical Fig 14 Vehicle Speed Sensor Location - 4WD - Typical DESCRIPTION The sensor input is used by the powertrain control module (PCM) to determine vehicle speed and distance traveled. OPERATION The speed sensor generates 8 pulses per sensor revolution. These signals, in conjunction with a closed throttle signal from the throttle position sensor, indicate a closed throttle deceleration to the PCM. When the vehicle is stopped at idle, a closed throttle signal is received by the PCM (but a speed sensor signal is not received). Under deceleration conditions, the PCM adjusts the idle air control (IAC) motor to maintain a desired Manifold Absolute Pressure (MAP) value. Under idle conditions, the PCM adjusts the IAC motor to maintain a desired engine speed. The vehicle speed sensor is located on the speedometer pinion gear adapter. The pinion gear adapter is located on the extension housing of the transmission (drivers side). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Component Test Vehicle Speed Sensor: Testing and Inspection Component Test To perform a complete test of the idle air control motor and circuits see Computers and System Diagnosis/Testing and Inspection/Diagnostic Charts. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Component Test > Page 2353 Vehicle Speed Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Crankshaft position sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Intake air temperature sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Page 2354 Vehicle Speed Sensor: Service and Repair Fig 91 Vehicle Speed Sensor Location - 2WD - Typical Fig 92 Vehicle Speed Sensor Location - 4WD - Typical The vehicle speed sensor is located on the speedometer pinion gear adapter (Fig. 91) or (Fig. 92). The pinion gear adapter is located on the extension housing of the transmission (drivers side). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Page 2355 Fig 93 Sensor Removal/Installation REMOVAL 1. Raise and support vehicle. 2. Disconnect the electrical connector from the sensor. 3. Remove the sensor mounting bolt (Fig. 93). 4. Remove the sensor (pull straight out) from the speedometer pinion gear adapter (Fig. 93). - Do not remove the gear adapter from the transmission. INSTALLATION 1. Clean the inside of speedometer pinion gear adapter before installing speed sensor. 2. Install sensor into speedometer gear adapter and install mounting bolt. - Before tightening bolt, verify speed sensor is fully seated (mounted flush) to speedometer pinion gear adapter. 3. Tighten sensor mounting bolt to 2.2 Nm (20 in lb) torque. 4. Connect electrical connector to sensor. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates Purge Flow Sensor: Technical Service Bulletins Engine Controls/Emissions/A/T - Manual Updates NUMBER: 26-06-98 GROUP: Miscellaneous DATE: June, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 2.5L, 3.9L, 5.2L, 5.9L 8.0L SFI/CNG/Diesel Diagnostic Manual - Publication Number 81-699-96041 DESCRIPTION OF CHANGES Revision to the diagnostic trouble codes Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2361 56 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2362 57 Revisions to the Throttle Position Sensor test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2363 162 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2364 166 Revisions to the Evap. Purge Flow Monitor tests Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2365 374 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2366 375 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2367 377 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2368 379 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2369 379A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2370 379B Revision to the EGR system Failure tests Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2371 432 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2372 433 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2373 434 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2374 435 Revision to the torque convertor clutch - no drop at lock up test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2375 465 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2376 467 Revision to the no temp rise seen at intake heater test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2377 514 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2378 515 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2379 516 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2380 517 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2381 518 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2382 519 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2383 520 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2384 521 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2385 521A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2386 521B Revision to the 12 volt supply relay test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2387 571 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates Throttle Position Sensor: Technical Service Bulletins Engine Controls/Emissions/A/T - Manual Updates NUMBER: 26-06-98 GROUP: Miscellaneous DATE: June, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 2.5L, 3.9L, 5.2L, 5.9L 8.0L SFI/CNG/Diesel Diagnostic Manual - Publication Number 81-699-96041 DESCRIPTION OF CHANGES Revision to the diagnostic trouble codes Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2393 56 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2394 57 Revisions to the Throttle Position Sensor test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2395 162 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2396 166 Revisions to the Evap. Purge Flow Monitor tests Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2397 374 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2398 375 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2399 377 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2400 379 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2401 379A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2402 379B Revision to the EGR system Failure tests Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2403 432 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2404 433 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2405 434 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2406 435 Revision to the torque convertor clutch - no drop at lock up test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2407 465 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2408 467 Revision to the no temp rise seen at intake heater test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2409 514 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2410 515 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2411 516 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2412 517 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2413 518 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2414 519 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2415 520 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2416 521 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2417 521A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2418 521B Revision to the 12 volt supply relay test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2419 571 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2420 Throttle Position Sensor: Technical Service Bulletins Fuel/Engine Controls - Injector Circuit/TPS Revisions NUMBER: 26-05-98F GROUP: Miscellaneous DATE: May, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 2.5L, 3.9L, 5.2L, 5.9L Truck Powertrain Diagnostic Manual - Publication Number 81-699-96041 DESCRIPTION OF CHANGES Revision to the injector connector diagram Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2421 224 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2422 225 Revision to the throttle position sensor test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2423 164 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2424 165 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2425 168 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2426 169 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2427 169A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2428 169B Revision to the TPS voltage test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2429 422 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2430 423 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2431 Throttle Position Sensor: Specifications DESCRIPTION .................................................................................................................................... .............................................................. TORQUE Throttle Position Sensor Mounting Screws ................................................................................................................................................... 7 Nm (60 in lb) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2432 Throttle Position Sensor: Locations Fig. 15 MAP And Throttle Position Sensor Location - Typical The TPS is mounted on the throttle body. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2433 Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2434 Throttle Position Sensor: Description and Operation DESCRIPTION The Throttle Position Sensor (TPS) is a variable resistor that provides the powertrain control module (PCM) with an input signal (voltage) that represents throttle blade position. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the resistance of the TPS changes. OPERATION 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 1 volt at minimum throttle opening (idle), to 4 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. This input signal is also used to determine overdrive and converter clutch shift schedule and to select the proper governor curve. Fig. 15 MAP And Throttle Position Sensor Location - Typical LOCATION The TPS is mounted on the throttle body. CIRCUIT OPERATION From the Powertrain Control Module (PCM), circuit K6 supplies 5 Volts to the Throttle Position Sensor (TPS). Circuit K6 connects to cavity A17 of the PCM. Circuit K22 delivers the TPS signal to the PCM. Circuit K22 connects to cavity A23 of the PCM. The PCM provides a ground for the TPS signal (circuit K22) through circuit K4. Circuit K4 connects to cavity A4 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Component Test Throttle Position Sensor: Testing and Inspection Component Test Fig 62 TPS To perform a complete test of the TPS and its circuitry, refer to Powertrain Management/Computers and Controls/Testing and Inspection/Diagnostic Charts. To test the TPS only, refer to the following: The TPS (Fig. 62) can be tested with a digital voltmeter. The center electrical terminal of the TPS is the output terminal. With the ignition key in the ON position, check the TPS output voltage at the center terminal wire of the connector. Check this at idle (throttle plate closed) and at wide open throttle (WOT). At idle, TPS output voltage should be greater than 0.350 millivolts but less than 900 millivolts. At wide open throttle, TPS output voltage must be less than 4.5 volts. The output voltage should increase gradually as the throttle plate is slowly opened from idle to WOT. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Component Test > Page 2437 Throttle Position Sensor: Testing and Inspection Helpful Information Circuit K6 splices to supply 5 Volts to the manifold absolute pressure sensor, crankshaft position sensor and camshaft position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Crankshaft position sensor - Intake air temperature sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Page 2438 Throttle Position Sensor: Service and Repair Fig 71 TPS Mounting Bolts Fig 72 Installation - Typical REMOVAL 1. Remove air duct at throttle body. 2. Disconnect TPS electrical connector. 3. Remove two TPS mounting bolts (Fig. 71). 4. Remove TPS from throttle body. NOTES: - The throttle shaft end of the throttle body slides into a socket in the TPS (Fig. 72). - The TPS must be installed so that it can be rotated a few degrees. - If the sensor will not rotate, install the sensor with the throttle shaft on the other side of the socket tangs. - The TPS will be under slight tension when rotated. INSTALLATION 1. Install the TPS and two retaining bolts. 2. Tighten bolts to 7 Nm (60 in lb) torque. 3. Manually operate the throttle control lever by hand to check for any binding of the TPS. 4. Connect TPS electrical connector to TPS. 5. Install air duct at throttle body. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations Camshaft Position Sensor: Component Locations Camshaft Position Sensor The Camshaft Position (CMP) Sensor is mounted in the distributor housing. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 2444 Distributor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2445 CPS Connector Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2446 Camshaft Position Sensor: Description and Operation LOCATION The camshaft position sensor is located in the distributor on all engines. DESCRIPTION The sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft. The pulse ring rotates 180 degrees through the sync signal generator. Its signal is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. OPERATION When the leading edge of the pulse ring (shutter) enters the sync signal generator, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a sync signal of approximately 5 volts. When the trailing edge of the pulse ring (shutter) leaves the sync signal generator, the change of the magnetic field causes the sync signal voltage to switch low to 0 volts. CIRCUIT OPERATION The camshaft position sensor is located internal to the distributor on all engine applications. The Powertrain Control Module (PCM) supplies 5 Volts to the camshaft position sensor on circuit K6. Circuit K6 connects to cavity A17 of the PCM. The PCM receives the camshaft position sensor signal on circuit K44. Circuit K44 connects to cavity A18 of the PCM. The PCM provides a ground for the camshaft position sensor (circuit K44) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2447 Camshaft Position Sensor: Testing and Inspection Circuit K6 splices to supply 5 Volts to the crankshaft position sensor, manifold absolute pressure sensor, and throttle position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Crankshaft position sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2448 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor NOTE: Distributor removal is not necessary to remove camshaft position sensor. REMOVAL 1. Remove air cleaner assembly 2. Disconnect negative cable from battery 3. Remove distributor cap from distributor (two screws). 4. Disconnect camshaft position sensor wiring harness from main engine wiring harness. 5. Remove distributor rotor from distributor shaft. 6. Lift the camshaft position sensor assembly from the distributor housing. INSTALLATION 1. Install camshaft position sensor to distributor. Align sensor into notch on distributor housing. 2. Connect wiring harness. 3. Install rotor 4. Install distributor cap. Tighten mounting screws. 5. Install air cleaner assembly. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications DESCRIPTION .................................................................................................................................... .............................................................. TORQUE Crankshaft Position Sensor ................................................................................................................. .......................................................... 8 Nm (70 in lb) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2452 Crankshaft Position Sensor: Locations Crankshaft Position Sensor The sensor is located on the top of cylinder block near the rear of right cylinder head. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2453 CKP Connector Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2454 Crankshaft Position Sensor: Description and Operation Fig. 4 Sensor Operation DESCRIPTION The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. The flywheel/drive plate has groups of notches at its outer edge. there are three sets of double notches and three sets of single notches. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. OPERATION Engine speed and crankshaft position are provided through the 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. CIRCUIT OPERATION The Powertrain Control Module (PCM) supplies 5 Volts to the crankshaft position sensor on circuit K6. Circuit K6 connects to cavity A17 of the PCM. The PCM receives the crankshaft position sensor signal on circuit K24. Circuit K24 connects to cavity A8 of the PCM. The PCM provides a ground for the crankshaft position sensor (circuit K24) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector. NOTE: The engine will not operate if the PCM does not receive a crankshaft position sensor input. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2455 Crankshaft Position Sensor: Testing and Inspection Circuit K6 splices to supply 5 Volts to the camshaft position sensor, manifold absolute pressure sensor, and throttle position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2456 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor NOTE: The sensor is bolted to the top of the cylinder block near the rear of right cylinder head. The sensor is accessed by removing the right front fender liner. REMOVAL 1. Remove right front tire and right front wheelhouse liner. 2. Disconnect crankshaft position sensor pigtail harness from main wiring harness. 3. Remove two sensor (recessed hex head) mounting bolts. 4. Remove sensor from engine. INSTALLATION 1. Position crankshaft position sensor to engine. 2. Install mounting bolts and tighten to 8 Nm (70 in lb) torque. 3. Connect main harness electrical connector to sensor. 4. Install right front tire and right front wheelhouse liner. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Description and Operation Ignition Switch: Description and Operation IGNITION SWITCH AND KEY LOCK CYLINDER The ignition switch is located on the steering column. The Key-In-Switch is located in the ignition switch module. For electrical diagnosis of the Key-In-Switch, refer to Chime/Buzzer Warning Systems. For removal/installation of either the key lock cylinder or ignition switch, refer to Ignition Switch and Key Cylinder Removal/Installation. On vehicles equipped with an automatic transmission, a cable connects an interlock device within the steering column assembly to the transmission floor shift lever. This interlock device is used to lock the transmission shifter in the PARK position when the key is in the LOCKED or ACCESSORY position. The interlock device is not serviceable. If repair is necessary, the steering column assembly must be replaced. Refer to procedures. The shifter interlock cable can be adjusted or replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Description and Operation > Page 2460 Ignition Switch: Service and Repair Fig 46 Shroud Removal/Installation - Typical IGNITION SWITCH AND KEY CYLINDER The ignition key must be in the key cylinder for cylinder removal. KEY CYLINDER REMOVAL 1. Disconnect negative cable from battery. 2. If equipped with tilt column, remove tilt lever by turning it counterclockwise. 3. Remove upper and lower covers (shrouds) from steering column. 4. If equipped with automatic transmission, place shifter in PARK position. Fig 47 Retaining Pin 5. A retaining pin is located at side of key cylinder assembly. a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder from ignition switch. IGNITION SWITCH REMOVAL 1. Remove key lock cylinder. Refer to previous steps. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Description and Operation > Page 2461 Fig 48 Switch Mounting Screws 2. Remove 3 ignition switch mounting screws. Use tamper proof torx bit (Snap-On SDMTR10 or equivalent) to remove screws. 3. Gently pull switch away from column. Release connector locks on 7-terminal wiring connector at ignition switch and remove connector. 4. Release connector lock on 4-terminal halo lamp wiring connector and remove connector. IGNITION SWITCH AND KEY CYLINDER INSTALLATION If installing ignition key lock cylinder only, proceed to following steps 2, 3 and 4. Also refer to following steps 12 through 18. If installing both switch and key cylinder, refer to steps 1 through 18. Fig 50 Flag In RUN Position Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Description and Operation > Page 2462 Fig 51 Key Cylinder - Rear View 1. Rotate flag on rear of ignition switch until in RUN position. This step must be done to allow tang on key cylinder to fit into slots within ignition switch. Fig 52 Installing Key Cylinder Into Switch 2. With key into ignition key cylinder, rotate key clockwise until retaining pin can be depressed. 3. Install key cylinder into ignition switch by aligning retaining pin into retaining pin slot. Push key cylinder into switch until retaining pin engages. After pin engages, rotate key to OFF or LOCK position. 4. Check for proper retention of key cylinder by attempting to pull cylinder from switch. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Description and Operation > Page 2463 Fig 53 Ignition Switch View From Column Fig 54 Park Lock Linkage - Automatic Transmission - Typical 5. Automatic Transmission Only: Before attaching ignition switch to steering column, the transmission shifter must be in PARK position. The park lock dowel pin on rear of ignition switch must also be properly indexed into the park lock linkag before installing switch. 6. The flag at rear of ignition switch must be properly indexed into steering column before installing switch. This flag is used to operate the steering wheel lock lever in steering column. This lever allows steering wheel position to be locked when key switch is in LOCK position. 7. Place ignition switch in LOCK position. The switch is in the LOCK position when column lock flag is parallel to ignition switch terminals. 8. Automatic Transmission Only: Apply a light coating of grease to park lock dowel pin and park lock slider linkage. Before installing switch, push the park lock slider linkage forward until it bottoms. Do a final positioning by pulling it rearward about one-quarter inch. 9. Apply a light coating of grease to both column lock flag and shaft at end of flag. 10. Place ignition switch into openings on steering column. a. Automatic Transmission Only: Be sure park lock dowel pin on rear of ignition switch enters slot in park lock slider linkage. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Description and Operation > Page 2464 Fig 55 Steering Wheel Lock Lever b. Be sure flag on rear of switch is positioned above steering wheel lock lever. c. Align dowel pins on rear of switch into holes on side of steering column. d. Install 3 ignition switch mounting screws. Tighten screws to 3 Nm +/- 5 Nm (26 in lb +/- 4 in lb) torque. 11. Connect electrical connectors to ignition switch and halo lamp. Make sure that switch locking tabs are fully seated in wiring connectors. 12. Install steering column covers (shrouds). Tighten screws to 2 Nm (17 in lb) torque. 13. Install tilt column lever (if equipped). 14. Connect negative cable to battery. 15. Check for proper operation of halo light. 16. Automatic Transmission Only: Shifter should lock in PARK position when key is in LOCK position (if equipped with shift lock device). Shifter should unlock when key rotated to ON position. 17. Check for proper operation of ignition switch in ACCESSORY, LOCK, OFF, ON, RUN, and START positions. 18. Steering wheel should lock when key is in LOCK position. Rotate steering wheel to verify Steering wheel should unlock when key is rotated to ON position. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Fuel Pressure Gauge Adapter - Usage Fuel Pressure: Technical Service Bulletins Fuel Pressure Gauge Adapter - Usage NO: 14-03-98 GROUP: Fuel DATE: May 1, 1998 SUBJECT: Fuel Pressure Gauge Adapter Usage MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) DISCUSSION: Currently, four different fuel pressure adapters are required, depending on application, to attach a fuel gauge for pressure testing. The matrix lists the adapter part numbers and their application. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Pressure, Vacuum and Temperature Specifications Fuel Pressure: Pressure, Vacuum and Temperature Specifications Fuel Pressure Engine at curb idle ............................................................................................................................... ........................................ 339 ± 34 kPa (49.2 ± 5 psi) Pressure Leakdown (fuel pump not engaged) ................................................................................................................. Not fall below 30 psi for 5 minutes Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Pressure, Vacuum and Temperature Specifications > Page 2472 Fuel Pressure: Capacity Specifications NOTE: Before performing this test, vent fuel pump pressure by performing the Fuel Pump Pressure Test. Use this test in conjunction with the Fuel Pressure Leak Down Test. 1. Release fuel system pressure. Refer to the Fuel Pressure Release Procedure. 2. Disconnect fuel supply line at fuel rail. Some engines may require air cleaner housing removal before line disconnection. 3. Connect appropriate Fuel Line Pressure Test Adapter Tool Hose (number 6631, 6923, 6541 or 6539) into disconnected fuel supply line. Insert other end of Adaptor Tool hose into a graduated container. 4. Remove fuel fill cap. 5. To activate fuel pump and pressurize system, obtain DRB scan tool and actuate ASD Fuel System Test. 6. A good fuel pump will deliver at least 1/4 liter of fuel in 7 seconds. Do not operate fuel pump for longer than 7 seconds with fuel line disconnected as fuel pump module reservoir may run empty. a. If capacity is lower than specification, but fuel pump can be heard operating through fuel fill cap opening, check for a kinked/damaged fuel supply line somewhere between fuel rail and fuel pump module. b. If line is not kinked/damaged, and fuel pressure is OK, but capacity is low, replace fuel filter/ fuel pressure regulator. The filter/regulator may be serviced separately on certain applications. Refer to Fuel Filter/Fuel Pressure Regulator Removal/Installation for additional information. c. If both fuel pressure and capacity are low, replace fuel pump module assembly Refer to Fuel Pump Module Removal/Installation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test Fuel Pressure: Testing and Inspection Fuel Pressure Leak Down Test Fig 11 Connecting Adapter Tool - Typical Fig 12 Connecting Adapter Tool - Typical NOTE: Use this test in conjunction with the Fuel Pump Pressure Test and Fuel Pump Capacity Test. Check Valve Operation: The electric fuel pump outlet contains a one-way check valve to prevent fuel flow back into the tank and to maintain fuel supply line pressure (engine warm) when pump is not operational. It is also used to keep the fuel supply line full of gasoline when pump is not operational. After the vehicle has cooled down, fuel pressure may drop to 0 psi (cold fluid contracts), but liquid gasoline will remain in fuel supply line between the check valve and fuel injectors. Fuel pressure that has dropped to 0 psi on a cooled down vehicle (engine off) is a normal condition. when the electric fuel pump is activated, fuel pressure should immediately rise to specification. Abnormally long periods of cranking to restart a hot engine that has been shut down for a short period of time may be caused by: ^ Fuel pressure bleeding past a fuel injector(s). ^ Fuel pressure bleeding past the check valve in the fuel pump module. Procedure 1. Disconnect the fuel inlet line at fuel rail. - On some engines, air cleaner housing removal may be necessary before fuel line disconnection. 2. Connect the appropriate Fuel Line Pressure Test Adapter Tool (number 6539, 6631, 6541 or 6923) between the disconnected fuel line and fuel rail (Fig. 11) or (Fig. 12). 3. Connect the 0-414 kPa (0-60 psi) fuel pressure test gauge (from Gauge Set 5069) to the test port on the appropriate Adaptor Tool. - The fittings on both tools must be in good condition and free from any small leaks before performing the proceeding test. 4. Start engine and bring to normal operating temperature. 5. Observe test gauge. Normal operating pressure should be 339 kPa +/- 34 kPa (49.2 psi +/- 5 psi). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 2475 6. Shut engine off. 7. Pressure should not fall below 30 psi for five minutes. 8. If pressure falls below 30 psi, it must be determined if a fuel injector, the check valve within the fuel pump module, or a fuel tube/line is leaking. 9. Again, start engine and bring to normal operating temperature. 10. Shut engine off. 11. Testing for fuel injector or fuel rail leakage: - Clamp off the rubber hose portion of Adaptor Tool between the fuel rail and the test port "T" on Adapter Tool. - If pressure now holds at or above 30 psi, a fuel injector or the fuel rail is leaking. 12. Testing for fuel pump check valve, filter/ regulator check valve or fuel tube/line leakage: - Clamp off the rubber hose portion of Adaptor Tool between the vehicle fuel line and test port "T" on Adapter Tool. - If pressure now holds at or above 30 psi, a leak may be found at a fuel tube/line. - If no leaks are found at fuel tubes or lines, one of the check valves in either the electric fuel pump or filter/ regulator may be leaking. NOTE: A quick loss of pressure usually indicates a defective check valve in the filter/regulator. A slow loss of pressure usually indicates a defective check valve in the electric fuel pump. The electric fuel pump is not serviced separately. Replace the fuel pump module assembly. The filter/regulator may be replaced separately on certain applications. Refer to Fuel Filter/Fuel Pressure Regulator Removal/Installation for additional information. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 2476 Fuel Pressure: Testing and Inspection Fuel Pressure Test - With Test Port Fig 8 Fuel Pressure Test Port - Typical WARNING: THE FUEL SYSTEM IS UNDER CONSTANT FUEL PRESSURE EVEN WITH THE ENGINE OFF. BEFORE DISCONNECTING FUEL LINE AT FUEL RAIL, THIS PRESSURE MUST BE RELEASED. REFER TO THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE. NOTE: Use this test in conjunction with the Fuel Pump Capacity Test and Fuel Pressure Leak Down Test found elsewhere. Check Valve Operation: The electric fuel pump outlet contains a one-way check valve to prevent fuel flow back into the tank and to maintain fuel supply line pressure (engine warm) when pump is not operational. - It is also used to keep the fuel supply line full of gasoline when pump is not operational. After the vehicle has cooled down, fuel pressure may drop to 0 psi (cold fluid contracts), but liquid gasoline will remain in fuel supply line between the check valve and fuel injectors. Fuel pressure that has dropped to 0 psi on a cooled down vehicle (engine off) is a normal condition. When the electric fuel pump is activated, fuel pressure should immediately rise to specification. NOTE: The fuel pressure test port is used on certain engines only. The test port is located on the fuel rail near the throttle position sensor (Fig. 8). A sealing cap is screwed onto the test port. All fuel systems are equipped with a fuel tank module mounted, combination fuel filter/fuel pressure regulator. The fuel pressure regulator is not controlled by engine vacuum. Procedure 1. Remove protective cap at fuel rail test port. Connect the 0-414 kPa (0-60 psi) fuel pressure gauge (from gauge set 5069) to test port pressure fitting on fuel rail. 2. Start and warm engine and note pressure gauge reading. Fuel pressure should be 339 kPa +/34 kPa (49.2 psi +/- 5 psi) at idle. 3. If engine runs but pressure is below 44.2 psi, check for a kinked fuel supply line somewhere between fuel rail and fuel pump module. If line is not kinked, replace fuel pump module assembly. Refer to Fuel Pump Module Removal/Installation. 4. If operating pressure is above 54.2 psi, electric fuel pump is OK, but fuel pressure regulator is defective. - Replace fuel filter/fuel pressure regulator. - Certain filter/regulators may be serviced separately and some require the replacement of the fuel pump module assembly Refer to Fuel Filter /Fuel Pressure Regulator Removal/Installation for more information. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 2477 Fuel Pressure: Testing and Inspection Fuel Pressure Test - Without Test Port Fig 10 Installing Adapter Tool And Pressure Gauge WARNING: THE FUEL SYSTEM IS UNDER CONSTANT FUEL PRESSURE EVEN WITH THE ENGINE OFF. BEFORE DISCONNECTING FUEL LINE AT FUEL RAIL, THIS PRESSURE MUST BE RELEASED. REFER TO THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE. NOTE: Use this test in conjunction with the Fuel Pump Capacity Test and Fuel Pressure Leak Down Test. Check Valve Operation: The electric fuel pump outlet contains a one-way check valve to prevent fuel flow back into the tank and to maintain fuel supply line pressure (engine warm) when pump is not operational. It is also used to keep the fuel supply line full of gasoline when pump is not operational. After the vehicle has cooled down, fuel pressure may drop to 0 psi (cold fluid contracts), but liquid gasoline will remain in fuel supply line between the check valve and fuel injectors. Fuel pressure that has dropped to 0 psi on a cooled down vehicle (engine off) is a normal condition. When the electric fuel pump is activated, fuel pressure should immediately rise to specification. All fuel systems are equipped with a fuel tank module mounted, combination fuel filter/fuel pressure regulator. The fuel pressure regulator is not controlled by engine vacuum. Procedure 1. Release fuel pressure. Refer to the Fuel System Pressure Release Procedure-Without Pressure Test Port. 2. Disconnect latch clip and fuel line at fuel rail. Refer to Quick-Connect Fittings for procedures. 3. Connect adapter tool number 6923 into the fuel rail (Fig. 10). Be sure adapter tool is fully seated into fuel rail. 4. Install latch clip to fuel rail. If latch clip can not be fully seated into fuel rail, check for adapter tool not fully seated to fuel rail. 5. Connect vehicle fuel line into adapter tool 6923 (Fig. 10). Be sure fuel line is fully seated into adapter tool 6923. 6. Remove protective cap at test port "T" on adapter tool number 6923. 7. Connect the 0-414 kPa (0-60 psi) fuel pressure gauge (from gauge set 5069) to the test port "T" (Fig. 10). 8. Start engine and note pressure gauge reading. Fuel pressure should be 339 kPa +/- 34 kPa (49.2 psi +/5 psi) at idle. 9. If engine runs but pressure is below 44.2 psi, check for a kinked fuel supply line somewhere between fuel rail and fuel pump module. If line is not kinked, replace fuel pump module assembly. Refer to Fuel Pump Module Removal/Installation. 10. If operating pressure is above 54.2 psi, electric fuel pump is OK, but fuel pressure regulator is defective. Replace fuel filter/fuel pressure regulator. Certain filter/regulators may be serviced separately and some require the replacement of the fuel pump module assembly. Refer to Fuel Filter/Fuel Pressure Regulator Removal/Installation for more information. 11. After performing pressure test, install fuel line into fuel rail. Install latch clip into fuel rail. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 2478 Fuel Pressure: Testing and Inspection Fuel Pump Capacity Test NOTE: Before performing this test, vent fuel pump pressure by performing the Fuel Pump Pressure Test. Use this test in conjunction with the Fuel Pressure Leak Down Test. 1. Release fuel system pressure. Refer to the Fuel Pressure Release Procedure. 2. Disconnect fuel supply line at fuel rail. Some engines may require air cleaner housing removal before line disconnection. 3. Connect appropriate Fuel Line Pressure Test Adapter Tool Hose (number 6631, 6923, 6541 or 6539) into disconnected fuel supply line. Insert other end of Adaptor Tool hose into a graduated container. 4. Remove fuel fill cap. 5. To activate fuel pump and pressurize system, obtain DRB scan tool and actuate ASD Fuel System Test. 6. A good fuel pump will deliver at least 1/4 liter of fuel in 7 seconds. Do not operate fuel pump for longer than 7 seconds with fuel line disconnected as fuel pump module reservoir may run empty. a. If capacity is lower than specification, but fuel pump can be heard operating through fuel fill cap opening, check for a kinked/damaged fuel supply line somewhere between fuel rail and fuel pump module. b. If line is not kinked/damaged, and fuel pressure is OK, but capacity is low, replace fuel filter/ fuel pressure regulator. The filter/regulator may be serviced separately on certain applications. Refer to Fuel Filter/Fuel Pressure Regulator Removal/Installation for additional information. c. If both fuel pressure and capacity are low, replace fuel pump module assembly Refer to Fuel Pump Module Removal/Installation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Minimum Air Flow Idle ......................................................................................................................... ......................................................... 500 to 900 rpm Note: Idle speed range achieved through Minimum Air Flow Idle Test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 2482 Idle Speed: Testing and Inspection The following test procedure has been developed to check throttle body calibrations for correct idle conditions. The procedure should be used to diagnose the throttle body for conditions that may cause idle problems. This procedure should be used only after normal diagnostic procedures have failed to produce results that indicate a throttle body related problem. Be sure to check for proper operation of the idle air control motor before performing this test. Fig. 73 Fixed Orifice Tool A special fixed orifice tool (number 6714) must be used for the following test. 1. Start the engine and bring to operating temperature. Be sure all accessories are off before performing this test. 2. Shut off the engine and remove the air cleaner element housing. Fig. 74 Install Orifice Tool 3. Disconnect the vacuum line at the PCV valve. 4. Install the 0.185 inch orifice tool (number 6714) into the disconnected vacuum line in place of the PCV valve. Fig. 75 Idle Purge Line Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 2483 5. Disconnect the idle purge vacuum line from fitting at throttle body This vacuum line is located on the front of throttle body next to the MAP sensor. Cap the fitting at throttle body after vacuum line has been removed. 6. Connect the DRB scan tool to the 16-way data link connector. This connector is located under the instrument panel to the left of the steering column. 7. Start the engine. 8. Using the DRB scan tool, scroll through the menus as follows: select-System, select-Engine, select-Fuel and Ignition, select-Actuator Tests, select Engine rpm and select-Minimum Air Flow. 9. The DRB scan tool will count down to stabilize the idle rpm and display the minimum air flow idle rpm. The idle rpm should be between 500 and 900 rpm. If the idle speed is outside of these specifications, replace the throttle body. 10. Disconnect the DRB scan tool from the vehicle. 11. Remove cap from idle purge fitting at throttle body and install vacuum line. 12. Remove orifice tool and connect vacuum line to PCV valve. 13. Install air cleaner element housing. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 2484 Idle Speed: Adjustments Idle speed is electronically controlled by the Powertrain Control Module (PCM) through the Idle Air Control (IAC) motor, and is not adjustable. CAUTION: This vehicle is equipped with a factory adjusted throttle plate position set screw. Never attempt to adjust idle speed using this screw, unless directed to do so in a service procedure. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > With Pressure Test Port Fuel Pressure Release: Service and Repair With Pressure Test Port WARNING: BECAUSE THE FUEL SYSTEM IS UNDER CONSTANT FUEL PRESSURE, IT MUST BE RELEASED BEFORE SERVICING ANY FUEL SYSTEM COMPONENT THIS DOES NOT APPLY TO THROTTLE BODY REMOVAL. NOTE: The fuel pressure test port is used on certain engines only. If equipped, the test port will be located on fuel rail. A sealing cap is screwed onto test port. - The fuel system is under constant fuel pressure (even with engine off). 1. Disconnect negative battery cable. 2. Remove fuel tank filler tube cap to release fuel tank pressure. 3. Remove protective cap from pressure test port on fuel rail. This is located on top of fuel rail. WARNING: DO NOT ALLOW FUEL TO SPILL ONTO ENGINE INTAKE OR EXHAUST MANIFOLDS. PLACE SHOP TOWELS UNDER AND AROUND PRESSURE PORT TO ABSORB FUEL WHEN PRESSURE IS RELEASED FROM FUEL RAIL. WARNING: WEAR PROPER EYE PROTECTION WHEN RELEASING FUEL SYSTEM PRESSURE. 4. Obtain fuel pressure gauge/hose assembly from fuel pressure gauge tool set 5069. Remove gauge from hose. 5. Place one end of hose (gauge end) into an approved gasoline container. 6. Place a shop towel under test port. 7. To release fuel pressure, screw other end of hose onto fuel pressure test port. 8. After fuel pressure has been released, remove hose from test port. 9. Install protective cap to fuel test port. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > With Pressure Test Port > Page 2490 Fuel Pressure Release: Service and Repair Without Pressure Test Port NOTE: Use the following procedure if the fuel rail is not equipped with a fuel pressure test port. 1. Remove the Fuel Pump relay from the Power Distribution Center (PDC). For location of the relay, refer to the label on the underside of the PDC cover. 2. Start and run engine until it stalls. 3. Attempt restarting engine until it will no longer run. 4. Turn ignition key to OFF position. CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within the fuel rail. Do not attempt to use the following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber. 5. Unplug connector from any injector. 6. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 7. Connect the other end of the jumper wire to the positive side of the battery 8. Connect one end of a second jumper wire to the remaining injector terminal. CAUTION: Supplying power to an injector for more than 4 seconds will permanently damage the injector. Do not leave the injector connected to power for more than 4 seconds. 9. Momentarily touch the other end of this jumper wire to the negative terminal of the battery for no more than 4 seconds. 10. Place a rag or towel below the fuel line at the quick connect to the rail. 11. Disconnect the quick connect fitting to the rail. Refer to Quick-Connect Fittings. 12. Return the fuel pump relay to the PDC. 13. One or more Diagnostic Trouble Codes (DTC's) may have been stored in the PCM memory due to fuel pump relay removal. The DRB scan tool must be used to erase a DTC. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Engine Firing Order - 3.9L Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks and Indicators > System Information > Locations Timing Marks and Indicators: Locations Align Timing Marks The timing marks are located on the timing cover, next to the vibration damper. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction Technical Service Bulletin # 18-48-98 Date: 981230 Ignition System - Cross Fire/Ignition Wire Induction NO: 18-48-98 GROUP: Vehicle Performance DATE: Dec. 30, 1998 SUBJECT: Ignition System Cross Fire/Secondary Ignition Wire Induction MODELS: 1994 - 1999 (AN) Dakota 1994 - 1999 (BR/BE)Ram Truck 1998 - 1999 (DN) Durango 1995 - 1998 (ZG) Grand Cherokee (International Market) 1994 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 3.9L, 5.2L, OR 5.9L ENGINE. AB MODELS WILL BE ADDED LATER (NEW PARTS REQUIRED). SYMPTOM/CONDITION: Some vehicles may exhibit one or more of the following: Spark knock complaints when the vehicle is under load. Various single cylinder misfire (1, 3, 7), especially 5 and/or 8. Surge in 4th gear with the Electronically Modulated Converter Clutch (EMCC) engaged (around 45 mph). Perceived torque converter EMCC engagement/disengagement around 45 mph. DIAGNOSIS: Using the Mopar Diagnostic System (MDS/MDS 2) or the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If other than mentioned Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present or if the above symptoms/conditions have been described by the customer, perform the Repair Procedure. NOTE: THIS REROUTING PROCEDURE SHOULD BE PERFORMED BEFORE ANY OTHER MISFIRE, SURGE, OR SPARK KNOCK REPAIRS ARE ATTEMPTED. PARTS REQUIRED: 3 56028186 Clip, Single Wire 2 06503441 Clip, Wire To Hose (5.2L & 5.9L) 1 04364375 Convolute, 10 ft Roll POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-12-15-92 - 3.9L (All) 0.2 Hrs. 08-12-15-93 (ZJ) 5.2/5.9L 0.2 Hrs. (AN/DN) 5.2/5.9L 0.3 Hrs. (BR/BE) 5.2/5.9L 0.4 Hrs. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 2506 FAILURE CODE: 9X - Routed Improperly Repair Procedure This bulletin involves rerouting the coil wire for all engines listed and rerouting the 4, 5, 7, and 8 plug wires for the 5.2/5.9L applications to minimize induction effects. NOTE: IF WIRES MUST CROSS DURING THE REROUTE PROCEDURE, THEY MUST CROSS AT A 90° ANGLE. 5.2L and 5.9L Engine Procedures 1. Coil Wire Routing (Figure 1 and 2) A. Remove the coil wire from the distributor cap coil wire tower terminal. B. Remove the coil wire from the rear five-wire clip, the center three-wire clip, and the front one-wire clip located along the lower side of the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover. Use the studs of the valve cover retaining bolts (Figure 1). NOTE: SOME APPLICATIONS MAY ONLY HAVE STUD LOCATIONS FOR 3 OF THE ONE-WIRE CLIPS. D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths 203 mm (8 in.), 101.5 mm (4 in.), and 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the 203 mm (8 in.) and the 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 2507 H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 2). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM AND/OR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. I. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. 2. No.8 Cylinder Plug Wire Routing (Figure 3) A. Remove the No.8 cylinder plug wire from the distributor cap tower terminal. B. Remove the No.8 cylinder plug wire from the five-wire clip located at the lower rear of the valve cover. C. Route the No.8 cylinder plug wire over the rear quarter of the right valve cover (Figure 3). D. Position the original piece convolute from the No.8 cylinder plug wire to prevent chafing at the right valve cover and with other engine components. E. Secure the No.8 cylinder plug wire and its convolute in place with the hose to wire clip p/n 06503441. The small end of the clip is positioned over the convolute. The large end of the clip is fastened to a heater hose (A/C line on ZJ models). NOTE: MAKE SURE THE NO.8 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE COIL WIRE AND THE NO.4 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. F. Install the No.8 cylinder plug wire to its distributor cap terminal. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 2508 3. No.4 Cylinder Plug Wire Routing (Figure 4 and 5) A. Remove the No.4 cylinder plug wire from the distributor cap terminal. B. At the three-wire clip (located at the center of the lower side of the right valve cover), keep the two wires from crossing and chafing each other. Position the No.2 cylinder plug wire in the top wire slot and the No.4 cylinder plug wire in the bottom wire slot. Leave the middle wire slot empty (Figure 5). C. At the five-wire clip (located at the right rear lower side of the valve cover), keep the plug wires from crossing and chafing each other. Position the No.4 cylinder plug wire in a slot that will obtain the maximum amount of distance allowable from the No.8 cylinder plug wire (Figure 6). Remove any slack in the No.4 cylinder plug wire between the three-wire and the five-wire clips. NOTE: EARLIER MODEL FIVE-WIRE CLIPS LOOK SLIGHTLY DIFFERENT BUT THE SAME WIRING LAYOUT APPLIES. D. Route the No.4 cylinder plug wire behind the transmission dipstick tube and heater hoses. On ZJ models this may not be possible due to the location of the bulkhead. NOTE: MAKE SURE THAT THE NO.4 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH AWAY FROM THE NO.8 CYLINDER PLUG WIRE. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 2509 E. Install the No.4 cylinder plug wire to its distributor cap terminal (Figure 7). 4. No.7 Cylinder Plug Wire Routing (Figure 8 and 9) A. Verify that the No.7 cylinder plug wire crosses over the distributor cap and leaves the distributor cap between the No.3 and the No.6 tower terminals (Figure 8). This is the original wire routing for 1998 and prior model years. B. For 1999 M.Y. vehicles the No.7 cylinder plug wire was shortened. Reroute the No.7 cylinder plug wire so that it crosses the distributor cap and leaves the distributor cap between the No.6 and the No.5 tower terminals (Figure 9). NOTE: MAKE SURE THE NO.7 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH, AWAY FROM THE NO.5 CYLINDER PLUG WIRE. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 2510 5. No. 5 Cylinder Plug Wire Routing (Figure 10) A. Remove the No.5 cylinder plug wire from its distributor cap terminal. B. Remove the No.5 cylinder plug wire from the five-wire clip located at the lower rear of the left valve cover. C. Route the No.5 cylinder plug wire over the left valve cover and in front of the breather tube elbow. D. Position the original convolute from the No.5 cylinder plug wire to prevent chafing against the valve cover and any engine components. Secure the small end of the hose to wire clip p/n 06503441 over the convolute. Secure the large end of the hose to wire clip to the breather hose. NOTE: MAKE SURE THE NO.5 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE NO.7 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. 3.9L Engine Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 2511 1. Coil Wire Routing (Figure 11 and 12) A. Remove the coil wire from the distributor cap tower terminal. B. Remove the coil wire from the right rear five-wire clip, the center three wire clip and the front one-wire clip on the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover studs (Figure 11). D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths. Two (2) at 101.5 mm (4 in.), and one (1) at 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the two 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 12). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM ANDIOR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Cable: > 08-39-97 > Nov > 97 > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction Technical Service Bulletin # 18-48-98 Date: 981230 Ignition System - Cross Fire/Ignition Wire Induction NO: 18-48-98 GROUP: Vehicle Performance DATE: Dec. 30, 1998 SUBJECT: Ignition System Cross Fire/Secondary Ignition Wire Induction MODELS: 1994 - 1999 (AN) Dakota 1994 - 1999 (BR/BE)Ram Truck 1998 - 1999 (DN) Durango 1995 - 1998 (ZG) Grand Cherokee (International Market) 1994 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 3.9L, 5.2L, OR 5.9L ENGINE. AB MODELS WILL BE ADDED LATER (NEW PARTS REQUIRED). SYMPTOM/CONDITION: Some vehicles may exhibit one or more of the following: Spark knock complaints when the vehicle is under load. Various single cylinder misfire (1, 3, 7), especially 5 and/or 8. Surge in 4th gear with the Electronically Modulated Converter Clutch (EMCC) engaged (around 45 mph). Perceived torque converter EMCC engagement/disengagement around 45 mph. DIAGNOSIS: Using the Mopar Diagnostic System (MDS/MDS 2) or the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If other than mentioned Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present or if the above symptoms/conditions have been described by the customer, perform the Repair Procedure. NOTE: THIS REROUTING PROCEDURE SHOULD BE PERFORMED BEFORE ANY OTHER MISFIRE, SURGE, OR SPARK KNOCK REPAIRS ARE ATTEMPTED. PARTS REQUIRED: 3 56028186 Clip, Single Wire 2 06503441 Clip, Wire To Hose (5.2L & 5.9L) 1 04364375 Convolute, 10 ft Roll POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-12-15-92 - 3.9L (All) 0.2 Hrs. 08-12-15-93 (ZJ) 5.2/5.9L 0.2 Hrs. (AN/DN) 5.2/5.9L 0.3 Hrs. (BR/BE) 5.2/5.9L 0.4 Hrs. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Cable: > 08-39-97 > Nov > 97 > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 2521 FAILURE CODE: 9X - Routed Improperly Repair Procedure This bulletin involves rerouting the coil wire for all engines listed and rerouting the 4, 5, 7, and 8 plug wires for the 5.2/5.9L applications to minimize induction effects. NOTE: IF WIRES MUST CROSS DURING THE REROUTE PROCEDURE, THEY MUST CROSS AT A 90° ANGLE. 5.2L and 5.9L Engine Procedures 1. Coil Wire Routing (Figure 1 and 2) A. Remove the coil wire from the distributor cap coil wire tower terminal. B. Remove the coil wire from the rear five-wire clip, the center three-wire clip, and the front one-wire clip located along the lower side of the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover. Use the studs of the valve cover retaining bolts (Figure 1). NOTE: SOME APPLICATIONS MAY ONLY HAVE STUD LOCATIONS FOR 3 OF THE ONE-WIRE CLIPS. D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths 203 mm (8 in.), 101.5 mm (4 in.), and 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the 203 mm (8 in.) and the 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Cable: > 08-39-97 > Nov > 97 > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 2522 H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 2). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM AND/OR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. I. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. 2. No.8 Cylinder Plug Wire Routing (Figure 3) A. Remove the No.8 cylinder plug wire from the distributor cap tower terminal. B. Remove the No.8 cylinder plug wire from the five-wire clip located at the lower rear of the valve cover. C. Route the No.8 cylinder plug wire over the rear quarter of the right valve cover (Figure 3). D. Position the original piece convolute from the No.8 cylinder plug wire to prevent chafing at the right valve cover and with other engine components. E. Secure the No.8 cylinder plug wire and its convolute in place with the hose to wire clip p/n 06503441. The small end of the clip is positioned over the convolute. The large end of the clip is fastened to a heater hose (A/C line on ZJ models). NOTE: MAKE SURE THE NO.8 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE COIL WIRE AND THE NO.4 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. F. Install the No.8 cylinder plug wire to its distributor cap terminal. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Cable: > 08-39-97 > Nov > 97 > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 2523 3. No.4 Cylinder Plug Wire Routing (Figure 4 and 5) A. Remove the No.4 cylinder plug wire from the distributor cap terminal. B. At the three-wire clip (located at the center of the lower side of the right valve cover), keep the two wires from crossing and chafing each other. Position the No.2 cylinder plug wire in the top wire slot and the No.4 cylinder plug wire in the bottom wire slot. Leave the middle wire slot empty (Figure 5). C. At the five-wire clip (located at the right rear lower side of the valve cover), keep the plug wires from crossing and chafing each other. Position the No.4 cylinder plug wire in a slot that will obtain the maximum amount of distance allowable from the No.8 cylinder plug wire (Figure 6). Remove any slack in the No.4 cylinder plug wire between the three-wire and the five-wire clips. NOTE: EARLIER MODEL FIVE-WIRE CLIPS LOOK SLIGHTLY DIFFERENT BUT THE SAME WIRING LAYOUT APPLIES. D. Route the No.4 cylinder plug wire behind the transmission dipstick tube and heater hoses. On ZJ models this may not be possible due to the location of the bulkhead. NOTE: MAKE SURE THAT THE NO.4 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH AWAY FROM THE NO.8 CYLINDER PLUG WIRE. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Cable: > 08-39-97 > Nov > 97 > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 2524 E. Install the No.4 cylinder plug wire to its distributor cap terminal (Figure 7). 4. No.7 Cylinder Plug Wire Routing (Figure 8 and 9) A. Verify that the No.7 cylinder plug wire crosses over the distributor cap and leaves the distributor cap between the No.3 and the No.6 tower terminals (Figure 8). This is the original wire routing for 1998 and prior model years. B. For 1999 M.Y. vehicles the No.7 cylinder plug wire was shortened. Reroute the No.7 cylinder plug wire so that it crosses the distributor cap and leaves the distributor cap between the No.6 and the No.5 tower terminals (Figure 9). NOTE: MAKE SURE THE NO.7 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH, AWAY FROM THE NO.5 CYLINDER PLUG WIRE. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Cable: > 08-39-97 > Nov > 97 > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 2525 5. No. 5 Cylinder Plug Wire Routing (Figure 10) A. Remove the No.5 cylinder plug wire from its distributor cap terminal. B. Remove the No.5 cylinder plug wire from the five-wire clip located at the lower rear of the left valve cover. C. Route the No.5 cylinder plug wire over the left valve cover and in front of the breather tube elbow. D. Position the original convolute from the No.5 cylinder plug wire to prevent chafing against the valve cover and any engine components. Secure the small end of the hose to wire clip p/n 06503441 over the convolute. Secure the large end of the hose to wire clip to the breather hose. NOTE: MAKE SURE THE NO.5 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE NO.7 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. 3.9L Engine Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Cable: > 08-39-97 > Nov > 97 > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 2526 1. Coil Wire Routing (Figure 11 and 12) A. Remove the coil wire from the distributor cap tower terminal. B. Remove the coil wire from the right rear five-wire clip, the center three wire clip and the front one-wire clip on the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover studs (Figure 11). D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths. Two (2) at 101.5 mm (4 in.), and one (1) at 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the two 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 12). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM ANDIOR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Cable: > Page 2527 Shift Cable: Adjustments GENERAL INFORMATION Check adjustment by starting the engine in Park and Neutral. Adjustment is OK if the engine starts only in these positions. Adjustment is incorrect if the engine starts in one but not both positions. If the engine starts in any position other than Park or Neutral, or if the engine will not start at all, the park/ neutral position switch may be faulty. PROCEDURE 1. Shift transmission into Park. 2. Release cable adjuster lock (underneath the power brake booster) to unlock cable. 3. Raise vehicle. 4. Slide cable eyelet off transmission shift lever. 5. Verify transmission shift lever is in Park detent by moving lever fully rearward. Last rearward detent is Park position. 6. Verify positive engagement of transmission park lock by attempting to rotate propeller shaft. Shaft will not rotate when park lock is engaged. 7. Slide cable eyelet onto transmission shift lever. 8. Lower vehicle and check engine starting. Engine should start only in Park and Neutral. 9. Lock shift cable by pressing cable adjuster clamp down until it snaps into place. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Component Information > Testing and Inspection Shift Cable: Testing and Inspection Gearshift cable adjustment is important because it positions the valve body manual valve. Incorrect adjustment will cause creeping in Neutral, premature clutch wear, delayed engagement in any gear, or a no-start in Park or Neutral position. Proper operation of the park/neutral position switch will provide a quick check of cable adjustment. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Component Information > Testing and Inspection > Page 2530 Shift Cable: Adjustments GENERAL INFORMATION Check adjustment by starting the engine in Park and Neutral. Adjustment is OK if the engine starts only in these positions. Adjustment is incorrect if the engine starts in one but not both positions. If the engine starts in any position other than Park or Neutral, or if the engine will not start at all, the park/ neutral position switch may be faulty. PROCEDURE 1. Shift transmission into Park. 2. Release cable adjuster lock (underneath the power brake booster) to unlock cable. 3. Raise vehicle. 4. Slide cable eyelet off transmission shift lever. 5. Verify transmission shift lever is in Park detent by moving lever fully rearward. Last rearward detent is Park position. 6. Verify positive engagement of transmission park lock by attempting to rotate propeller shaft. Shaft will not rotate when park lock is engaged. 7. Slide cable eyelet onto transmission shift lever. 8. Lower vehicle and check engine starting. Engine should start only in Park and Neutral. 9. Lock shift cable by pressing cable adjuster clamp down until it snaps into place. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Component Information > Testing and Inspection > Page 2531 Shift Cable: Service and Repair REMOVAL 1. Shift transmission into Park. 2. Remove nuts retaining the shift cable housing to the dash panel. 3. Disconnect cable at lower column lever and feed cable through dash panel opening to underside of vehicle. 4. Raise vehicle. 5. Disengage cable eyelet at transmission shift lever and pull cable adjuster out of mounting bracket. Remove old cable from vehicle. INSTALLATION 1. Snap the cable into the transmission bracket so the retaining ears are engaged and connect cable end fitting onto the manual control lever ball stud. 2. Lower vehicle. 3. Route cable through hole in dash panel. Seat cable bracket to dash panel. Install retaining nuts to cable housing bracket studs inside the vehicle at the dash panel. 4. Place the auto transmission manual shift control lever in "Park" detent (rear-most) position and rotate prop shaft to ensure transmission is in park. 5. Connect shift cable to shifter lever by snapping cable retaining ears into shifter bracket and press cable end fitting into lever. 6. Check for proper operation of Park/Neutral switch. 7. If the gearshift cable is out of adjustment, refer to Adjustments section. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Component Information > Locations O/D (3-4) Solenoid, TCC Solenoid, Governor Pressure Sensor, Governor Pressure Solenoid Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Component Information > Page 2534 Shift Cable: Service and Repair REMOVAL 1. Shift transmission into Park. 2. Remove nuts retaining the shift cable housing to the dash panel. 3. Disconnect cable at lower column lever and feed cable through dash panel opening to underside of vehicle. 4. Raise vehicle. 5. Disengage cable eyelet at transmission shift lever and pull cable adjuster out of mounting bracket. Remove old cable from vehicle. INSTALLATION 1. Snap the cable into the transmission bracket so the retaining ears are engaged and connect cable end fitting onto the manual control lever ball stud. 2. Lower vehicle. 3. Route cable through hole in dash panel. Seat cable bracket to dash panel. Install retaining nuts to cable housing bracket studs inside the vehicle at the dash panel. 4. Place the auto transmission manual shift control lever in "Park" detent (rear-most) position and rotate prop shaft to ensure transmission is in park. 5. Connect shift cable to shifter lever by snapping cable retaining ears into shifter bracket and press cable end fitting into lever. 6. Check for proper operation of Park/Neutral switch. 7. If the gearshift cable is out of adjustment, refer to Adjustments section. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Cap > Component Information > Testing and Inspection Distributor Cap: Testing and Inspection Fig. 22 Cap Inspection - External - Typical (V6 Shown) Fig. 23 Cap Inspection - Internal - Typical (V6 Shown) Remove the distributor cap and wipe it clean with a dry lint free cloth. Visually inspect the cap for cracks, carbon paths, broken towers or damaged rotor button. Also check for white deposits on the inside (caused by condensation entering the cap through cracks). Replace any cap that displays charred or eroded terminals. NOTE: A small amount of erosion is expected from normal operation. Examine the terminal ends for evidence of mechanical interference with the rotor tip. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Testing and Inspection Ignition Rotor: Testing and Inspection Fig. 24 Rotor Inspection - Typical Visually inspect the rotor for cracks, evidence of corrosion, or the effects of arcing on the metal tip. Also check for evidence of mechanical interference with the cap. Some charring is normal on the end of the metal tip. The silicone-dielectric-varnish-compound applied to the rotor tip for radio interference noise suppression, will appear charred. This is normal. Do not remove the charred compound. Test the spring for insufficient tension. Replace a rotor that displays any of these adverse conditions. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Electrode Gap ...................................................................................................................................... ..................................................... 1.01 mm (0.040 in) Torque ............................................................ ............................................................................................................................................. 41 Nm (30 ft. lb.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2545 Spark Plug: Application and ID Plug Type ............................................................................................................................................ .................................................................... RC12LC4 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2546 Spark Plug: Description and Operation DESCRIPTION All engines use resistor type spark plugs. 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 recommended intervals. Spark plugs that have low milage may be cleaned and reused if not otherwise defective, carbon or oil fouled. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator Spark Plug: Testing and Inspection Broken, Cracked or Chipped 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 Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2549 Spark Plug: Testing and Inspection Brown to Gray/Tan Color - Normal Operating Condition Normal Operation And Carbon Fouling The few deposits present on the spark plug will probably be light tan or slightly gray in color. This is evident with most grades of commercial gasoline. There will not be evidence of electrode burning. Gap growth will not average more than approximately 0.025 mm (.001 in) per 1600 km (1000 miles) of operation. Spark plugs that have normal wear can usually be cleaned, have the electrodes filed, have the gap set and then be installed. Some fuel refiners in several areas of the United States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT causes the entire tip of the spark plug to be coated with a rust colored deposit. This rust color can be misdiagnosed as being caused by coolant in the combustion chamber. Spark plug performance is not affected by MMT deposits. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2550 Spark Plug: Testing and Inspection Dry, Fluffy Black Deposits - Cold or Carbon Fouling Normal Operation And Carbon Fouling Cold fouling is sometimes referred to as carbon fouling. The deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or defective spark plug cables. Cold (carbon) fouling of the entire set of spark plugs may be caused by a clogged air filter or repeated short operating times (short trips). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2551 Spark Plug: Testing and Inspection 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 Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2552 Spark Plug: Testing and Inspection Broken, Cracked or Chipped 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. Brown to Gray/Tan Color - Normal Operating Condition Normal Operation And Carbon Fouling The few deposits present on the spark plug will probably be light tan or slightly gray in color. This is evident with most grades of commercial gasoline. There will not be evidence of electrode burning. Gap growth will not average more than approximately 0.025 mm (.001 in) per 1600 km (1000 miles) of operation. Spark plugs that have normal wear can usually be cleaned, have the electrodes filed, have the gap set and then be installed. Some fuel refiners in several areas of the United States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT causes the entire tip of the spark plug to be coated with a rust colored deposit. This rust color can be misdiagnosed as being caused by coolant in the combustion chamber. Spark plug performance is not affected by MMT deposits. Dry, Fluffy Black Deposits - Cold or Carbon Fouling Normal Operation And Carbon Fouling Cold fouling is sometimes referred to as carbon fouling. The deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or defective spark plug cables. Cold (carbon) fouling of the entire set of spark plugs may be caused by a clogged air filter or repeated short operating times (short trips). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2553 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. 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. Overheating Spark Plug Overheating Overheating is indicated by a white or gray center electrode insulator that also appears blistered. The increase in electrode gap will be considerably in excess of 0.001 inch per 1000 miles of operation. This suggests that a plug with a cooler heat range rating should be used. Over advanced ignition Premature Electrode Wear - Preignition Damage Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2554 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.) 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. 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 Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 2555 Spark Plug: Service and Repair Fig. 31 Heat Shields Spark plug cable heat shields are pressed into the cylinder head to surround each cable boot and spark plug. If removal of the heat shield(s) is necessary, remove the spark plug cable and compress the sides of shield for removal. Each shield is slotted to allow for compression and removal. To install the shields, align shield to machined opening in cylinder head and tap into place with a block of wood. Fig. 11 Cable Removal PLUG REMOVAL 1. Always remove spark plug or ignition coil cables by grasping at the cable boot. Turn the cable boot 1/2 turn and pull straight back in a steady motion. Never pull directly on the cable. Internal damage to cable will result. 2. Prior to removing the spark plug, spray compressed air around the spark plug hole and the area around the spark plug. This will help prevent foreign material from entering the combustion chamber. 3. Remove the spark plug using a quality socket with a rubber or foam insert. 4. Inspect the spark plug condition. PLUG CLEANING The plugs may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file the center electrode flat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator and will cause plug misfire. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 2556 Fig. 44 Setting Spark Plug Gap - Typical PLUG GAP ADJUSTMENT Check the spark plug gap with a gap gauge tool. If the gap is not correct, adjust it by bending the ground electrode. Never attempt to adjust the gap by bending the center electrode. SPARK PLUG GAP 1.01 mm (0.040 in). PLUG INSTALLATION Special care should be taken when installing spark plugs into the cylinder head spark plug wells. Be sure the plugs do not drop into the plug wells as electrodes can be damaged. Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap or a cracked porcelain insulator. When replacing the spark plug and ignition coil cables, route the cables correctly and secure them in the appropriate retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise. It could cause cross ignition of the spark plugs or short circuit the cables to ground. 1. Start the spark plug into the cylinder head by hand to avoid cross threading. 2. Tighten spark plugs to 35-41 Nm (26-30 ft lb) torque. 3. Install spark plug cables over spark plugs. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression should not be less than 689 kPa (100 psi) and not vary more than 172 kPa (25 psi) from cylinder to cylinder. If cylinder(s) have abnormally low compression pressures, repeat procedure. - If the same cylinder(s) repeat an abnormally low reading, it could indicate the existence of a problem in the cylinder. NOTE: The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should NOT be disassembled to determine the cause of low compression unless some malfunction is present. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2560 Compression Check: Testing and Inspection NOTE: - 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. CAUTION: DO NOT overspeed the engine. a. Check engine oil level and add oil, if necessary. b. Drive the vehicle until engine reaches normal operating temperature. c. Select a route free from traffic and other forms of congestion, observe all traffic laws and briskly accelerate through the gears several times. The higher engine speed may help clean out valve seat deposits which can prevent accurate compression readings. d. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for abnormal firing indicators-fouled, hot, oily, etc. Record cylinder number of spark plug for future reference. e. Disconnect coil wire from distributor and secure to good ground to prevent a spark from starting a fire. f. Be sure throttle blades are fully open during the compression check. g. Insert compression gauge adapter into the No. 1 spark plug hole. Crank engine until maximum pressure is reached on gauge. Record this pressure as No.1 cylinder pressure. h. Repeat above step for all remaining cylinders. i. Compression should not be less than 689 kPa (100 psi) and not vary more than 172 kPa (25 psi) from cylinder to cylinder. j. If cylinder(s) have abnormally low compression pressures, repeat procedure. k. If the same cylinder(s) repeat an abnormally low reading, it could indicate the existence of a problem in the cylinder. NOTE: The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should NOT be disassembled to determine the cause of low compression unless some malfunction is present. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates this engine is equipped with hydraulic lifters or lash adjusters and therefore does not require adjustment. See "Rocker Arm: Service and Repair" for further information. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Description and Operation A/C Signal: Description and Operation NOTE: The A/C control system information applies to factory installed air conditioning units. A/C SELECT SIGNAL: When the A/C switch is in the ON position, an input signal is sent to the powertrain control module (PCM). The signal informs the PCM that the A/C has been selected. The PCM adjusts idle speed to a pre-programmed rpm through the idle air control (IAC) motor to compensate for increased engine load. A/C REQUEST SIGNAL: Once A/C has been selected, the powertrain control module (PCM) receives the A/C request signal from the clutch cycling pressure switch. The input indicates that the evaporator pressure is in the proper range for A/C application. The PCM uses this input to cycle the A/C compressor clutch (through the A/C relay). It will also determine the correct engine idle speed through the idle air control (IAC) motor position. If the A/C low-pressure switch or high-pressure switch opens (indicating a low or high refrigerant pressure), the PCM will not receive an A/C request signal. The PCM will then remove the ground from the A/C relay This will deactivate the A/C compressor clutch. If the switch opens, (indicating that evaporator is not in proper pressure range), the PCM will not receive the A/C request signal. The PCM will then remove the ground from the A/C relay, deactivating the A/C compressor clutch. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications Intake Air Temperature Sensor: Specifications DESCRIPTION .................................................................................................................................... .............................................................. TORQUE Intake Manifold Air Temp. Sensor ............................................................................................................................................................. 28 Nm (20 ft lb) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2571 Fig 59 Intake Manifold Air Temperature Sensor - Typical Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2572 IAT Connector Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2573 Intake Air Temperature Sensor: Description and Operation Fig 8 Intake Manifold Air Temperature Sensor PURPOSE The sensor provides an input voltage to the powertrain control module (PCM) indicating intake manifold air temperature. The input is used along with inputs from other sensors to determine injector pulse width. OPERATION As the temperature of the air-fuel stream in the manifold varies, the sensor resistance changes. This results in a different input voltage to the PCM. CIRCUIT OPERATION The intake air temperature sensor provides an input to the Powertrain Control Module (PCM) on circuit K21. Circuit K21 connects to cavity A15 of the PCM. From circuit K21, the intake air temperature sensor draws voltage from the PCM. The sensor is a variable resistor. As intake air temperature changes, the resistance in the sensor changes, causing a change in current draw. The PCM provides a ground for the intake air temperature sensor signal (circuit K21) through circuit K4. Circuit K4 connects to cavity A4 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Sensor Test Intake Air Temperature Sensor: Testing and Inspection Sensor Test Fig 59 Intake Manifold Air Temperature Sensor - Typical Sensor Resistance Chart (OHMS) To perform a complete test of the intake manifold air temperature sensor and its circuitry, refer to Powertrain Management/Computers and Controls/Testing and Inspection/Diagnostic Charts. To test the sensor only, refer to the following; 1. Disconnect the wire harness connector from the intake manifold air temperature sensor (Fig. 59). 2. Test the resistance of the sensor with an input impedance (digital) volt-ohmmeter. - The resistance (as measured across the sensor terminals) should be as shown in the Sensor Resistance Chart. - Replace the sensor if it is not within the range of resistance specified in the chart. 3. Test the resistance of the wire harness. - Do this between the PCM wire harness connector A-15 and the sensor connector terminal. - Also check between PCM connector A-4 to the sensor connector terminal. - Repair the wire harness as necessary if the resistance is greater than 1 ohm. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Sensor Test > Page 2576 Intake Air Temperature Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Crankshaft position sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Page 2577 Intake Air Temperature Sensor: Service and Repair Fig 88 Intake Manifold Air Temperature Sensor - Typical The intake manifold air temperature sensor is located in the front/side of the intake manifold (Fig. 88). REMOVAL 1. Remove air duct at throttle body. 2. Disconnect electrical connector at sensor (Fig. 88). 3. Remove sensor from intake manifold. INSTALLATION 1. Install sensor to intake manifold. Tighten to 28 Nm (20 ft lb) torque. 2. Install electrical connector. 3. Install air duct at throttle body. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations > Page 2581 MAP Connector Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Battery Temp. Sensor Location Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2585 Battery Temp. Sensor Connector Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2586 Battery Temperature Sensor: Service Precautions WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN . Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2587 Battery Temperature Sensor: Description and Operation SYSTEM OPERATION The battery temperature sensor 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. CIRCUIT OPERATION The Powertrain Control Module (PCM) determines battery temperature on circuit K118. Circuit K118 connects the PCM to the battery temperature sensor. Circuit K4 provides ground for the sensor. Circuit K118 connects to cavity C15 of the PCM. Circuit K4 connects to cavity A4. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Testing Battery Temperature Sensor: Testing and Inspection Testing To perform a complete test of this sensor and its circuitry, refer to the appropriate Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Charts Procedures. To test the sensor only, refer to the following: Battery Temperature Sensor 1. The sensor is located under the battery and is attached to the battery tray. A two-wire pigtail harness is attached directly to the sensor. The opposite end of this harness connects the sensor to the engine wiring harness. 2. Disconnect the two-wire pigtail harness from the engine harness. 3. Attach ohmmeter leads to the wire terminals of the pigtail harness. 4. At room temperature of 25 °C (75 - 80 °F), an ohmmeter reading of 9,000 (9K) to 11,000 (11K) ohms should be observed. 5. If reading is above or below the specification, replace the sensor. 6. Refer to the Removal and Installation for procedures. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Page 2590 Battery Temperature Sensor: Service and Repair Battery Temperature Sensor The battery temperature sensor is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray. The sensor is located under the battery on drivers side of vehicle. REMOVAL 1. Remove battery. 2. Disconnect sensor pigtail harness from engine wire harness. 3. Pry sensor straight up from battery tray mounting hole. INSTALLATION 1. Feed pigtail harness through mounting hole in top of battery tray and press sensor into top of tray (snaps in). 2. Connect pigtail harness. 3. Install battery. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Locations > Data Link Connector DLC Location Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Locations > Data Link Connector > Page 2595 Module Locations Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Locations > Data Link Connector > Page 2596 Module Locations Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Locations > Data Link Connector > Page 2597 Module Locations Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions Central Timer Module ( CTM ) High Option: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2600 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 Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2601 Electrostatic Discharge Symbol All Electrostatic Discharge (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, especially 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. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2602 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2603 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2604 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2605 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2606 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2607 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2608 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2609 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. 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. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2610 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2611 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2612 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2613 Central Timer Module ( CTM ) High Option: Diagnostic Aids 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 in 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 and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2614 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. 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 every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. 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 fuse circuit. 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 the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2615 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools 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 - This instrument is 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 vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. 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 non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2616 Central Timer Module ( CTM ) High Option: Connector Views Data Link Connector Pinout ABCM Connector Pinout Passenger Airbag Connector Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2617 Drivers Airbag Squib Connector Pinout Clockspring 2-Way Connector Pinout Central Timer Module (CTM) Connector "A" Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2618 Central Timer Module (CTM) Connector "B" Pinout Left Instrument Cluster Connector "A" (Black) Pinout Right Instrument Cluster Connector "B" (Gray) Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2619 Overhead Console Compass/Mini-Trip Computer Pinout Ambient Temperature Sensor Connector Pinout Door Jamb Switch Connector Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2620 Door Disarm Switch Connector Pinout Power Door Lock Switch Connections Door Lock Actuator Connector Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2621 Key-In Ignition Connector Pinout Multifunction Switch Connector Pinout Windshield Wiper Motor Connector Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2622 Central Timer Module ( CTM ) High Option: Electrical Diagrams Airbag System Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2623 Chrysler Collision Detection (CCD) Bus System Compass/Mini-Trip Computer System Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2624 Central Timer Module Block Diagram Power Lock System Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2625 Windshield Wiper System Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Service Precautions > Technician Safety Information Central Timer Module ( CTM ) High Option: Technician Safety Information Technician Safety Information DANGER!!! Engines produce carbon monoxide that is odorless, causes slower reaction time, and can lead to serious injury. When the engine is operating, keep service areas WELL VENTILATED or attach the vehicle exhaust system to the shop exhaust removal system. Set the parking brake and block the wheels before testing or repairing the vehicle. It is especially important to block the wheels on front-wheel drive vehicles; the parking brake does not hold the drive wheels. When servicing a vehicle, always wear eye protection, and remove any metal jewelry such as watchbands or bracelets that might make an inadvertent electrical contact. When diagnosing a body system problem, it is important to follow approved procedures where applicable. Following these procedures is very important to the safety of individuals performing diagnostic tests. 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. Servicing Sub-Assemblies SERVICING SUB-ASSEMBLIES Some components of the body system are intended to be serviced in 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 Service and Repair procedures should be serviced. DRB III Safety Information DRBIII SAFETY INFORMATION WARNING: Exceeding the limits of the DRB 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 DRB 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 function for the measurement. Do not try voltage or current measurements that may exceed the rated capacity. DRB III Safety Limits - Do not exceed the limits shown in the table below: - Voltage between any terminal and ground must not exceed 500v DC or 500v peak AC. - Use caution when measuring voltage above 25v DC or 25v AC. - The circuit being tested must be protected by a 10A fuse or circuit breaker. - Use the low current shunt to measure circuits up to 10A. Use the high current clamp to measure circuits exceeding 10A. - 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Service Precautions > Technician Safety Information > Page 2628 - 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 DRB away from spark plug or coil wires to avoid measuring error from outside interference. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Service Precautions > Technician Safety Information > Page 2629 Central Timer Module ( CTM ) High Option: Vehicle Damage Warnings Vehicle Damage Warnings 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. Road Testing A Complaint Vehicle ROAD TESTING A COMPLAINT VEHICLE 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 screen while in motion. Do not hang the DRB from the rear view mirror or operate it yourself. Have an assistant available to operate the DRB. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Service Precautions > Page 2630 Central Timer Module ( CTM ) High Option: Application and ID GLOSSARY OF ACRONYMS ACM ..................................................................................................................................................... ....................................... Airbag Control Module CAB ........................................................................ ................................................................................................................ Controller Anti-lock Brake CCD ................................................................................................................................... Chrysler Collision Detection (Vehicle Communications Bus) CMTC ................................................................. ................................................................................................................ Compass/mini-trip Computer CTM .................................................................................................................................... .......................................................... Central Timer Module DAB ....................................................... ...................................................................................................................................................... Driver Airbag DLC ............................................................................................................................... ................................................................... Data Link Connector DTC ............................................... ............................................................................................................................................ Diagnostic Trouble Code MIC ............................................................................................................................... ................................................... Mechanical Instrument Cluster PAB ................................................ ........................................................................................................................................................ Passenger Airbag PCM ....................................................................................................................... ................................................................ Powertrain Control Module PDC ........................................ .................................................................................................................................................. Power Distribution Center RKE ...................................................................................................................... ......................................................................... Remote Keyless Entry SQUIB ................................................................................................................................... Also Called Initiator (Located In Rear Of Airbag Module) VTSS ............................................................................ ..................................................................................................... Vehicle Theft Security System Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System Central Timer Module ( CTM ) High Option: Description and Operation Airbag System Airbag System Description AIRBAG SYSTEM The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front end collision. The system is most effective when used in conjunction with the seat belt system. The airbag control module (ACM) is an electronic module that monitors the airbag system for proper operation, stores Diagnostic Trouble Code (DTCs), controls the airbag warning lamp, monitors the pressure in the passenger airbag module 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 the diagnostic information DTCs to the technician through the DRB III via the CCD bus. Some circuits are tested continuously; others are checked only under certain circumstances. The warning lamp is driven with messages relayed to the Mechanical Instrument Cluster (MIC) from the ACM via the CCD bus. The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be observed by the customer. Whenever the ignition key is turned to the run or start" position, the airbag control module performs a lamp check by turning the AIRBAG warning lamp on for 6-8 seconds. If the lamp remains off, it means that the ACM has checked the system and found it to be free of discernible malfunctions. If the lamp remains on, there could be an active fault in the system or the circuit that operates the lamp may be shorted to ground. If the lamp comes on and stays on for a period longer than 6-8 seconds, then goes off, there is usually an intermittent problem in the system. Perform the WARNING LAMP CIRCUIT OPEN procedure in this book to find the cause of any customer complaint regarding the AIRBAG warning lamp, such as: Warning Lamp Does Not Illuminate - Warning Lamp Stays Illuminated WARNING! The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must first disconnect and isolate the battery negative (ground) cable. Then wait two minutes for the system capacitor to discharge before further system service. This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Never strike or kick the airbag control module, as it can damage the impact sensor or affect its calibration. If an airbag control module is accidentally dropped during service, the module must be scrapped and replaced with a new unit. Airbag Diagnostic Trouble Codes AIRBAG DIAGNOSTIC TROUBLE CODES Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Always begin by reading the diagnostic trouble codes using the DRB. This procedure begins with AIRBAG TEST 1A - Identifying Airbag System Problems. This will direct you to the specific test(s) that must be performed. Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures within this manual, diagnostic trouble codes are used as a diagnostic tool. ACTIVE CODES The codes become 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 are automatically erased 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 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 2633 "Loss of Ignition Run Only" code which is an active code only. A "stored" code indicates that there was an active code present at some time. However, the code currently may not be present as an active code, although another code could be. When a trouble code occurs, the airbag warning lamp illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. If a malfunction is detected a diagnostic trouble code is stored and will remain stored as long as the malfunction exists. When and if the malfunction ceases to exist, and ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of that same malfunction, the diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. If no obvious problems are found, erase stored codes, and with the ignition "on" wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 2634 Central Timer Module ( CTM ) High Option: Description and Operation Interior Lighting INTERIOR LIGHTING The courtesy lights are controlled by the CTM. The door switches are inputs to the CTM and the courtesy lights are outputs. The glove box lamp and the ash receiver lamp (if equipped) are not controlled by the CTM. They are hardwired to individual switches and fuses. The ignition key halo lamp is controlled by the CTM and will remain on for thirty seconds after the door is closed. The Highline CTM also provides for an illuminated entry option. If the CTM detects an unlock signal from the RKE transmitter, a door disarm switch input or the door jamb switch input, the interior courtesy lights will be turned on. The illuminated entry function is cancelled if the CTM senses an ignition "on" condition or the "lock" command from a valid key fob. If a door is left open or the dome lamp switch is left in the "on" position for more than fifteen minutes, the CTM will extinguish the lamps to avoid discharging the battery. If the lamps are turned on by rotation of the headlamp panel dimmer switch, the CTM will not be able to turn them off. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 2635 Central Timer Module ( CTM ) High Option: Description and Operation Central Timer Module INTRODUCTION Central Timer Module The Central Timer Module (CTM) is used to supply the vehicles occupants with visual and audible information, control various vehicle functions, and provide a centralized power distribution for the passenger compartment. To both provide and receive vehicle information the BCM is interfaced to the CCD Bus. Power for the CTM is supplied from three sources. Circuit F12 supplies power to the CTM in the START and RUN position. This circuit is protected by a 10 Amp fuse located in the junction block. Power is also supplied to the CTM on circuit F35. This circuit is HOT at all times and protected by a 20 Amp fuse located in the junction block. In the RUN position circuit V6 provides battery power to the CTM. This circuit is protected by a 20 Amp fuse located in the junction block. Ground for the ECM is provided by circuits Z1 and Z2. CCD Bus interface is accomplished on circuits D1 and D2. The D1 circuit is used for Bus (+), and D2 is for Bus (-). SYSTEM OPERATION Central Timer Module Two versions of the Central Timer Module (CTM) are available on this vehicle, a base version and a high-line version. The base version of the CTM is used on base models of the vehicle. The base version of the CTM combines the functions of a chime/buzzer module, an intermittent wipe module, and an ignition lamp time delay relay in a single unit. The high-line version of the CTM is used on highline vehicles. The high-line CTM provides all of the functions of the base version CTM, but also is used to control and integrate many of the additional electronic functions and features included on the high- line models. The high-line version of the CTM contains a central processing unit and interfaces with other modules in the vehicle on the Chrysler Collision Detection (CCD) data bus network. The CCD data bus network allows the sharing of sensor information. This helps to reduce wire harness complexity, reduce internal controller hardware, and reduce component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. The power lock and Remote Keyless Entry (RKE) systems are two of the systems that the high-line CTM controls. The high-line CTM receives hard-wired inputs from the power lock switches, CCD message inputs from the Powertrain Control Module (PCM) and Airbag Control Module (ACM), and coded radio signal inputs from the RKE transmitters. In response to those inputs, the internal programming of the CTM sends the proper outputs to control the power lock motors, the horn relay, and the courtesy lamps. Some of the features and functions of the power lock and Remote Keyless Entry (RKE) systems made possible because of the communication of the CTM on the CCD data bus network include: - A door-lock inhibit feature which prevents the power lock system from being energized with a power door lock switch if the key is in the ignition and/or the headlamps are on. However, the locks can still be operated manually with a key or energized with the RKE transmitter. - An enhanced accident response feature will prevent the doors from locking, then unlock both doors after receiving a CCD message from the ACM indicating a frontal impact requiring airbag deployment. This feature will also turn on the courtesy lamps ten seconds after receiving the ACM deployment message, if the CCD vehicle speed message from the PCM indicates the vehicle is not moving. Of course, these responses are dependent upon functional battery power and wiring circuitry following the impact. - Rolling door locks is a programmable feature of the power lock system. This feature will automatically lock all of the doors after the vehicle reaches a speed of about 24 kilometers-per-hour (15 miles-per-hour) or greater. This feature will also lock the doors if a door is opened, then closed again at any speed above 24 kilometers-per-hour (15 miles-per-hour). This feature can be enabled or disabled using the DRB scan tool and the proper Diagnostic Procedures. - A programmable feature of the RKE system is the enabling or disabling of the horn chirp following the RKE Lock function. This feature can be enabled or disabled using the DRB scan tool and the proper Diagnostic Procedures. The horn relay is one of the outputs that the high-line CTM can control. The high-line CTM is programmed to energize or de-energize the horn relay in response to certain inputs from the Vehicle Theft Security System (VTSS) and the Remote Keyless Entry (RKE) system. One of the features that the high-line CTM supports and controls is the Vehicle Theft Security System (VTSS). In the VTSS, the CTM receives hard-wired inputs from the door jamb, door lock cylinder, and ignition switches. The programming in the CTM allows it to process the information from these inputs and send control outputs to energize or de-energize the headlamp relay, horn relay, and the Security lamp. The CTM also sends CCD data bus messages to the Powertrain Control Module (PCM) to control the engine no-run feature of the VTSS The CTM also contains the receiver and control logic for the power lock and Remote Keyless Entry (RKE) systems, which are integrated into the arming, disarming, and triggering functions of the VTSS. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 2636 Both versions of the CTM are mounted under the passenger side end of the instrument panel, behind the instrument panel top cover and outboard of the glove box opening. For diagnosis of the base version of the CTM, refer to Wiper and Washer Systems or Chime/Buzzer Warning Systems. For diagnosis of the high-line version of the CTM or the CCD data bus, a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 2637 Central Timer Module ( CTM ) High Option: Description and Operation Chime System CHIME SYSTEM The chime system is built into the CTM. The system also supports an external chime request from the instrument cluster. This feature allows the instrument cluster to request a chime from the CTM for gauge problems and tell-tale warnings. There are two chime rates, Low; 50 chimes per minute for reminders and High; 180 chimes per minute for serious conditions that require immediate attention. The high rate chime sounds when the key is left in the ignition and the doors are open or the headlights are left on. The low rate chime sounds for any of the other conditions. There is a variable rate feature that allows the chime to sound continuously for key-in and headlamp warning as long as the door is open. The seat belt warning chime is activated for six seconds, and all other chime conditions will activate the chime once at the time the warning light on the cluster is illuminated. The chime will sound for the following conditions: - Ignition oft, key in ignition, driver's door open - Ignition oft, headlamps on, driver's door open - Seat belt warning - Check engine lamp illuminated (after prove-out) - Airbag lamp illuminated (after prove-out) - Anti-lock lamp illuminated (after prove-out if equipped) - Check gauges lamp illuminated - Low fuel - Low washer fluid - Engine temp critical - Engine oil press too low CIRCUIT OPERATION Seat Belt Warning Chime The seat belt chime is used to indicate to the operator that the seat belt is not fastened when the ignition switch is in the RUN position. The seat belt switch is normally OPEN with the seat belt buckled. Circuit G10 is connected between the Central Timer Module (CTM) and the switch. Ground for the switch is provided on circuit Z1. Exterior Lamp-On Warning Chime The exterior lamp ON chime is used to indicate to the operator that the lamps are ON with the drivers door OPEN and the key removed from the ignition. The Central Timer Module (CTM) uses information from circuit G26 to determine if the lamps are ON, and circuit G16 for drivers door ajar. Key-In Ignition Warning Chime The Key-In chime is used to indicate to the operator that the key is in the ignition with the driver's door OPEN. If the key is in the ignition, a ground path is completed from the G26 circuit at the Central Timer Module (CTM), through the CLOSED switch, to the Z1 circuit. The Z1 circuit is the ground circuit. When the driver's door is open the normally OPEN door ajar switch CLOSES completing a path to ground on circuit G16. The CTM processes this information and turns on the chime. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 2638 Central Timer Module ( CTM ) High Option: Description and Operation Airbag System Description AIRBAG SYSTEM The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front end collision. The system is most effective when used in conjunction with the seat belt system. The airbag control module (ACM) is an electronic module that monitors the airbag system for proper operation, stores Diagnostic Trouble Code (DTCs), controls the airbag warning lamp, monitors the pressure in the passenger airbag module 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 the diagnostic information DTCs to the technician through the DRB III via the CCD bus. Some circuits are tested continuously; others are checked only under certain circumstances. The warning lamp is driven with messages relayed to the Mechanical Instrument Cluster (MIC) from the ACM via the CCD bus. The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be observed by the customer. Whenever the ignition key is turned to the run or start" position, the airbag control module performs a lamp check by turning the AIRBAG warning lamp on for 6-8 seconds. If the lamp remains off, it means that the ACM has checked the system and found it to be free of discernible malfunctions. If the lamp remains on, there could be an active fault in the system or the circuit that operates the lamp may be shorted to ground. If the lamp comes on and stays on for a period longer than 6-8 seconds, then goes off, there is usually an intermittent problem in the system. Perform the WARNING LAMP CIRCUIT OPEN procedure in this book to find the cause of any customer complaint regarding the AIRBAG warning lamp, such as: Warning Lamp Does Not Illuminate - Warning Lamp Stays Illuminated WARNING! The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must first disconnect and isolate the battery negative (ground) cable. Then wait two minutes for the system capacitor to discharge before further system service. This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Never strike or kick the airbag control module, as it can damage the impact sensor or affect its calibration. If an airbag control module is accidentally dropped during service, the module must be scrapped and replaced with a new unit. Airbag Diagnostic Trouble Codes AIRBAG DIAGNOSTIC TROUBLE CODES Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Always begin by reading the diagnostic trouble codes using the DRB. This procedure begins with AIRBAG TEST 1A - Identifying Airbag System Problems. This will direct you to the specific test(s) that must be performed. Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures within this manual, diagnostic trouble codes are used as a diagnostic tool. ACTIVE CODES The codes become 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 are automatically erased 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 2639 A "stored" code indicates that there was an active code present at some time. However, the code currently may not be present as an active code, although another code could be. When a trouble code occurs, the airbag warning lamp illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. If a malfunction is detected a diagnostic trouble code is stored and will remain stored as long as the malfunction exists. When and if the malfunction ceases to exist, and ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of that same malfunction, the diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. If no obvious problems are found, erase stored codes, and with the ignition "on" wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Interior Lighting INTERIOR LIGHTING The courtesy lights are controlled by the CTM. The door switches are inputs to the CTM and the courtesy lights are outputs. The glove box lamp and the ash receiver lamp (if equipped) are not controlled by the CTM. They are hardwired to individual switches and fuses. The ignition key halo lamp is controlled by the CTM and will remain on for thirty seconds after the door is closed. The Highline CTM also provides for an illuminated entry option. If the CTM detects an unlock signal from the RKE transmitter, a door disarm switch input or the door jamb switch input, the interior courtesy lights will be turned on. The illuminated entry function is cancelled if the CTM senses an ignition "on" condition or the "lock" command from a valid key fob. If a door is left open or the dome lamp switch is left in the "on" position for more than fifteen minutes, the CTM will extinguish the lamps to avoid discharging the battery. If the lamps are turned on by rotation of the headlamp panel dimmer switch, the CTM will not be able to turn them off. Central Timer Module INTRODUCTION Central Timer Module The Central Timer Module (CTM) is used to supply the vehicles occupants with visual and audible information, control various vehicle functions, and provide a centralized power distribution for the passenger compartment. To both provide and receive vehicle information the BCM is interfaced to the CCD Bus. Power for the CTM is supplied from three sources. Circuit F12 supplies power to the CTM in the START and RUN position. This circuit is protected by a 10 Amp fuse located in the junction block. Power is also supplied to the CTM on circuit F35. This circuit is HOT at all times and protected by a 20 Amp fuse located in the junction block. In the RUN position circuit V6 provides battery power to the CTM. This circuit is protected by a 20 Amp fuse located in the junction block. Ground for the ECM is provided by circuits Z1 and Z2. CCD Bus interface is accomplished on circuits D1 and D2. The D1 circuit is used for Bus (+), and D2 is for Bus (-). SYSTEM OPERATION Central Timer Module Two versions of the Central Timer Module (CTM) are available on this vehicle, a base version and a high-line version. The base version of the CTM is used on base models of the vehicle. The base version of the CTM combines the functions of a chime/buzzer module, an intermittent wipe module, and an ignition lamp time delay relay in a single unit. The high-line version of the CTM is used on highline vehicles. The high-line CTM provides all of the functions of the base version CTM, but also is used to control and integrate many of the additional electronic functions and features included on the high- line models. The high-line version of the CTM contains a central processing unit and interfaces with other modules in the vehicle on the Chrysler Collision Detection (CCD) data bus network. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 2640 The CCD data bus network allows the sharing of sensor information. This helps to reduce wire harness complexity, reduce internal controller hardware, and reduce component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. The power lock and Remote Keyless Entry (RKE) systems are two of the systems that the high-line CTM controls. The high-line CTM receives hard-wired inputs from the power lock switches, CCD message inputs from the Powertrain Control Module (PCM) and Airbag Control Module (ACM), and coded radio signal inputs from the RKE transmitters. In response to those inputs, the internal programming of the CTM sends the proper outputs to control the power lock motors, the horn relay, and the courtesy lamps. Some of the features and functions of the power lock and Remote Keyless Entry (RKE) systems made possible because of the communication of the CTM on the CCD data bus network include: - A door-lock inhibit feature which prevents the power lock system from being energized with a power door lock switch if the key is in the ignition and/or the headlamps are on. However, the locks can still be operated manually with a key or energized with the RKE transmitter. - An enhanced accident response feature will prevent the doors from locking, then unlock both doors after receiving a CCD message from the ACM indicating a frontal impact requiring airbag deployment. This feature will also turn on the courtesy lamps ten seconds after receiving the ACM deployment message, if the CCD vehicle speed message from the PCM indicates the vehicle is not moving. Of course, these responses are dependent upon functional battery power and wiring circuitry following the impact. - Rolling door locks is a programmable feature of the power lock system. This feature will automatically lock all of the doors after the vehicle reaches a speed of about 24 kilometers-per-hour (15 miles-per-hour) or greater. This feature will also lock the doors if a door is opened, then closed again at any speed above 24 kilometers-per-hour (15 miles-per-hour). This feature can be enabled or disabled using the DRB scan tool and the proper Diagnostic Procedures. - A programmable feature of the RKE system is the enabling or disabling of the horn chirp following the RKE Lock function. This feature can be enabled or disabled using the DRB scan tool and the proper Diagnostic Procedures. The horn relay is one of the outputs that the high-line CTM can control. The high-line CTM is programmed to energize or de-energize the horn relay in response to certain inputs from the Vehicle Theft Security System (VTSS) and the Remote Keyless Entry (RKE) system. One of the features that the high-line CTM supports and controls is the Vehicle Theft Security System (VTSS). In the VTSS, the CTM receives hard-wired inputs from the door jamb, door lock cylinder, and ignition switches. The programming in the CTM allows it to process the information from these inputs and send control outputs to energize or de-energize the headlamp relay, horn relay, and the Security lamp. The CTM also sends CCD data bus messages to the Powertrain Control Module (PCM) to control the engine no-run feature of the VTSS The CTM also contains the receiver and control logic for the power lock and Remote Keyless Entry (RKE) systems, which are integrated into the arming, disarming, and triggering functions of the VTSS. Both versions of the CTM are mounted under the passenger side end of the instrument panel, behind the instrument panel top cover and outboard of the glove box opening. For diagnosis of the base version of the CTM, refer to Wiper and Washer Systems or Chime/Buzzer Warning Systems. For diagnosis of the high-line version of the CTM or the CCD data bus, a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. Chime System CHIME SYSTEM The chime system is built into the CTM. The system also supports an external chime request from the instrument cluster. This feature allows the instrument cluster to request a chime from the CTM for gauge problems and tell-tale warnings. There are two chime rates, Low; 50 chimes per minute for reminders and High; 180 chimes per minute for serious conditions that require immediate attention. The high rate chime sounds when the key is left in the ignition and the doors are open or the headlights are left on. The low rate chime sounds for any of the other conditions. There is a variable rate feature that allows the chime to sound continuously for key-in and headlamp warning as long as the door is open. The seat belt warning chime is activated for six seconds, and all other chime conditions will activate the chime once at the time the warning light on the cluster is illuminated. The chime will sound for the following conditions: - Ignition oft, key in ignition, driver's door open - Ignition oft, headlamps on, driver's door open - Seat belt warning - Check engine lamp illuminated (after prove-out) - Airbag lamp illuminated (after prove-out) - Anti-lock lamp illuminated (after prove-out if equipped) - Check gauges lamp illuminated - Low fuel - Low washer fluid - Engine temp critical - Engine oil press too low Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 2641 CIRCUIT OPERATION Seat Belt Warning Chime The seat belt chime is used to indicate to the operator that the seat belt is not fastened when the ignition switch is in the RUN position. The seat belt switch is normally OPEN with the seat belt buckled. Circuit G10 is connected between the Central Timer Module (CTM) and the switch. Ground for the switch is provided on circuit Z1. Exterior Lamp-On Warning Chime The exterior lamp ON chime is used to indicate to the operator that the lamps are ON with the drivers door OPEN and the key removed from the ignition. The Central Timer Module (CTM) uses information from circuit G26 to determine if the lamps are ON, and circuit G16 for drivers door ajar. Key-In Ignition Warning Chime The Key-In chime is used to indicate to the operator that the key is in the ignition with the driver's door OPEN. If the key is in the ignition, a ground path is completed from the G26 circuit at the Central Timer Module (CTM), through the CLOSED switch, to the Z1 circuit. The Z1 circuit is the ground circuit. When the driver's door is open the normally OPEN door ajar switch CLOSES completing a path to ground on circuit G16. The CTM processes this information and turns on the chime. Compass Mini-Trip Computer (CMTC) SYSTEM OPERATION A mini trip computer is available on this model to provide several electronic functions and features. The trip computer contains a central processing unit and interfaces with other modules in the vehicle on the Chrysler Collision Detection (CCD) data bus network. The CCD data bus network allows the sharing of sensor information. This helps to reduce wire harness complexity, reduce internal controller hardware, and reduce component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. Some of the functions and features that the trip computer supports and/or controls, include the following display options: Compass and temperature - Trip odometer (ODO) - Average fuel economy (AVG ECO) - Instant fuel economy (ECO) - Distance to empty (DTE) - Elapsed time (ET) - Blank display Momentarily depressing and releasing the Step button when the ignition switch is in the On position will cause the overhead console display to step sequentially through the listed display options. Momentarily depressing and releasing the U.S./Metric button toggles the display between U.S. and Metric measurements. For more information on the trip computer features and functions, refer to the owner 5 manual in the vehicle glove box. The push button (Step and U.S./Metric) switches and the compass flux-gate unit are integral to the trip computer, compass, and thermometer display module unit. The ambient temperature sensor is hard-wired to the module. Data input for all other trip computer functions is received through CCD data bus messages. The trip computer uses its internal programming and all of these inputs to calculate and display the requested data. If the data displayed is incorrect, perform the self-diagnostic tests as described. If these tests prove inconclusive, the use of a DRB scan tool and the proper Diagnostic Procedures are recommended for further testing of the trip computer and the CCD data bus. The trip computer, compass, and thermometer display module cannot be repaired, and are only available for service as a unit. If faulty or damaged, the complete module must be replaced. COMPASS MINI-TRIP COMPUTER (CMTC) This system, located in the overhead console, displays information on outside temperature, compass direction and trip information. Compass And Temperature Display This display provides the outside temperature and one of eight compass readings to indicate the direction the vehicle is facing. Trip Odometer (ODO) Shows the distance travelled since the last reset. Average Fuel Economy (AVE ECO) Shows the average fuel economy in MPG (miles per gallon) or L/100Km since the last reset. Instantaneous Fuel Economy Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 2642 Shows the fuel economy for the last few seconds in MPG or L/100Km. Distance to Empty (DTE) Shows the estimated distance that can be travelled with the fuel remaining in the tank. This is calibrated using the MPG for the last few minutes. Elapsed Time (ET) Shows the accumulated ignition on time since the last reset. Step Button Press this button to cycle through all the mini-trip computer displays. US/M Button Press this button to convert all vehicle displays from US to metric to US. To Reset the Display Press the Step and US/M buttons simultaneously for at least two seconds and all resettable conditions will be rest. This will occur only if a resettable function (AVG ECO, ECO, ET) is currently being displayed. Automatic Compass Calibration This compass is self-calibrating which eliminates the need to manually set the compass. When the vehicle is new, the compass may appear erratic and the CAL symbol will be displayed. After completing three 360° turns in an area free from large metal or metallic objects, the CAL symbol will turn off and the compass will function normally. Compass Variance Compass Variance is the difference between Magnetic North and Geographic North. In some areas of the country, the difference between Magnetic and Geographic North is great enough to cause the compass to give false readings. If this occurs, the compass variance must be set. Enhanced Accident Response (Highline CTM only) If the Airbag Control Module (ACM) deploys the airbags, a message is transmitted over the CCD bus to the CTM module to unlock the doors. The interior lights will be turned on when the vehicle speed message on the CCD bus indicates 0 mph or the message is not present. In addition to unlocking the doors, the door lock feature will be disabled for a predetermined amount of time following the deployment. Once the ignition key has been cycled to the "off" position, normal operation will resume. Disclaimers DISCLAIMERS All information, illustrations, and specifications contained in this database are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice. Glossary of Terms/Acronyms GLOSSARY OF ACRONYMS ACM ..................................................................................................................................................... ....................................... Airbag Control Module CAB ........................................................................ ................................................................................................................ Controller Anti-lock Brake CCD ................................................................................................................................... Chrysler Collision Detection (Vehicle Communications Bus) CMTC ................................................................. ................................................................................................................ Compass/mini-trip Computer CTM .................................................................................................................................... .......................................................... Central Timer Module DAB ....................................................... ...................................................................................................................................................... Driver Airbag DLC ............................................................................................................................... ................................................................... Data Link Connector DTC ............................................... ............................................................................................................................................ Diagnostic Trouble Code MIC ............................................................................................................................... ................................................... Mechanical Instrument Cluster PAB ................................................ ........................................................................................................................................................ Passenger Airbag PCM ....................................................................................................................... ................................................................ Powertrain Control Module PDC ........................................ .................................................................................................................................................. Power Distribution Center RKE ...................................................................................................................... ......................................................................... Remote Keyless Entry SQUIB ................................................................................................................................... Also Called Initiator (Located In Rear Of Airbag Module) VTSS ............................................................................ ..................................................................................................... Vehicle Theft Security System Introduction SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION The body system consists of four modules that communicate over the (CCD) bus (Chrysler Collision Detection multiplex system). There are two additional modules, the Powertrain Control Module (PCM) and the Controller Anti-lock Brake (CAB) that are not part of the body system, but do utilize the CCD bus for communication. The CAB also utilizes the bus for diagnostics. The PCM sends and receives messages on the CCD bus, Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 2643 however diagnostics are performed through the Serial Communication Interface or (SCI), the same as last year. All of the information about the functioning of all the systems is organized, controlled, and communicated by the CCD bus. Through the CCD bus, information about the operation of vehicle components and circuits is relayed quickly to the appropriate module(s). All modules receive all the information transmitted on the bus even though a module may not require all information to perform it's function. It will only respond to messages "addressed" to it through a binary coding process. This method of data transmission significantly reduces the complexity of the wiring in the vehicle and the size of the wiring harnesses. Mechanical Instrument Cluster (MIC) MECHANICAL INSTRUMENT CLUSTER (MIC) The MIC is available in 4 different versions. Two of the versions are Canadian clusters. There is a Highline and a low line cluster available. The difference between Highline and low line is the addition of a tachometer in the Highline. In order to accomplish this, the fuel level gauge is reduced in size and the oil pressure gauge is relocated. The cluster positions it's gauges with bus messages received from the Powertrain Control Module (PCM). The odometer is a Liquid Crystal Display (LCD). The cluster will provide bus bias and the PCM provides termination. The MIC has an internal self-test routine that can be accessed by pushing and holding the trip odometer and rotating the key to the on position. The cluster will then place all the gauges at their calibration points and will light all the CCD driven tell-tales. It will also light all the segments of the LCD display for a visual verification check. All of the red warning symbols are non-replaceable LED's, amber tell-tales are serviceable incandescent bulbs. The MIC is not addressable with the DRB. All diagnostics are performed with the on-board sequence described above. If there are faults found during the diagnostic routine, the cluster will report them on the LCD odometer display. For further information about the diagnostic routine and the explanation of faults, please refer to Powertrain Management/Computers and Control Systems/Testing and Inspection/. Power Door Lock System POWER DOOR LOCKS The CTM controls the door lock actuator assemblies to handle locking and unlocking with the key fob or interior switch. There is also a door lock inhibit feature that prevents power locking of the doors if the ignition is off and the key is in the ignition. Automatic or "rolling locks" are included as a DRB programmable feature. If the vehicle is moving approximately 15 mph and approximately 10 degrees of throttle opening is seen by the PCM, (the PCM will send this info to the CTM via the CCD bus) indicating acceleration, the CTM will cycle the lock actuators. Remote Keyless Entry (RKE) /Vehicle Theft Security System (VTSS) INTRODUCTION Remote Keyless Entry System The Remote Keyless Entry (RKE) system is a radio frequency system that allows the use of a remote transmitter to control the power lock and illuminated entry systems. If the vehicle is so equipped, the RKE transmitter can also control the vehicle theft alarm system. The RKE system consists of the remote key fob transmitter and a receiver with program logic, which is integral to the high-line version of the Central Timer Module (CTM). The RKE system can retain the vehicle access codes of up to four transmitters. The transmitter codes are retained in memory, even if the battery is disconnected. If a transmitter is faulty or lost, new transmitter vehicle access codes can be programmed into the system using a DRE scan tool and the proper Diagnostic Procedures. The high line Central Timer Module (CTM) provides for Remote Keyless Entry (RKE) and the Vehicle Theft Security System (VTSS). The base CTM is not able to provide these functions. The presence of either of these options dictates that the vehicle be equipped with a Highline CTM. The VTSS system monitors the door jamb switches and ignition switch to detect unauthorized entry into the vehicle. Once the vehicle is "armed", any one of these inputs can cause the VTSS system to be tripped. Once tripped, the horn and lights will pulse for 3 minutes and if an attempt is made to start the engine, it will start and stall. If the trigger condition is still present, the lights will continue to flash for an additional 15 minutes. After 15 minutes the system will stop pulsing the lights and return to the "armed" state. The cause of the last 4 alarm triggers is stored by the CTM and may be retrieved by the DRB. The system may be disarmed by either an unlock command from a valid RKE key fob or by using a key in either door. Both front door key cylinders are equipped with disarm switches. There is also a VTSS lamp on the dash that provides information to the driver about the state of the vehicle theft system. The RKE system is placed in the programming mode by the DRB. The system will stores up to four key fob codes. Through the DRB, programming of one key fob without deleting the others is possible. If the key fob is stolen, all the fob codes stored previously may be erased to provide the owner of the vehicle with an extra sense of security. Wiper System SPEED SENSITIVE INTERMITTENT WIPERS The Dakota trucks equipped with a Highline Central Timer Module (CTM) will utilize speed sensitive intermittent wipers. Only a Highline CTM will be able to support this feature. A base CTM will provide for intermittent wipers without the speed sensitive feature. The low and high speeds Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 2644 are controlled through the wiper stalk switch. The intermittent portion of the wiper control is handled by the CTM through the intermittent wiper relay. When the module detects a decrease in delay time as selected by the driver, an immediate wipe of the windshield takes place and the new delay interval is implemented. This feature is present only on the Highline CTM. hen the vehicle is moving at speeds at or below 10 mph, the delay time ranges from 1 to 36 seconds. When the speed rises above 10 mph, the delay times are cut in half for a range of 1/2 to 18 seconds. The speed signal is provided to the CTM from the PCM over the CCD bus. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Central Timer Module ( CTM ) High Option: Initial Inspection and Diagnostic Overview VEHICLE COMMUNICATION The Chrysler Collision Detection multiplex system (CCD bus) consists of a twisted pair of wires. These wires run from one module to another. They receive and deliver coded information between the modules. The information is coded to identify the message as well as the importance of the message. When there are multiple messages trying to access the CCD bus at one time, the code determines the message that has higher priority, and is then allowed to access the bus first. The two wires of the twisted pair that make up the CCD multiplex system are called "bus+" (bus plus) and "bus-" (bus minus) respectively. Each wire has a measurable voltage level of roughly 2.5 volts. In order to maintain the 2.5 volts on each line and provide a means of transportation for the coded messages, there is a "voltage divider network" located in the module that supplies bus bias or voltage. Along with the module that supplies bias, some modules provide termination. Bias is the voltage necessary to make the bus operational. At least one point of termination is necessary, some systems use more than one. Some modules are capable of biasing and terminating the bus by themselves. Termination in the circuitry (a 120 ohm resistor placed across the bus) is required to complete the voltage divider network and also provides some electromagnetic protection for the bus. In this vehicle, the bias is supplied by the instrument cluster and termination is provided by the Powertrain Control Module (PCM). Without termination, voltage on the bus goes to approximately 5 volts on one wire and 0 volts on the other wire. In this application, the instrument cluster supplies bus bias and termination and the PCM supplies an additional point of termination. NOTE: Communication over the bus is essential to the proper operation of the vehicle's on-board diagnostic systems and the DRB. Problems with the operation of the bus or DRB must be corrected before proceeding with diagnostic testing. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2647 Central Timer Module ( CTM ) High Option: Component Tests and General Diagnostics DIAGNOSTICS The Central Timer Module (CTM) is fully addressable with DRB III and it is the recommended method for diagnosis. The CTM reports 6 Diagnostic Trouble Codes. All of the inputs to the CTM can be read with DRB and the outputs can be actuated. If the inputs are OK and the outputs can be cycled with the DRB, the problem is "USUALLY" the Central Timer Module. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2648 Central Timer Module ( CTM ) High Option: Scan Tool Testing and Procedures DRB III Does Not Power Up (Blank Screen) DRB III ERROR MESSAGES AND BLANK SCREEN Under normal operation, the DRB will display one of only two error messages: - User-Requested WARM Boot - User-Requested COLD Boot If the DRB should display any other error message, record the entire display and call the MDS Hotline, or call for information and assistance at 1-800-825-8737. This is a sample of such an error message display: VER: 2.14 date: 26 Jul93 file: key_itf.cc date: Jul 26 1993 line: 548 err. Ox1 User-Requested COLD boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. DRB III DOES NOT POWER UP (BLANK SCREEN) 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. If all connection are proper between the DRB and the Vehicle or other devices, and the vehicle battery is fully charged, an inoperative DRB may be the result of faulty cable of vehicle wiring. Perform Vehicle Communication TEST 1A. DRB III Safety Limits WARNING: Never exceed DRBIII safety limits! Display Is Not Visible DISPLAY IS NOT VISIBLE Low temperatures will effect the visibility of the display. Adjust the contrast to compensate for this condition. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Adjustments > Setting the Compass Central Timer Module ( CTM ) High Option: Adjustments Setting the Compass SETTING THE COMPASS The compass/mini-trip module is self-calibrated and requires no adjustment. The word CAL will be displayed to indicate that the compass is in the fast calibrating mode. CAL will turn off after the vehicle has gone in three complete circles without stopping, in an area free of magnetic disturbance. If the module displays the temperature while the compass is blank or shows a false reading, the vehicle must be demagnetized. If the compass still goes blank after the vehicle is demagnetized, the compass/mini-trip module must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Adjustments > Setting the Compass > Page 2651 Central Timer Module ( CTM ) High Option: Adjustments Setting the Variance SETTING THE VARIANCE Setting The Variance Variance is the difference between magnetic north and geographic north. To determine the variance for the area you are in, refer to the zone map provided. The number shown for your area is the variance number for your area. 1. Set the Compass/Mini-Trip Console (CMTC) to compass/temperature mode. 2. Press and hold down the reset button for 5 seconds. NOTE: If the buttons are held for 10 seconds instead of 5, the CMTC will set the variance to 8 and enter the fast calibration mode. 3. The VAR light will come on and the last variance setting will be displayed. 4. Press the STEP button to set the zone number. 5. Press the US/M button and resume normal operation. NOTE: Do not attach any magnetic device such as a magnetic CB antenna to the vehicle. This can cause the compass to give false readings. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Service and Repair > Maintenance and Service Information Central Timer Module ( CTM ) High Option: Service and Repair Maintenance and Service Information MAINTENANCE AND SERVICE INFORMATION When replacing a blown fuse, it is important to use only a fuse having the correct amperage rating. The use of a fuse with a rating other than indicated may result in a dangerous electrical system overload. If a properly rated fuse continues to blow, it indicates a problem in the circuit that must be corrected. When replacing any bulbs, do not touch the new bulb with your fingers. Oil contamination will severely shorten bulb life. If the bulb comes in contact with an oily surface, clean the bulb with rubbing alcohol. WARNING: Failure to have the airbag system properly serviced by an authorized dealer may lead to possible injury in the event of an accident. Aside from the maintenance required in response to the airbag lamp conditions, an inspection of the mechanical and electrical components of the system is included in the regular maintenance service recommended for every 3 years or 30,000 miles. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Service and Repair > Maintenance and Service Information > Page 2654 Central Timer Module ( CTM ) High Option: Service and Repair Setting the Compass SETTING THE COMPASS The compass/mini-trip module is self-calibrated and requires no adjustment. The word CAL will be displayed to indicate that the compass is in the fast calibrating mode. CAL will turn off after the vehicle has gone in three complete circles without stopping, in an area free of magnetic disturbance. If the module displays the temperature while the compass is blank or shows a false reading, the vehicle must be demagnetized. If the compass still goes blank after the vehicle is demagnetized, the compass/mini-trip module must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Service and Repair > Maintenance and Service Information > Page 2655 Central Timer Module ( CTM ) High Option: Service and Repair Setting the Variance SETTING THE VARIANCE Setting The Variance Variance is the difference between magnetic north and geographic north. To determine the variance for the area you are in, refer to the zone map provided. The number shown for your area is the variance number for your area. 1. Set the Compass/Mini-Trip Console (CMTC) to compass/temperature mode. 2. Press and hold down the reset button for 5 seconds. NOTE: If the buttons are held for 10 seconds instead of 5, the CMTC will set the variance to 8 and enter the fast calibration mode. 3. The VAR light will come on and the last variance setting will be displayed. 4. Press the STEP button to set the zone number. 5. Press the US/M button and resume normal operation. NOTE: Do not attach any magnetic device such as a magnetic CB antenna to the vehicle. This can cause the compass to give false readings. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Service and Repair > Page 2656 Central Timer Module ( CTM ) High Option: Tools and Equipment REQUIRED TOOLS AND EQUIPMENT DRB III (diagnostic read-out box) Jumper Wires Ohmmeter Voltmeter Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Description and Operation Brake Signal: Description and Operation PURPOSE Allows Engine Controller to monitor brake application. OPERATION The switch, mounted on brake pedal support bracket, closes when pedal is depressed. The engine controller uses switch input to determine engine load and maintain idle speed. The engine controller vents speed control system vacuum and turns speed control system OFF when brake switch actuation is sensed. The brake switch is also used as an input to signal deceleration. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Component Locations Camshaft Position Sensor: Component Locations Camshaft Position Sensor The Camshaft Position (CMP) Sensor is mounted in the distributor housing. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 2664 Distributor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2665 CPS Connector Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2666 Camshaft Position Sensor: Description and Operation LOCATION The camshaft position sensor is located in the distributor on all engines. DESCRIPTION The sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft. The pulse ring rotates 180 degrees through the sync signal generator. Its signal is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. OPERATION When the leading edge of the pulse ring (shutter) enters the sync signal generator, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a sync signal of approximately 5 volts. When the trailing edge of the pulse ring (shutter) leaves the sync signal generator, the change of the magnetic field causes the sync signal voltage to switch low to 0 volts. CIRCUIT OPERATION The camshaft position sensor is located internal to the distributor on all engine applications. The Powertrain Control Module (PCM) supplies 5 Volts to the camshaft position sensor on circuit K6. Circuit K6 connects to cavity A17 of the PCM. The PCM receives the camshaft position sensor signal on circuit K44. Circuit K44 connects to cavity A18 of the PCM. The PCM provides a ground for the camshaft position sensor (circuit K44) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2667 Camshaft Position Sensor: Testing and Inspection Circuit K6 splices to supply 5 Volts to the crankshaft position sensor, manifold absolute pressure sensor, and throttle position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Crankshaft position sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2668 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor NOTE: Distributor removal is not necessary to remove camshaft position sensor. REMOVAL 1. Remove air cleaner assembly 2. Disconnect negative cable from battery 3. Remove distributor cap from distributor (two screws). 4. Disconnect camshaft position sensor wiring harness from main engine wiring harness. 5. Remove distributor rotor from distributor shaft. 6. Lift the camshaft position sensor assembly from the distributor housing. INSTALLATION 1. Install camshaft position sensor to distributor. Align sensor into notch on distributor housing. 2. Connect wiring harness. 3. Install rotor 4. Install distributor cap. Tighten mounting screws. 5. Install air cleaner assembly. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications DESCRIPTION .................................................................................................................................... .............................................................. TORQUE Engine Coolant Temperature Sensor ........................................................................................................................................................... 11 Nm (96 in lb) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2672 Fig 6 Engine Coolant Temperature Sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2673 ECT Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2674 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig 6 Engine Coolant Temperature Sensor DESCRIPTION The engine coolant temperature sensor is installed in the intake manifold next to the thermostat housing. OPERATION The sensor provides an input voltage to the powertrain control module (PCM) relating coolant temperature. The PCM uses this input along with inputs from other sensors to determine injector pulse width and ignition timing. As coolant temperature varies, the coolant temperature sensor resistance will change. This change in resistance results in a different input voltage to the PCM. 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. CIRCUIT OPERATION The engine coolant temperature (ECT) sensor provides an input to the Powertrain Control Module (PCM) on circuit K2. From circuit K2, the engine coolant temperature sensor draws up to 5 Volts from the PCM. The sensor is a variable resistor. As coolant temperature changes, the resistance in the sensor changes, causing a change in current draw. The K2 circuit connects to cavity A16 of the PCM. The PCM provides a ground for the engine coolant temperature sensor signal (circuit K2) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Testing Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Component Testing Fig 57 Engine Coolant Temperature Sensor - Typical Sensor Resistance Chart (OHMS) To perform a complete test of the engine coolant temperature sensor and its circuitry, refer to Powertrain Management/Computers and Controls/Testing and Inspection/Procedures/Diagnostic Charts. To test the sensor only, refer to the following: 1. Disconnect wire harness connector from coolant temperature sensor (Fig. 57). 2. Engines with air conditioning: - When removing the connector from sensor, do not pull directly on wiring harness. - Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). - Place the hook part of tool under the connector for removal. - The connector is snapped onto the sensor. - It is not equipped with a lock type tab. 3. Test the resistance of the sensor with a high input impedance (digital) volt-ohmmeter. - The resistance (as measured across the sensor terminals) should be as shown in the Coolant Temperature Sensor/Intake Air Temperature Sensor resistance chart. - Replace the sensor if it is not within the range of resistance specified in the chart. 4. Test continuity of the wire harness between the PCM wire harness connector and the coolant sensor connector terminals. - Diagrams/Electrical/Connector Views for terminal/cavity locations. - Repair the wire harness if an open circuit is indicated. 5. After tests are completed, connect electrical connector to sensor. - The sensor connector is symmetrical (not indexed). - It can be installed to the sensor in either direction. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Testing > Page 2677 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Crankshaft position sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Page 2678 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig. 66 Engine Coolant Temperature Sensor WARNING: Hot, pressurized coolant can cause injury by scalding. cooling system must be partially drained before removing the coolant temperature sensor. REMOVAL 1. Partially drain cooling system. 2. Remove air cleaner assembly 3. Disconnect electrical connector from sensor. 4. Engines with air conditioning: - When removing the connector from sensor, do not pull directly on wiring harness. - Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). - Place the hook part of tool under the connector for removal. - The connector is snapped onto the sensor. - It is not equipped with a lock type tab. 5. Remove sensor from intake manifold. INSTALLATION 1. Install sensor. 2. Tighten to 11 Nm (8 ft lb) torque. 3. Connect electrical connector to sensor. - The sensor connector is symmetrical (not indexed). - It can be installed to the sensor in either direction. 4. Install air cleaner assembly 5. Replace any lost engine coolant. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications DESCRIPTION .................................................................................................................................... .............................................................. TORQUE Crankshaft Position Sensor ................................................................................................................. .......................................................... 8 Nm (70 in lb) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2682 Crankshaft Position Sensor: Locations Crankshaft Position Sensor The sensor is located on the top of cylinder block near the rear of right cylinder head. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2683 CKP Connector Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2684 Crankshaft Position Sensor: Description and Operation Fig. 4 Sensor Operation DESCRIPTION The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. The flywheel/drive plate has groups of notches at its outer edge. there are three sets of double notches and three sets of single notches. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. OPERATION Engine speed and crankshaft position are provided through the 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. CIRCUIT OPERATION The Powertrain Control Module (PCM) supplies 5 Volts to the crankshaft position sensor on circuit K6. Circuit K6 connects to cavity A17 of the PCM. The PCM receives the crankshaft position sensor signal on circuit K24. Circuit K24 connects to cavity A8 of the PCM. The PCM provides a ground for the crankshaft position sensor (circuit K24) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector. NOTE: The engine will not operate if the PCM does not receive a crankshaft position sensor input. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2685 Crankshaft Position Sensor: Testing and Inspection Circuit K6 splices to supply 5 Volts to the camshaft position sensor, manifold absolute pressure sensor, and throttle position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2686 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor NOTE: The sensor is bolted to the top of the cylinder block near the rear of right cylinder head. The sensor is accessed by removing the right front fender liner. REMOVAL 1. Remove right front tire and right front wheelhouse liner. 2. Disconnect crankshaft position sensor pigtail harness from main wiring harness. 3. Remove two sensor (recessed hex head) mounting bolts. 4. Remove sensor from engine. INSTALLATION 1. Position crankshaft position sensor to engine. 2. Install mounting bolts and tighten to 8 Nm (70 in lb) torque. 3. Connect main harness electrical connector to sensor. 4. Install right front tire and right front wheelhouse liner. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations DLC Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 2690 DLC Pin Out Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 2691 Data Link Connector: Description and Operation Fig. 20 16-Way Data Link Connector OPERATION The 16-way data link connector (diagnostic scan tool connector) links the Diagnostic Readout Box (DRB) scan tool or the Mopar Diagnostic System (MDS) with the powertrain control module (PCM). The data link connector is located at lower edge of instrument panel near steering column. CIRCUIT OPERATION Circuit M1 supplies battery voltage to the data link connector. Circuit M1 originates in the junction block and is protected by a 10 amp fuse. Circuit D20 connects to cavity C29 of the Power-train Control Module (PCM). Circuit D20 is the SCI receive circuit for the PCM. Circuit D21 connects to cavity C27 of the PCM. Circuit D21 is the SCI transmit circuit for the PCM. Circuits Z1 and Z12 provide ground for the data link connector. To communicate with the other modules and controllers in the vehicle the CCD bus is used. The circuits involved are D1 for CCD (+) and D2 for CCD (-). On vehicles equipped with Rear Wheel Anti-Lock (RWAL) brakes, or Anti-Lock Brakes (ABS) circuits B112 and B113 are connected to the universal data link connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 2692 Data Link Connector: Testing and Inspection - The grounding point for circuit Z12 is the rear of the engine. - Circuit Z12 also supplies a ground for the PCM high current drivers. - If the system loses ground for the Z12 circuits at the rear of the engine, the vehicle will not operate. Check the connection at the ganged-ground circuit eyelet. - Check the 10 amp fuse in the junction block Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 18-13-97A > Jun > 97 > PCM - Cold Engine Idle Fluctuation Powertrain Control Module: Customer Interest PCM - Cold Engine Idle Fluctuation NO: 18-13-97 Rev.A GROUP: Vehicle Performance DATE: Jun. 13, 1997 SUBJECT: Cold Engine Idle Fluctuation THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-13-97 DATED MAR. 14, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL CHANGES ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES PART NUMBER AND MODEL ADDITIONS. MODELS: **1997 (AB) Ram Van/Wagon ** 1997 (AN) Dakota **1997 (BR) Ram Truck** NOTE: THIS BULLETIN APPLIES TO 1997 VEHICLES WITH A 3.9L ENGINE BUILT PRIOR TO THE FOLLOWING DATES: (AB) JUN. 2, 1997 (MDH 0602XX), (AN) FEB. 19, 1997 (MDH 0219XX) (BR) JUN. 2, 1997 (MDH 0602XX). SYMPTOM/CONDITION: The vehicle may exhibit an idle fluctuation following a cold engine start. This condition is most noticeable while the transmission selector is in either the park or neutral position. The incidence for idle fluctuation increases with lower engine start temperatures and is less likely to occur in a warm engine. DIAGNOSIS: Verify that the vehicle engine and powertrain control module are close to ambient temperature. Set the vehicle parking brake, place the transmission selector in Park or Neutral, and start the engine. Without giving the engine any throttle assist, allow time for the fuel system to enter "closed loop" fuel control and warm to normal operating temperatures. The engine idle speed should gradually decrease as the engine warms. If the engine exhibits idle fluctuation during engine warm-up, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves replacing the Powertrain Control Module (PCM) with revised parts. 1. Following service manual procedures, replace the PCM. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 18-13-97A > Jun > 97 > PCM - Cold Engine Idle Fluctuation > Page 2701 2. Type the necessary information on the Authorized Modification Label p/n 04275086. Attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-03-92 0.7 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 18-21-98 > Jun > 98 > Powertrain Control Module - Service Precaution Powertrain Control Module: All Technical Service Bulletins Powertrain Control Module - Service Precaution NO: 18-21-98 GROUP: Vehicle Performance DATE: Jun. 5, 1998 SUBJECT: Powertrain Control Module (PCM) Service Caution MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1997 - 1998 (TJ) Wrangler 1996-1998 (XJ) Cherokee 1996-1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (European Market) DISCUSSION: Whenever any connector on the PCM is disconnected, the ignition switch must be in the "OFF" position for a minimum of 5 seconds before connector removal. It has been found under certain key "ON" or momentary key "OFF" conditions, when the black connector is unplugged, the PCM may attempt to write information to the EEPROM processor within the PCM. Sometimes this inadvertent write will set the target charging voltage to 0 (zero) volts. The result will prevent the charging system from charging the battery. If this occurs, the only correction is PCM replacement. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 18-13-97A > Jun > 97 > PCM - Cold Engine Idle Fluctuation Powertrain Control Module: All Technical Service Bulletins PCM - Cold Engine Idle Fluctuation NO: 18-13-97 Rev.A GROUP: Vehicle Performance DATE: Jun. 13, 1997 SUBJECT: Cold Engine Idle Fluctuation THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-13-97 DATED MAR. 14, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL CHANGES ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES PART NUMBER AND MODEL ADDITIONS. MODELS: **1997 (AB) Ram Van/Wagon ** 1997 (AN) Dakota **1997 (BR) Ram Truck** NOTE: THIS BULLETIN APPLIES TO 1997 VEHICLES WITH A 3.9L ENGINE BUILT PRIOR TO THE FOLLOWING DATES: (AB) JUN. 2, 1997 (MDH 0602XX), (AN) FEB. 19, 1997 (MDH 0219XX) (BR) JUN. 2, 1997 (MDH 0602XX). SYMPTOM/CONDITION: The vehicle may exhibit an idle fluctuation following a cold engine start. This condition is most noticeable while the transmission selector is in either the park or neutral position. The incidence for idle fluctuation increases with lower engine start temperatures and is less likely to occur in a warm engine. DIAGNOSIS: Verify that the vehicle engine and powertrain control module are close to ambient temperature. Set the vehicle parking brake, place the transmission selector in Park or Neutral, and start the engine. Without giving the engine any throttle assist, allow time for the fuel system to enter "closed loop" fuel control and warm to normal operating temperatures. The engine idle speed should gradually decrease as the engine warms. If the engine exhibits idle fluctuation during engine warm-up, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves replacing the Powertrain Control Module (PCM) with revised parts. 1. Following service manual procedures, replace the PCM. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 18-13-97A > Jun > 97 > PCM - Cold Engine Idle Fluctuation > Page 2711 2. Type the necessary information on the Authorized Modification Label p/n 04275086. Attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-03-92 0.7 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 080197 > Feb > 97 > PCM - Wire Harness Connector Repair Package Technical Service Bulletin # 080197 Date: 970203 Discussion NO: 08-01-97 GROUP: Electrical EFFECTIVE DATE: Feb. 3, 1997 SUBJECT: JTEC Powertrain Control Module Wiring Harness Connector Repair Packages MODELS: 1996 - 1997 (AB) Ram Van 1996 - 1997 (AN) Dakota 1996 - 1997 (BR) Ram Truck 1996 - 1997 (SR) Viper/Viper GTS 1997 (TJ) Wrangler 1996-1997 (XJ) Cherokee 1996-1997 (ZJ) Grand Cherokee 1996 - 1997 (ZG) Grand Cherokee (International Markets) DISCUSSION: The following Jeep/Truck Engine Controller (JTEC) Powertrain Control Module (PCM) electrical connector and terminal repair components are available to aid in powertrain electrical wiring repairs. These components allow repairs of individual wiring circuits without the need to replace the entire engine harness. If you have determined that a powertrain customer complaint could be related to a poor electrical connection, the PCM connectors should be inspected. The following diagnosis and inspection can be utilized to determine the condition of the PCM connectors and their terminals. Diagnosis Inspection of the connector begins with a thorough inspection of the insulator. 1. Record the radio station presets. 2. Disconnect and isolate the battery negative cable (both batteries should be disconnected if the vehicle is equipped with a 5.9L Cummins Diesel). 3. Disconnect the connector from the PCM. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 080197 > Feb > 97 > PCM - Wire Harness Connector Repair Package > Page 2716 4. Inspect the connector lock tab on the side of the insulator (Figure 1) for damage and replace the insulator if damaged is identified. 5. Gently pull on the wires of the connector one at a time. The initial and final locks will need to be inspected if the wire pulls out of the insulator. 6. Push in the single lock tab on the side of the insulator (Figure 2). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 080197 > Feb > 97 > PCM - Wire Harness Connector Repair Package > Page 2717 7. Then, insert the probe of special tool 6934 (Figure 3) into the back of the insulator cavity. 8. Grasp the wire and tool 6934 and slowly remove the wire and terminal from the insulator (Figure 4). Then, remove the strain relief and wire seal (Figure 1). 9. Inspect the initial and final locks of the insulator (Figure 1) for damage. Replace the insulator if there are any signs of damage. 10. Inspect all wire terminals for corrosion. If corrosion is evident, replace the terminal ends and the insulator. 11. To verify how secure the cavity of the terminal fits onto the PCM pins, insert and remove the wire end terminal onto the mating pin of the PGM. Then, rotate the terminal 90°, 180°, and 270° while inserting and removing the terminal from the pin. If any connection is loose, replace the wire end terminal. 12. Inspect and replace the PCM connector cover or connector plug if the locking tabs are damaged. Perform the following Repair Procedure if damage or wear is identified in any component of the insulator or terminals (including corrosion on the terminal). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 080197 > Feb > 97 > PCM - Wire Harness Connector Repair Package > Page 2718 PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves replacing either the insulator or terminals of the PCM connectors. Insulator Replacement NOTE: THIS PROCEDURE ASSUMES THAT THE WIRE END TERMINALS WERE ALREADY REMOVED WHEN THE DIAGNOSIS WAS PERFORMED. 1. Utilizing the appropriate insulator (see Parts Required list), install the wire and terminal into the appropriate cavities of the insulator. Refer to the appropriate Service Manual, Group 8W-80, for proper terminal-to-cavity locations in the connector. Fully seat all terminals into the insulator. 2. Push in the two lock tabs on the side of the connector (Figure 5). 3. Install the connector into the proper cavity of the PCM. 4. Connect the battery negative cable (both batteries should be connected if the vehicle is equipped with a 5.9L Cummins Diesel). 5. Reset the clock and reprogram the radio stations to the presets recorded in step 1 of the Diagnosis. Wire End Terminal Replacement NOTE: THIS PROCEDURE ASSUMES THAT THE DAMAGED OR CORRODED WIRE END TERMINAL WAS ALREADY REMOVED WHEN THE DIAGNOSIS WAS PERFORMED. 1. The wire of the terminal end that needs repaired will need to be cut and discarded. Measure approximately three inches down the wire from the end of the terminal and cut the wire. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 080197 > Feb > 97 > PCM - Wire Harness Connector Repair Package > Page 2719 2. Cut one of the wires with terminal ends from package P/N 04882087 in half. This action will allow for two repairs if necessary. 3. Remove approximately one inch of insulation from the wires that are being spliced together. 4. Place a piece of heat shrink tubing over one of the wires. Make sure the tubing will be long enough to cover and seal the entire repair. 5. Spread the strands of the wire apart on each part of the exposed wire (Example 1) (Figure 6). 6. Push the ends of the two wires together until the strands of wire are close to the insulation (Example 2) (Figure 6). 7. Twist the wires together (Example 3) (Figure 6). 8. Solder the connection together using rosin core type solder only. Do not use acid core solder. 9. Center the heat shrink tubing over the joint and heat the tubing using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 10. Secure the wires to the existing harness to prevent chafing or damage to the insulation. 11. Install the wire terminal end into the appropriate cavity of the insulator. Fully seat all terminals into the insulator. 12. Push in the single lock tab on the side of the connector (Figure 5). 13. Install the connector into the proper cavity of the PCM. 14. Connect the battery negative cable (both batteries should be connected if the vehicle is equipped with a 5.9L Cummins Diesel). 15. Reset the clock and reprogram the radio stations to the presets recorded in step 1 of the Diagnosis. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 18-21-98 > Jun > 98 > Powertrain Control Module - Service Precaution Powertrain Control Module: All Technical Service Bulletins Powertrain Control Module - Service Precaution NO: 18-21-98 GROUP: Vehicle Performance DATE: Jun. 5, 1998 SUBJECT: Powertrain Control Module (PCM) Service Caution MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1997 - 1998 (TJ) Wrangler 1996-1998 (XJ) Cherokee 1996-1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (European Market) DISCUSSION: Whenever any connector on the PCM is disconnected, the ignition switch must be in the "OFF" position for a minimum of 5 seconds before connector removal. It has been found under certain key "ON" or momentary key "OFF" conditions, when the black connector is unplugged, the PCM may attempt to write information to the EEPROM processor within the PCM. Sometimes this inadvertent write will set the target charging voltage to 0 (zero) volts. The result will prevent the charging system from charging the battery. If this occurs, the only correction is PCM replacement. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 080197 > Feb > 97 > PCM - Wire Harness Connector Repair Package Technical Service Bulletin # 080197 Date: 970203 Discussion NO: 08-01-97 GROUP: Electrical EFFECTIVE DATE: Feb. 3, 1997 SUBJECT: JTEC Powertrain Control Module Wiring Harness Connector Repair Packages MODELS: 1996 - 1997 (AB) Ram Van 1996 - 1997 (AN) Dakota 1996 - 1997 (BR) Ram Truck 1996 - 1997 (SR) Viper/Viper GTS 1997 (TJ) Wrangler 1996-1997 (XJ) Cherokee 1996-1997 (ZJ) Grand Cherokee 1996 - 1997 (ZG) Grand Cherokee (International Markets) DISCUSSION: The following Jeep/Truck Engine Controller (JTEC) Powertrain Control Module (PCM) electrical connector and terminal repair components are available to aid in powertrain electrical wiring repairs. These components allow repairs of individual wiring circuits without the need to replace the entire engine harness. If you have determined that a powertrain customer complaint could be related to a poor electrical connection, the PCM connectors should be inspected. The following diagnosis and inspection can be utilized to determine the condition of the PCM connectors and their terminals. Diagnosis Inspection of the connector begins with a thorough inspection of the insulator. 1. Record the radio station presets. 2. Disconnect and isolate the battery negative cable (both batteries should be disconnected if the vehicle is equipped with a 5.9L Cummins Diesel). 3. Disconnect the connector from the PCM. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 080197 > Feb > 97 > PCM - Wire Harness Connector Repair Package > Page 2729 4. Inspect the connector lock tab on the side of the insulator (Figure 1) for damage and replace the insulator if damaged is identified. 5. Gently pull on the wires of the connector one at a time. The initial and final locks will need to be inspected if the wire pulls out of the insulator. 6. Push in the single lock tab on the side of the insulator (Figure 2). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 080197 > Feb > 97 > PCM - Wire Harness Connector Repair Package > Page 2730 7. Then, insert the probe of special tool 6934 (Figure 3) into the back of the insulator cavity. 8. Grasp the wire and tool 6934 and slowly remove the wire and terminal from the insulator (Figure 4). Then, remove the strain relief and wire seal (Figure 1). 9. Inspect the initial and final locks of the insulator (Figure 1) for damage. Replace the insulator if there are any signs of damage. 10. Inspect all wire terminals for corrosion. If corrosion is evident, replace the terminal ends and the insulator. 11. To verify how secure the cavity of the terminal fits onto the PCM pins, insert and remove the wire end terminal onto the mating pin of the PGM. Then, rotate the terminal 90°, 180°, and 270° while inserting and removing the terminal from the pin. If any connection is loose, replace the wire end terminal. 12. Inspect and replace the PCM connector cover or connector plug if the locking tabs are damaged. Perform the following Repair Procedure if damage or wear is identified in any component of the insulator or terminals (including corrosion on the terminal). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 080197 > Feb > 97 > PCM - Wire Harness Connector Repair Package > Page 2731 PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves replacing either the insulator or terminals of the PCM connectors. Insulator Replacement NOTE: THIS PROCEDURE ASSUMES THAT THE WIRE END TERMINALS WERE ALREADY REMOVED WHEN THE DIAGNOSIS WAS PERFORMED. 1. Utilizing the appropriate insulator (see Parts Required list), install the wire and terminal into the appropriate cavities of the insulator. Refer to the appropriate Service Manual, Group 8W-80, for proper terminal-to-cavity locations in the connector. Fully seat all terminals into the insulator. 2. Push in the two lock tabs on the side of the connector (Figure 5). 3. Install the connector into the proper cavity of the PCM. 4. Connect the battery negative cable (both batteries should be connected if the vehicle is equipped with a 5.9L Cummins Diesel). 5. Reset the clock and reprogram the radio stations to the presets recorded in step 1 of the Diagnosis. Wire End Terminal Replacement NOTE: THIS PROCEDURE ASSUMES THAT THE DAMAGED OR CORRODED WIRE END TERMINAL WAS ALREADY REMOVED WHEN THE DIAGNOSIS WAS PERFORMED. 1. The wire of the terminal end that needs repaired will need to be cut and discarded. Measure approximately three inches down the wire from the end of the terminal and cut the wire. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 080197 > Feb > 97 > PCM - Wire Harness Connector Repair Package > Page 2732 2. Cut one of the wires with terminal ends from package P/N 04882087 in half. This action will allow for two repairs if necessary. 3. Remove approximately one inch of insulation from the wires that are being spliced together. 4. Place a piece of heat shrink tubing over one of the wires. Make sure the tubing will be long enough to cover and seal the entire repair. 5. Spread the strands of the wire apart on each part of the exposed wire (Example 1) (Figure 6). 6. Push the ends of the two wires together until the strands of wire are close to the insulation (Example 2) (Figure 6). 7. Twist the wires together (Example 3) (Figure 6). 8. Solder the connection together using rosin core type solder only. Do not use acid core solder. 9. Center the heat shrink tubing over the joint and heat the tubing using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 10. Secure the wires to the existing harness to prevent chafing or damage to the insulation. 11. Install the wire terminal end into the appropriate cavity of the insulator. Fully seat all terminals into the insulator. 12. Push in the single lock tab on the side of the connector (Figure 5). 13. Install the connector into the proper cavity of the PCM. 14. Connect the battery negative cable (both batteries should be connected if the vehicle is equipped with a 5.9L Cummins Diesel). 15. Reset the clock and reprogram the radio stations to the presets recorded in step 1 of the Diagnosis. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 2733 Powertrain Control Module: Specifications DESCRIPTION .................................................................................................................................... .............................................................. TORQUE Powertrain Control Module Mounting Screws ..................................................................................................................................... 3-5 Nm (30-40 in lb) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 2734 Powertrain Control Module: Locations Powertrain Control Module (PCM) The Powertrain Control Module (PCM) is mounted in the engine compartment. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2737 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 Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2738 Electrostatic Discharge Symbol All Electrostatic Discharge (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, especially 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. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2739 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2740 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2741 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2742 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2743 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2744 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2745 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2746 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. 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. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2747 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2748 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2749 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2750 Powertrain Control Module: Diagnostic Aids 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 in 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 and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2751 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. 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 every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. 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 fuse circuit. 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 the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2752 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools 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 - This instrument is 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 vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. 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 non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2753 PCM Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Five Volt Sensor Supply-Primary Powertrain Control Module: Description and Operation Five Volt Sensor Supply-Primary Supplies the required 5 volt power source to the crankshaft position sensor, camshaft position sensor, Manifold Absolute Pressure (MAP) sensor and throttle position sensor. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Five Volt Sensor Supply-Primary > Page 2756 Powertrain Control Module: Description and Operation Five Volt Sensor Supply-Secondary Supplies the required 5 volt power source to the transmission pressure sensor and the vehicle speed sensor. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Five Volt Sensor Supply-Primary > Page 2757 Powertrain Control Module: Description and Operation Power Grounds The power ground is used to control ground circuits for the following powertrain control module (PCM) loads: Generator field winding - Fuel injectors - Ignition coil - Certain relays/solenoids Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Five Volt Sensor Supply-Primary > Page 2758 Powertrain Control Module: Description and Operation Sensor Return-PCM Input Sensor Return provides a low noise ground reference for all system sensors. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Five Volt Sensor Supply-Primary > Page 2759 Powertrain Control Module: Description and Operation Five Volt Sensor Supply-Primary Supplies the required 5 volt power source to the crankshaft position sensor, camshaft position sensor, Manifold Absolute Pressure (MAP) sensor and throttle position sensor. Five Volt Sensor Supply-Secondary Supplies the required 5 volt power source to the transmission pressure sensor and the vehicle speed sensor. Power Grounds The power ground is used to control ground circuits for the following powertrain control module (PCM) loads: Generator field winding - Fuel injectors - Ignition coil - Certain relays/solenoids Sensor Return-PCM Input Sensor Return provides a low noise ground reference for all system sensors. Signal Ground-PCM Input Signal ground provides a low noise ground to the data link connector. System Description Fig 1 Powertrain Control Module (PCM) SYSTEM DIAGNOSIS The Powertrain Control Module (PCM) can test many of its own input and output circuits. If the PCM senses a fault in a major system, it stores a Diagnostic Trouble Code (DTC) in its memory. Technicians can display stored DTC's with different methods. One way is using the DRB scan tool. Another way is using the malfunction indicator (check engine) lamp. On certain models the vehicle odometer can be used to display the numeric DTC. POWERTRAIN CONTROL MODULE (PCM) The powertrain control module (PCM) (Fig. 1) operates the fuel system. The PCM was formerly referred to as the SBEC or engine controller. The PCM is a pre-programmed, dual microprocessor digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, certain transmission features, speed control, air conditioning compressor clutch engagement and idle speed. The PCM can adapt its programming to meet changing operating conditions. The PCM receives input signals from various switches and sensors. Based on these inputs, the PCM regulates various engine and vehicle operations through different system components. These components are referred to as Powertrain Control Module (PCM) Outputs. The sensors and switches that provide inputs to the PCM are considered Powertrain Control Module (PCM) Inputs. The PCM adjusts ignition timing based upon inputs it receives from sensors that react to: engine rpm, manifold absolute pressure, engine coolant temperature, throttle position, transmission gear selection (automatic transmission), vehicle speed and the brake switch. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Five Volt Sensor Supply-Primary > Page 2760 The PCM adjusts idle speed based on inputs it receives from sensors that react to: throttle position, vehicle speed, transmission gear selection, engine coolant temperature and from inputs it receives from the air conditioning clutch switch and brake switch. Based on inputs that it receives, the PCM adjusts ignition coil dwell. The PCM also adjusts the generator charge rate through control of the generator field and provides speed control operation. PCM INPUTS: - A/C request (if equipped with factory A/C) - A/C select (if equipped with factory A/C) - Auto shutdown (ASD) sense - Battery temperature - Battery voltage - Brake switch - CCD bus (+) circuits - CCD bus (-) circuits - Camshaft position sensor signal - Crankshaft position sensor - Data link connection for DRB scan tool - Engine coolant temperature sensor - Fuel level - Generator (battery voltage) output - Ignition circuit sense (ignition switch in on/of/ crank/run position) - Intake manifold air temperature sensor - Leak detection pump (switch) sense (if equipped) - Manifold absolute pressure (MAP) sensor - Oil pressure - Output shaft speed sensor - Overdrive/override switch - Oxygen sensors - Park/neutral switch (auto. trans. only) - Power ground - Sensor return - Signal ground - Speed control multiplexed single wire input - Throttle position sensor - Transmission governor pressure sensor - Transmission temperature sensor - Vehicle speed sensor PCM OUTPUTS: - A/C clutch relay - Auto shutdown (ASD) relay - CCD bus (+) circuits - CCD bus (-) circuits - Data link connection for DRB scan tool - EGR valve control solenoid (if equipped) - EVAP canister purge solenoid - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel injectors - Fuel pump relay - Generator field driver (-) - Generator field driver (+) - Generator lamp (if equipped) - Idle air control (IAC) motor - Ignition coil - Leak detection pump - Malfunction indicator lamp (Check engine lamp) -- Driven through CCD circuits. - Overdrive indicator lamp (if equipped) - Speed control vacuum solenoid - Speed control vent solenoid - Tachometer (if equipped). Driven through CCD circuits. - Transmission convertor clutch circuit - Transmission 3-4 shift solenoid - Transmission relay Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Five Volt Sensor Supply-Primary > Page 2761 - Transmission temperature lamp (if equipped) - Transmission variable force solenoid The powertrain control module (PCM) contains a voltage convertor. This converts battery voltage to a regulated 5.0 volts. It is used to power the crankshaft position sensor, camshaft position sensor and vehicle speed sensor. The PCM also provides a five (5) volt supply for the manifold absolute pressure (MAP) sensor and throttle position sensor (TPS). SPEED CONTROL SYSTEM OPERATION The speed control electronic control circuitry is integrated into the Powertrain Control Module (PCM). The PCM is located in the engine compartment. The PCM speed control functions are monitored by the On-Board Diagnostics (OBD). All OBD-sensed systems are monitored by the PCM. Each monitored circuit is assigned a Diagnostic Trouble Code (DTC). The PCM will store a DTC in electronic memory for certain failures it detects. See Starting and Charging/Charging System/Testing and Inspection/Procedures/On-Board Diagnostic Test For Speed Control System for more information. The PCM cannot be repaired and must be replaced if faulty. CIRCUIT OPERATION Battery Feed Circuit A14 from the Power Distribution Center (PDC) supplies battery voltage to cavity A22 of the Powertrain Control Module (PCM). A 30 amp fuse in cavity 1 of the PDC protects circuit A14. Ignition Feed Circuit F18 provides an input to the Powertrain Control Module (PCM). This circuit is HOT in the START and RUN position and protected by a 10 amp fuse located in the junction block. Power for the fuse is supplied by circuit A21 from the ignition switch. Transmission Control The Powertrain Control Module (PCM) controls operation of the converter clutch, overdrive clutch, and governor pressure solenoid. The control module determines transmission shift points based on input signals from the transmission thermistor, transmission output shaft speed sensor, crankshaft position sensor, vehicle speed sensor, throttle position sensor, and battery temperature sensor. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Powertrain Control Module: Initial Inspection and Diagnostic Overview Battery Feed - Check the 20 amp fuse located in cavity 1 of the PDC Ignition Feed - Check the 10 amp fuse located in the junction block Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Testing and Inspection > Page 2764 Powertrain Control Module: Service and Repair Powertrain Control Module (PCM) REMOVAL 1. Disconnect the negative battery cable at battery. 2. Carefully unplug the three 32-way connectors from PCM. 3. Remove three Powertrain Control Module (PCM) mounting bolts and remove PCM from vehicle. INSTALLATION 1. Install PCM and mounting bolts to vehicle. 2. Tighten bolts to 3-5 Nm (30-40 in lb). 3. Check pin connectors in the PCM and the three 32-way connectors for corrosion or damage. Repair as necessary 4. Install three 32-way connectors. 5. Install battery cable. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation The fuel level sensor (fuel gauge sending unit) sends a signal to the PCM to indicate fuel level. The purpose of this feature is to prevent a false setting of misfire and fuel system monitor trouble codes if the fuel level is less than approximately 15 percent of its rated capacity It is also used to send a signal for fuel gauge operation via the CCD bus circuits. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications Idle Speed/Throttle Actuator - Electronic: Specifications DESCRIPTION .................................................................................................................................... .............................................................. TORQUE IAC Motor-To-Throttle Body Bolts ............................................................................................................................................................. 7 Nm (60 in lb) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 2771 Fig 10 MAP And Throttle Position Sensor Location - Typical Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 2772 IAC Connector Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 2773 Idle Speed/Throttle Actuator - Electronic: Description and Operation Fig 10 MAP And Throttle Position Sensor Location - Typical DESCRIPTION The throttle body has an air control passage that provides air for the engine at idle (the throttle plate is closed). The Idle Air Control (IAC) motor pintle protrudes into the air control passage and regulates air flow through it. OPERATION Based on various sensor inputs, the powertrain control module (PCM) adjusts engine idle speed by moving the IAC motor pintle in and out of the air control passage. The IAC motor is positioned when the ignition key is turned to the On position. A (factory adjusted) set screw is used to mechanically limit the position of the throttle body throttle plate. Never attempt to adjust the engine idle speed using this screw. All idle speed functions are controlled by the PCM. CIRCUIT OPERATION The Powertrain Control Module (PCM) operates the Idle Air Control motor through four circuits; K39, K40, K59, and K60. Each circuit connects to separate cavities in the PCM connector. Circuit K39 connects to cavity A19 of the PCM connector. - Circuit K40 connects to cavity A11 of the PCM connector. - Circuit K59 connects to cavity A20 of the PCM connector. - Circuit K60 connects to cavity A10 of the PCM connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 2774 Idle Speed/Throttle Actuator - Electronic: Testing and Inspection To perform a complete test of the idle air control motor and circuits see Computers and System Diagnosis/Testing and Inspection/Diagnostic Charts. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 2775 Idle Speed/Throttle Actuator - Electronic: Adjustments A (factory adjusted) set screw is used to mechanically limit the position of the throttle body throttle plate. Never attempt to adjust the engine idle speed using this screw. All idle speed functions are controlled by the powertrain control module (PCM). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 2776 Idle Speed/Throttle Actuator - Electronic: Service and Repair Fig 75 Mounting Bolts (Screws) - IAC Motor The IAC motor is located on the back of the throttle body (Fig. 75). REMOVAL 1. Remove air duct at throttle body. 2. Disconnect electrical connector from IAC motor. 3. Remove two mounting bolts (screws) (Fig. 75). 4. Remove IAC motor from throttle body INSTALLATION 1. Install IAC motor to throttle body 2. Install and tighten two mounting bolts (screws) to 7 Nm (60 in lb) torque. 3. Install electrical connector. 4. Install air duct at throttle body Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Ignition Output Signal > Component Information > Description and Operation Ignition Output Signal: Description and Operation The ignition circuit sense input tells the Powertrain Control Module (PCM) the ignition switch has energized the ignition circuit. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation > Chrysler Collision Detection Multiplex System (CCD Bus) Information Bus: Description and Operation Chrysler Collision Detection Multiplex System (CCD Bus) VEHICLE COMMUNICATION The Chrysler Collision Detection multiplex system (CCD bus) consists of a twisted pair of wires. These wires run from one module to another. They receive and deliver coded information between the modules. The information is coded to identify the message as well as the importance of the message. When there are multiple messages trying to access the CCD bus at one time, the code determines the message that has higher priority, and is then allowed to access the bus first. The two wires of the twisted pair that make up the CCD multiplex system are called "bus+" (bus plus) and "bus-" (bus minus) respectively. Each wire has a measurable voltage level of roughly 2.5 volts. In order to maintain the 2.5 volts on each line and provide a means of transportation for the coded messages, there is a "voltage divider network" located in the module that supplies bus bias or voltage. Along with the module that supplies bias, some modules provide termination. Bias is the voltage necessary to make the bus operational. At least one point of termination is necessary, some systems use more than one. Some modules are capable of biasing and terminating the bus by themselves. Termination in the circuitry (a 120 ohm resistor placed across the bus) is required to complete the voltage divider network and also provides some electromagnetic protection for the bus. In this vehicle, the bias is supplied by the instrument cluster and termination is provided by the Powertrain Control Module (PCM). Without termination, voltage on the bus goes to approximately 5 volts on one wire and 0 volts on the other wire. In this application, the instrument cluster supplies bus bias and termination and the PCM supplies an additional point of termination. NOTE: Communication over the bus is essential to the proper operation of the vehicle's on-board diagnostic systems and the DRB. Problems with the operation of the bus or DRB must be corrected before proceeding with diagnostic testing. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation > Chrysler Collision Detection Multiplex System (CCD Bus) > Page 2784 Information Bus: Description and Operation Circuit Operation CIRCUIT OPERATION CCD Bus The CCD Bus and the universal data link connector are used for access to the diagnostic capabilities of the radio. Circuits D1 and D2 are used. The D1 circuit is used for CCD (+) and circuit D2 is used for CCD (-) To allow the Powertrain Control Module (PCM) to communicate with other controllers and modules, along with the universal data link connector, the CCD bus is used. The circuits involved are D1 for CCD (+), and D2 for CCD (-). The D1 circuit connects to cavity C30 of the PCM connector, and the D2 circuit connects to cavity C28. The CCD Bus is used to supply all of the communications between the Central Timer Module (CTM) and the instrument cluster. The bus wires are a twisted pair. There are two different circuits used for the bus. The positive side of the bus wire is accomplished on the D1 circuit, and the negative is on the D2 circuit. Ground Circuit Z12 connects to cavities A31 and A32 of the Powertrain Control Module (PCM). The Z12 circuit provides ground for PCM internal drivers that operate high current devices like the injectors and ignition coil. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Component Tests and General Diagnostics Information Bus: Component Tests and General Diagnostics - The grounding point for circuit Z12 is the rear of the engine. - If the system loses ground for the Z12 circuits, the vehicle will not operate. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates Automatic Shut Down (ASD) Relay: Technical Service Bulletins Engine Controls/Emissions/A/T Manual Updates NUMBER: 26-06-98 GROUP: Miscellaneous DATE: June, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 2.5L, 3.9L, 5.2L, 5.9L 8.0L SFI/CNG/Diesel Diagnostic Manual - Publication Number 81-699-96041 DESCRIPTION OF CHANGES Revision to the diagnostic trouble codes Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2791 56 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2792 57 Revisions to the Throttle Position Sensor test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2793 162 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2794 166 Revisions to the Evap. Purge Flow Monitor tests Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2795 374 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2796 375 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2797 377 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2798 379 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2799 379A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2800 379B Revision to the EGR system Failure tests Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2801 432 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2802 433 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2803 434 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2804 435 Revision to the torque convertor clutch - no drop at lock up test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2805 465 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2806 467 Revision to the no temp rise seen at intake heater test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2807 514 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2808 515 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2809 516 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2810 517 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2811 518 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2812 519 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2813 520 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2814 521 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2815 521A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2816 521B Revision to the 12 volt supply relay test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 2817 571 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Page 2818 Automatic Shut Down (ASD) Relay: Locations Power Distribution Center Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Page 2819 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Page 2820 Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Page 2821 Automatic Shut Down (ASD) Relay: Description and Operation CIRCUIT OPERATION Automatic Shut Down (ASD) Relay Circuit A16 from the Power Distribution Center (PDC) supplies battery voltage to the contact side of the Automatic Shut Down (ASD) relay. In the START or RUN position, the ignition switch connects circuit F18 from the 10 amp fuse in the junction block to the coil side of the ASD relay. The Powertrain Control Module (PCM) provides the ground path for the coil side of the relay on circuit K51. Circuit K51 connects to cavity C3 of the PCM. When the ASD relay energizes, it connects circuit A16 and circuit A142. Circuit A142 splices to supply voltage to the fuel injectors, ignition coil, and heated oxygen sensors. Circuit A142 also splices to cavity C12 of the PCM. This input tells the PCM the ASD relay has energized. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Relay Tests Automatic Shut Down (ASD) Relay: Testing and Inspection Relay Tests Fig 91 ASD And Fuel Pump Relay Terminals ASD and Fuel Pump Relay Test The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relay. The terminals on the bottom of each relay are numbered (Fig. 91). RELAY OPERATION Terminal 30: Connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. Terminal 85: The PCM grounds the coil side of the relay through this terminal. Terminal 86: Supplies voltage to the coil side of the relay. Terminal 87A: 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. Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TESTING 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 between 70 - 80 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. CAUTION: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter should now show continuity between relay terminals 87 and 30. - The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. - If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Relay Tests > Page 2824 Automatic Shut Down (ASD) Relay: Testing and Inspection Helpful Information - Check the 30 amp fuse located in the PDC - Check the 10 amp fuse located in the junction block Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Page 2825 Automatic Shut Down (ASD) Relay: Service and Repair Power Distribution Center NOTE: The Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). The PDC is located in the engine compartment. Refer to label on PDC cover for relay location. REMOVAL 1. Remove the PDC cover. 2. Remove the relay by lifting straight up. INSTALLATION 1. Check condition of relay terminals at PDC for corrosion or damage. - Also check the heights of relay terminal pins at PDC. Pin height should be same for all pins. - Repair as necessary before installing relay. 2. Push the relay into the connector. 3. Install the relay cover. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation MALFUNCTION INDICATOR LAMP (MIL) As a functional test, the MIL (check engine) illuminates at key-on before engine cranking. Whenever the Powertrain Control Module (PCM) sets a Diagnostic Trouble Code (DTC) that affects vehicle emissions, it illuminates the MIL. If a problem is detected, the PCM sends a message to the instrument cluster to illuminate the lamp. The PCM illuminates the MIL only for DTC's that affect vehicle emissions. There are some monitors that may take two consecutive trips, with a detected fault, before the MIL is illuminated. The MIL stays on continuously when the PCM has entered a Limp-In mode or identified a failed emission component. Also, the MIL either flashes or illuminates continuously when the PCM detects active engine misfire. Refer to Misfire Monitoring. Additionally, the PCM may reset (turn off) the MIL when one of the following occur: PCM does not detect the malfunction for 3 consecutive trips (except misfire and Fuel system Monitors). - PCM does not detect a malfunction while performing three successive engine misfire or fuel system tests. The PCM performs these tests while the engine is operating within +/- 375 RPM of and within 10% of the load of the operating condition at which the malfunction was first detected. BULB CHECK Each time the ignition key is turned to the ON position, the malfunction indicator (check engine) lamp on the instrument panel should illuminate for approximately 2 seconds then go out. This is done for a bulb check. CIRCUIT OPERATION The Powertrain Control Module (PCM) provides ground for the MIL on circuit G3. Circuit G3 connects to cavity C17 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 2829 Malfunction Indicator Lamp: Testing and Inspection The diagnosis found here addresses an inoperative malfunction indicator lamp condition. If the malfunction indicator lamp comes on and stays on with the engine running, refer to Instrument Panel, Gauges and Warning Indicators for diagnosis. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. If the malfunction indicator lamp fails to light during the bulb test (about two seconds after the ignition switch is turned to the On position), replace the malfunction indicator lamp bulb with a known good unit. If the indicator lamp still fails to operate, diagnosis of the Powertrain Control Module (PCM) and the Chrysler Collision Detection (CCD) data bus should be performed with a DRB scan tool. For diagnosis of the malfunction indicator lamp and the instrument cluster circuitry, see Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Instrument Cluster. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications Manifold Pressure/Vacuum Sensor: Specifications DESCRIPTION .................................................................................................................................... .............................................................. TORQUE MAP Sensor Mounting Screws ............................................................................................................ ......................................................... 3 Nm (25 in lb) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2833 Manifold Pressure/Vacuum Sensor: Locations Fig 10 MAP And Throttle Position Sensor Location - Typical The MAP sensor is mounted into the right side of the intake manifold. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2834 Manifold Pressure/Vacuum Sensor: Description and Operation Fig 10 MAP And Throttle Position Sensor Location - Typical DESCRIPTION The Manifold Absolute Pressure (MAP) sensor reacts to absolute pressure in the intake manifold. It provides an input voltage to the powertrain control module (PCM). The MAP sensor is mounted into the right side of the intake manifold. OPERATION As engine load changes, manifold pressure varies. The change in manifold pressure causes MAP sensor voltage to change. The change in MAP sensor voltage results in a different input voltage to the PCM. The input voltage level supplies the PCM with information about ambient barometric pressure during engine start-up (cranking) and engine load while the engine is running. The PCM uses this input along with inputs from other sensors to adjust air-fuel mixture. CIRCUIT OPERATION From the Powertrain Control Module (PCM), circuit K6 supplies 5 Volts to the Manifold Absolute Pressure (MAP) sensor Circuit K6 connects to cavity A17 of the PCM. Circuit K1 delivers the MAP signal to the PCM. Circuit K1 connects to cavity A27 of the PCM. The PCM provides a ground for the MAP sensor signal (circuit K1) through circuit K4. Circuit K4 connects to cavity A4 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Helpful Information Manifold Pressure/Vacuum Sensor: Testing and Inspection Helpful Information Circuit K6 splices to supply 5 Volts to the Throttle Position Sensor (TPS), camshaft position sensor, and crankshaft position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Crankshaft position sensor - Intake air temperature sensor - Throttle position sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2837 Manifold Pressure/Vacuum Sensor: Testing and Inspection Component Test Fig 49 MAP Sensor - Typical NOTE: To perform a complete test of MAP sensor (Fig. 49) and its circuitry, refer to Powertrain Management/Computers and Controls/Testing and Inspection/Diagnostic Charts. To test the MAP sensor only, refer to the following: Fig 50 Rubber L-Shaped Fitting - MAP Sensor-to-Throttle Body 1. Inspect the rubber L-shaped fitting from the MAP sensor to the throttle body (Fig. 50). Repair as necessary. CAUTION: When testing the MAP sensor, be sure that the harness wires are not damaged by the test meter probes. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2838 Fig 51 MAP Sensor Connector Terminals - Typical 2. Test the MAP sensor output voltage at the MAP sensor connector between terminals A and B (Fig. 51). With the ignition switch ON and the engine OFF output voltage should be 4-to-5 volts. The voltage should drop to 1.5-to-2.1 volts with a hot, neutral idle speed condition. 3. Test powertrain control module (PCM) cavity A-27 for the same voltage described above to verify the wire harness condition. Repair as necessary 4. Test MAP sensor supply voltage at sensor connector between terminals A and C (Fig. 51) with the ignition ON. - The voltage should be approximately 5 volts (+/- 0.5V). - Five volts (+/- 0.5V) should also be at cavity A-17 of the PCM wire harness connector. - Repair or replace the wire harness as necessary. 5. Test the MAP sensor ground circuit at sensor connector terminal A (Fig. 51) and PCM connector A-4. - Repair the wire harness if necessary Refer to Diagrams/Electrical/Connector Views for cavity locations. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Page 2839 Manifold Pressure/Vacuum Sensor: Service and Repair Fig 77 MAP Sensor Location Fig 78 MAP Sensor L-Shaped Rubber Fitting The MAP sensor is located on the front of the throttle body (Fig. 77). An L-shaped rubber fitting is used to connect the MAP sensor to throttle body (Fig. 78). REMOVAL 1. Remove air duct at throttle body 2. Remove two MAP sensor mounting bolts (screws) (Fig. 77). 3. While removing MAP sensor, slide the vacuum rubber L-shaped fitting (Fig. 78) from the throttle body 4. Remove rubber L-shaped fitting from MAP sensor. INSTALLATION 1. Install rubber L-shaped fitting to MAP sensor. 2. Position sensor to throttle body while guiding rubber fitting over throttle body vacuum nipple. 3. Install MAP sensor mounting bolts (screws). Tighten screws to 3 Nm (25 in lb) torque 4. Install air duct at throttle body. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Description and Operation Oil Pressure Sensor: Description and Operation Sends a signal from the oil pressure sending unit to the Powertrain Control Module (PCM) relating to engine oil pressure. CIRCUIT OPERATION The engine oil pressure sensor is a variable resistor. As engine oil pressure changes the resistance on circuit G60 changes. The G60 circuit connects to cavity B23 of the Powertrain Control Module (PCM) connector. Ground for the sensor is supplied on circuit K4. This circuit connects to cavity A4 of the PCM connector. This circuit is the ground circuit for many of the components in the fuel/ignition system. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Oxygen Sensor .................................................................................................................................... ......................................................... 30 Nm (22 ft lb) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations Oxygen Sensor: Locations Oxygen Sensor Bank Locations Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 2848 Oxygen Sensor: Locations Oxygen Sensor Location Fig 82 Upstream Oxygen Sensor Locations Fig 83 Downstream Oxygen Sensor Location The upstream and downstream Oxygen (02S) sensors are located at the inlet and outlet ends of the catalytic converter. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 2849 Oxygen Sensor Configuration Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2850 Oxygen Sensor: Diagrams Pinout Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2851 Oxygen Sensor: Application and ID Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2852 Oxygen Sensor: Description and Operation OXYGEN SENSOR (O2S)-PCM INPUT Two heated O2S sensors are used. The sensors produce voltages from 0 to 1 volt, depending upon the oxygen content of the exhaust gas in the exhaust manifold. When a large amount of oxygen is present (caused by a lean air/fuel mixture), the sensors produces a low voltage. When there is a lesser amount present (rich air/fuel mixture) it produces a higher voltage. By monitoring the oxygen content and converting it to electrical voltage, the sensors act as a rich-lean switch. In Closed Loop operation, the PCM monitors the O2S sensor input (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. The oxygen sensors are equipped with a heating element that keeps the sensors at proper operating temperature during all operating modes. 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. The Automatic Shutdown (ASD) relay supplies battery voltage to both the upstream and downstream heated oxygen sensors. The oxygen sensors are equipped with a heating element. The heating elements reduce the time required for the sensors to reach operating temperature. UPSTREAM HEATED OXYGEN SENSOR The upstream O2S sensor is located near the inlet end of the catalytic converter. It 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 the air/fuel ratio by adjusting injector pulse width. DOWNSTREAM HEATED OXYGEN SENSOR The downstream heated oxygen sensor is located near the outlet end of the catalytic converter The downstream heated oxygen sensor input is used to detect catalytic convertor deterioration. As the convertor deteriorates, the input from the downstream sensor begins to match the upstream sensor input except for a slight time delay By comparing the downstream heated oxygen sensor input to the input from the upstream sensor, the PCM calculates catalytic convertor efficiency. When the catalytic converter efficiency drops below emission standards, the PCM stores a diagnostic trouble code and illuminates the Malfunction Indicator Lamp (MIL). For more information, refer to Emission Control Systems. CIRCUIT OPERATION When the Automatic Shut Down (ASD) relay contacts CLOSE, they connect circuits A16 and A142. Circuit A142 splices to supply voltage to the heated oxygen sensors. Circuit K141 delivers the signal from the center heated oxygen sensor to the PCM. Circuit K141 connects to cavity A24 of the Powertrain Control Module (PCM). Circuit K341 delivers the signal from the rear sensor and connects to cavity A25 of the PCM. Circuit K241 delivers the signal from the right heated oxygen sensor to the PCM. Circuit K241 connects to cavity A26 of the Powertrain Control Module (PCM). Circuit K441 delivers the signal from the left sensor and connects to cavity A25 of the PCM. The PCM provides a ground for the heated oxygen sensor signals (circuits K141 and K341) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector. Circuit Z1 provides a ground for the heater circuit in the sensors. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Helpful Information Oxygen Sensor: Testing and Inspection Helpful Information Circuit A142 splices to supply voltage to the fuel injectors and ignition coil. Circuit K4 splices to supply ground for the signals from the following: - Camshaft position sensor - Crankshaft position sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Helpful Information > Page 2855 Oxygen Sensor: Testing and Inspection Sensor Heating Element Test Fig 82 Upstream Oxygen Sensor Locations Fig 83 Downstream Oxygen Sensor Location The upstream O2S sensor is located in the exhaust downpipe. The downstream sensor is located near outlet end of catalytic converter. Refer to (Fig. 82) or (Fig. 83). WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. REMOVAL 1. Raise and support the vehicle. 2. Disconnect the wire connector from the O2S sensor. CAUTION: When disconnecting the sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove the O2S sensor. Snap-On oxygen sensor wrench (number YA 8875) may be used for removal and installation. NOTE: Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to the threads of a new oxygen sensor. INSTALLATION 1. Install the 02S sensor. Tighten to 30 Nm (22 ft lb) torque. 2. Connect the O2S sensor wire connector. 3. Lower the vehicle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Page 2856 Oxygen Sensor: Service and Repair Fig 82 Upstream Oxygen Sensor Locations Fig 83 Downstream Oxygen Sensor Location NOTE: The upstream and downstream Oxygen (02S) sensors are located at the inlet and outlet ends of the catalytic converter. REMOVAL WARNING: The exhaust manifold, exhaust pipes and catalytic converter become very hot during engine operation. Allow engine to cool before removing oxygen sensor. 1. Raise and support the vehicle. 2. Disconnect the wire connector from the 02S sensor. CAUTION: When disconnecting the sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove the O2S sensor. Snap-On oxygen sensor wrench (number YA 8875) may be used for removal and installation. INSTALLATION Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to the threads of a new oxygen sensor. 1. Install the 02S sensor. Tighten to 30 Nm (22 ft lb) torque. 2. Connect the 02S sensor wire connector. 3. Lower the vehicle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Power Steering - Pressure Switch Torque Revisions Power Steering Pressure Switch: Technical Service Bulletins Power Steering - Pressure Switch Torque Revisions NUMBER: 26-10-96B GROUP: Miscellaneous DATE: October, 1996 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 Dakota - Publication Number 81-270-7146 DESCRIPTION OF CHANGES Revised power steering pressure switch torque (124-195 In. Lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Power Steering - Pressure Switch Torque Revisions > Page 2861 14-65 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Power Steering - Pressure Switch Torque Revisions > Page 2862 14-66 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Page 2863 Power Steering Pressure Switch: Specifications The content of this article reflects changes called for in TSB 26-10-96. Power Steering Pressure Switch ................................................................................................................................................ 14-22 Nm (124-195 in.lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Locations > Data Link Connector DLC Location Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Locations > Data Link Connector > Page 2869 Module Locations Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Locations > Data Link Connector > Page 2870 Module Locations Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Locations > Data Link Connector > Page 2871 Module Locations Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions Central Timer Module ( CTM ) High Option: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2874 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 Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2875 Electrostatic Discharge Symbol All Electrostatic Discharge (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, especially 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. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2876 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2877 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2878 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2879 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2880 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2881 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2882 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2883 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. 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. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2884 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2885 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2886 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2887 Central Timer Module ( CTM ) High Option: Diagnostic Aids 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 in 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 and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2888 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. 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 every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. 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 fuse circuit. 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 the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2889 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools 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 - This instrument is 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 vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. 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 non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2890 Central Timer Module ( CTM ) High Option: Connector Views Data Link Connector Pinout ABCM Connector Pinout Passenger Airbag Connector Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2891 Drivers Airbag Squib Connector Pinout Clockspring 2-Way Connector Pinout Central Timer Module (CTM) Connector "A" Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2892 Central Timer Module (CTM) Connector "B" Pinout Left Instrument Cluster Connector "A" (Black) Pinout Right Instrument Cluster Connector "B" (Gray) Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2893 Overhead Console Compass/Mini-Trip Computer Pinout Ambient Temperature Sensor Connector Pinout Door Jamb Switch Connector Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2894 Door Disarm Switch Connector Pinout Power Door Lock Switch Connections Door Lock Actuator Connector Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2895 Key-In Ignition Connector Pinout Multifunction Switch Connector Pinout Windshield Wiper Motor Connector Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2896 Central Timer Module ( CTM ) High Option: Electrical Diagrams Airbag System Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2897 Chrysler Collision Detection (CCD) Bus System Compass/Mini-Trip Computer System Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2898 Central Timer Module Block Diagram Power Lock System Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2899 Windshield Wiper System Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Service Precautions > Technician Safety Information Central Timer Module ( CTM ) High Option: Technician Safety Information Technician Safety Information DANGER!!! Engines produce carbon monoxide that is odorless, causes slower reaction time, and can lead to serious injury. When the engine is operating, keep service areas WELL VENTILATED or attach the vehicle exhaust system to the shop exhaust removal system. Set the parking brake and block the wheels before testing or repairing the vehicle. It is especially important to block the wheels on front-wheel drive vehicles; the parking brake does not hold the drive wheels. When servicing a vehicle, always wear eye protection, and remove any metal jewelry such as watchbands or bracelets that might make an inadvertent electrical contact. When diagnosing a body system problem, it is important to follow approved procedures where applicable. Following these procedures is very important to the safety of individuals performing diagnostic tests. 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. Servicing Sub-Assemblies SERVICING SUB-ASSEMBLIES Some components of the body system are intended to be serviced in 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 Service and Repair procedures should be serviced. DRB III Safety Information DRBIII SAFETY INFORMATION WARNING: Exceeding the limits of the DRB 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 DRB 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 function for the measurement. Do not try voltage or current measurements that may exceed the rated capacity. DRB III Safety Limits - Do not exceed the limits shown in the table below: - Voltage between any terminal and ground must not exceed 500v DC or 500v peak AC. - Use caution when measuring voltage above 25v DC or 25v AC. - The circuit being tested must be protected by a 10A fuse or circuit breaker. - Use the low current shunt to measure circuits up to 10A. Use the high current clamp to measure circuits exceeding 10A. - 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Service Precautions > Technician Safety Information > Page 2902 - 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 DRB away from spark plug or coil wires to avoid measuring error from outside interference. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Service Precautions > Technician Safety Information > Page 2903 Central Timer Module ( CTM ) High Option: Vehicle Damage Warnings Vehicle Damage Warnings 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. Road Testing A Complaint Vehicle ROAD TESTING A COMPLAINT VEHICLE 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 screen while in motion. Do not hang the DRB from the rear view mirror or operate it yourself. Have an assistant available to operate the DRB. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Service Precautions > Page 2904 Central Timer Module ( CTM ) High Option: Application and ID GLOSSARY OF ACRONYMS ACM ..................................................................................................................................................... ....................................... Airbag Control Module CAB ........................................................................ ................................................................................................................ Controller Anti-lock Brake CCD ................................................................................................................................... Chrysler Collision Detection (Vehicle Communications Bus) CMTC ................................................................. ................................................................................................................ Compass/mini-trip Computer CTM .................................................................................................................................... .......................................................... Central Timer Module DAB ....................................................... ...................................................................................................................................................... Driver Airbag DLC ............................................................................................................................... ................................................................... Data Link Connector DTC ............................................... ............................................................................................................................................ Diagnostic Trouble Code MIC ............................................................................................................................... ................................................... Mechanical Instrument Cluster PAB ................................................ ........................................................................................................................................................ Passenger Airbag PCM ....................................................................................................................... ................................................................ Powertrain Control Module PDC ........................................ .................................................................................................................................................. Power Distribution Center RKE ...................................................................................................................... ......................................................................... Remote Keyless Entry SQUIB ................................................................................................................................... Also Called Initiator (Located In Rear Of Airbag Module) VTSS ............................................................................ ..................................................................................................... Vehicle Theft Security System Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System Central Timer Module ( CTM ) High Option: Description and Operation Airbag System Airbag System Description AIRBAG SYSTEM The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front end collision. The system is most effective when used in conjunction with the seat belt system. The airbag control module (ACM) is an electronic module that monitors the airbag system for proper operation, stores Diagnostic Trouble Code (DTCs), controls the airbag warning lamp, monitors the pressure in the passenger airbag module 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 the diagnostic information DTCs to the technician through the DRB III via the CCD bus. Some circuits are tested continuously; others are checked only under certain circumstances. The warning lamp is driven with messages relayed to the Mechanical Instrument Cluster (MIC) from the ACM via the CCD bus. The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be observed by the customer. Whenever the ignition key is turned to the run or start" position, the airbag control module performs a lamp check by turning the AIRBAG warning lamp on for 6-8 seconds. If the lamp remains off, it means that the ACM has checked the system and found it to be free of discernible malfunctions. If the lamp remains on, there could be an active fault in the system or the circuit that operates the lamp may be shorted to ground. If the lamp comes on and stays on for a period longer than 6-8 seconds, then goes off, there is usually an intermittent problem in the system. Perform the WARNING LAMP CIRCUIT OPEN procedure in this book to find the cause of any customer complaint regarding the AIRBAG warning lamp, such as: Warning Lamp Does Not Illuminate - Warning Lamp Stays Illuminated WARNING! The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must first disconnect and isolate the battery negative (ground) cable. Then wait two minutes for the system capacitor to discharge before further system service. This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Never strike or kick the airbag control module, as it can damage the impact sensor or affect its calibration. If an airbag control module is accidentally dropped during service, the module must be scrapped and replaced with a new unit. Airbag Diagnostic Trouble Codes AIRBAG DIAGNOSTIC TROUBLE CODES Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Always begin by reading the diagnostic trouble codes using the DRB. This procedure begins with AIRBAG TEST 1A - Identifying Airbag System Problems. This will direct you to the specific test(s) that must be performed. Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures within this manual, diagnostic trouble codes are used as a diagnostic tool. ACTIVE CODES The codes become 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 are automatically erased 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 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 2907 "Loss of Ignition Run Only" code which is an active code only. A "stored" code indicates that there was an active code present at some time. However, the code currently may not be present as an active code, although another code could be. When a trouble code occurs, the airbag warning lamp illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. If a malfunction is detected a diagnostic trouble code is stored and will remain stored as long as the malfunction exists. When and if the malfunction ceases to exist, and ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of that same malfunction, the diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. If no obvious problems are found, erase stored codes, and with the ignition "on" wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 2908 Central Timer Module ( CTM ) High Option: Description and Operation Interior Lighting INTERIOR LIGHTING The courtesy lights are controlled by the CTM. The door switches are inputs to the CTM and the courtesy lights are outputs. The glove box lamp and the ash receiver lamp (if equipped) are not controlled by the CTM. They are hardwired to individual switches and fuses. The ignition key halo lamp is controlled by the CTM and will remain on for thirty seconds after the door is closed. The Highline CTM also provides for an illuminated entry option. If the CTM detects an unlock signal from the RKE transmitter, a door disarm switch input or the door jamb switch input, the interior courtesy lights will be turned on. The illuminated entry function is cancelled if the CTM senses an ignition "on" condition or the "lock" command from a valid key fob. If a door is left open or the dome lamp switch is left in the "on" position for more than fifteen minutes, the CTM will extinguish the lamps to avoid discharging the battery. If the lamps are turned on by rotation of the headlamp panel dimmer switch, the CTM will not be able to turn them off. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 2909 Central Timer Module ( CTM ) High Option: Description and Operation Central Timer Module INTRODUCTION Central Timer Module The Central Timer Module (CTM) is used to supply the vehicles occupants with visual and audible information, control various vehicle functions, and provide a centralized power distribution for the passenger compartment. To both provide and receive vehicle information the BCM is interfaced to the CCD Bus. Power for the CTM is supplied from three sources. Circuit F12 supplies power to the CTM in the START and RUN position. This circuit is protected by a 10 Amp fuse located in the junction block. Power is also supplied to the CTM on circuit F35. This circuit is HOT at all times and protected by a 20 Amp fuse located in the junction block. In the RUN position circuit V6 provides battery power to the CTM. This circuit is protected by a 20 Amp fuse located in the junction block. Ground for the ECM is provided by circuits Z1 and Z2. CCD Bus interface is accomplished on circuits D1 and D2. The D1 circuit is used for Bus (+), and D2 is for Bus (-). SYSTEM OPERATION Central Timer Module Two versions of the Central Timer Module (CTM) are available on this vehicle, a base version and a high-line version. The base version of the CTM is used on base models of the vehicle. The base version of the CTM combines the functions of a chime/buzzer module, an intermittent wipe module, and an ignition lamp time delay relay in a single unit. The high-line version of the CTM is used on highline vehicles. The high-line CTM provides all of the functions of the base version CTM, but also is used to control and integrate many of the additional electronic functions and features included on the high- line models. The high-line version of the CTM contains a central processing unit and interfaces with other modules in the vehicle on the Chrysler Collision Detection (CCD) data bus network. The CCD data bus network allows the sharing of sensor information. This helps to reduce wire harness complexity, reduce internal controller hardware, and reduce component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. The power lock and Remote Keyless Entry (RKE) systems are two of the systems that the high-line CTM controls. The high-line CTM receives hard-wired inputs from the power lock switches, CCD message inputs from the Powertrain Control Module (PCM) and Airbag Control Module (ACM), and coded radio signal inputs from the RKE transmitters. In response to those inputs, the internal programming of the CTM sends the proper outputs to control the power lock motors, the horn relay, and the courtesy lamps. Some of the features and functions of the power lock and Remote Keyless Entry (RKE) systems made possible because of the communication of the CTM on the CCD data bus network include: - A door-lock inhibit feature which prevents the power lock system from being energized with a power door lock switch if the key is in the ignition and/or the headlamps are on. However, the locks can still be operated manually with a key or energized with the RKE transmitter. - An enhanced accident response feature will prevent the doors from locking, then unlock both doors after receiving a CCD message from the ACM indicating a frontal impact requiring airbag deployment. This feature will also turn on the courtesy lamps ten seconds after receiving the ACM deployment message, if the CCD vehicle speed message from the PCM indicates the vehicle is not moving. Of course, these responses are dependent upon functional battery power and wiring circuitry following the impact. - Rolling door locks is a programmable feature of the power lock system. This feature will automatically lock all of the doors after the vehicle reaches a speed of about 24 kilometers-per-hour (15 miles-per-hour) or greater. This feature will also lock the doors if a door is opened, then closed again at any speed above 24 kilometers-per-hour (15 miles-per-hour). This feature can be enabled or disabled using the DRB scan tool and the proper Diagnostic Procedures. - A programmable feature of the RKE system is the enabling or disabling of the horn chirp following the RKE Lock function. This feature can be enabled or disabled using the DRB scan tool and the proper Diagnostic Procedures. The horn relay is one of the outputs that the high-line CTM can control. The high-line CTM is programmed to energize or de-energize the horn relay in response to certain inputs from the Vehicle Theft Security System (VTSS) and the Remote Keyless Entry (RKE) system. One of the features that the high-line CTM supports and controls is the Vehicle Theft Security System (VTSS). In the VTSS, the CTM receives hard-wired inputs from the door jamb, door lock cylinder, and ignition switches. The programming in the CTM allows it to process the information from these inputs and send control outputs to energize or de-energize the headlamp relay, horn relay, and the Security lamp. The CTM also sends CCD data bus messages to the Powertrain Control Module (PCM) to control the engine no-run feature of the VTSS The CTM also contains the receiver and control logic for the power lock and Remote Keyless Entry (RKE) systems, which are integrated into the arming, disarming, and triggering functions of the VTSS. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 2910 Both versions of the CTM are mounted under the passenger side end of the instrument panel, behind the instrument panel top cover and outboard of the glove box opening. For diagnosis of the base version of the CTM, refer to Wiper and Washer Systems or Chime/Buzzer Warning Systems. For diagnosis of the high-line version of the CTM or the CCD data bus, a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 2911 Central Timer Module ( CTM ) High Option: Description and Operation Chime System CHIME SYSTEM The chime system is built into the CTM. The system also supports an external chime request from the instrument cluster. This feature allows the instrument cluster to request a chime from the CTM for gauge problems and tell-tale warnings. There are two chime rates, Low; 50 chimes per minute for reminders and High; 180 chimes per minute for serious conditions that require immediate attention. The high rate chime sounds when the key is left in the ignition and the doors are open or the headlights are left on. The low rate chime sounds for any of the other conditions. There is a variable rate feature that allows the chime to sound continuously for key-in and headlamp warning as long as the door is open. The seat belt warning chime is activated for six seconds, and all other chime conditions will activate the chime once at the time the warning light on the cluster is illuminated. The chime will sound for the following conditions: - Ignition oft, key in ignition, driver's door open - Ignition oft, headlamps on, driver's door open - Seat belt warning - Check engine lamp illuminated (after prove-out) - Airbag lamp illuminated (after prove-out) - Anti-lock lamp illuminated (after prove-out if equipped) - Check gauges lamp illuminated - Low fuel - Low washer fluid - Engine temp critical - Engine oil press too low CIRCUIT OPERATION Seat Belt Warning Chime The seat belt chime is used to indicate to the operator that the seat belt is not fastened when the ignition switch is in the RUN position. The seat belt switch is normally OPEN with the seat belt buckled. Circuit G10 is connected between the Central Timer Module (CTM) and the switch. Ground for the switch is provided on circuit Z1. Exterior Lamp-On Warning Chime The exterior lamp ON chime is used to indicate to the operator that the lamps are ON with the drivers door OPEN and the key removed from the ignition. The Central Timer Module (CTM) uses information from circuit G26 to determine if the lamps are ON, and circuit G16 for drivers door ajar. Key-In Ignition Warning Chime The Key-In chime is used to indicate to the operator that the key is in the ignition with the driver's door OPEN. If the key is in the ignition, a ground path is completed from the G26 circuit at the Central Timer Module (CTM), through the CLOSED switch, to the Z1 circuit. The Z1 circuit is the ground circuit. When the driver's door is open the normally OPEN door ajar switch CLOSES completing a path to ground on circuit G16. The CTM processes this information and turns on the chime. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 2912 Central Timer Module ( CTM ) High Option: Description and Operation Airbag System Description AIRBAG SYSTEM The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front end collision. The system is most effective when used in conjunction with the seat belt system. The airbag control module (ACM) is an electronic module that monitors the airbag system for proper operation, stores Diagnostic Trouble Code (DTCs), controls the airbag warning lamp, monitors the pressure in the passenger airbag module 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 the diagnostic information DTCs to the technician through the DRB III via the CCD bus. Some circuits are tested continuously; others are checked only under certain circumstances. The warning lamp is driven with messages relayed to the Mechanical Instrument Cluster (MIC) from the ACM via the CCD bus. The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be observed by the customer. Whenever the ignition key is turned to the run or start" position, the airbag control module performs a lamp check by turning the AIRBAG warning lamp on for 6-8 seconds. If the lamp remains off, it means that the ACM has checked the system and found it to be free of discernible malfunctions. If the lamp remains on, there could be an active fault in the system or the circuit that operates the lamp may be shorted to ground. If the lamp comes on and stays on for a period longer than 6-8 seconds, then goes off, there is usually an intermittent problem in the system. Perform the WARNING LAMP CIRCUIT OPEN procedure in this book to find the cause of any customer complaint regarding the AIRBAG warning lamp, such as: Warning Lamp Does Not Illuminate - Warning Lamp Stays Illuminated WARNING! The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must first disconnect and isolate the battery negative (ground) cable. Then wait two minutes for the system capacitor to discharge before further system service. This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Never strike or kick the airbag control module, as it can damage the impact sensor or affect its calibration. If an airbag control module is accidentally dropped during service, the module must be scrapped and replaced with a new unit. Airbag Diagnostic Trouble Codes AIRBAG DIAGNOSTIC TROUBLE CODES Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Always begin by reading the diagnostic trouble codes using the DRB. This procedure begins with AIRBAG TEST 1A - Identifying Airbag System Problems. This will direct you to the specific test(s) that must be performed. Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures within this manual, diagnostic trouble codes are used as a diagnostic tool. ACTIVE CODES The codes become 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 are automatically erased 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 2913 A "stored" code indicates that there was an active code present at some time. However, the code currently may not be present as an active code, although another code could be. When a trouble code occurs, the airbag warning lamp illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. If a malfunction is detected a diagnostic trouble code is stored and will remain stored as long as the malfunction exists. When and if the malfunction ceases to exist, and ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of that same malfunction, the diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. If no obvious problems are found, erase stored codes, and with the ignition "on" wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Interior Lighting INTERIOR LIGHTING The courtesy lights are controlled by the CTM. The door switches are inputs to the CTM and the courtesy lights are outputs. The glove box lamp and the ash receiver lamp (if equipped) are not controlled by the CTM. They are hardwired to individual switches and fuses. The ignition key halo lamp is controlled by the CTM and will remain on for thirty seconds after the door is closed. The Highline CTM also provides for an illuminated entry option. If the CTM detects an unlock signal from the RKE transmitter, a door disarm switch input or the door jamb switch input, the interior courtesy lights will be turned on. The illuminated entry function is cancelled if the CTM senses an ignition "on" condition or the "lock" command from a valid key fob. If a door is left open or the dome lamp switch is left in the "on" position for more than fifteen minutes, the CTM will extinguish the lamps to avoid discharging the battery. If the lamps are turned on by rotation of the headlamp panel dimmer switch, the CTM will not be able to turn them off. Central Timer Module INTRODUCTION Central Timer Module The Central Timer Module (CTM) is used to supply the vehicles occupants with visual and audible information, control various vehicle functions, and provide a centralized power distribution for the passenger compartment. To both provide and receive vehicle information the BCM is interfaced to the CCD Bus. Power for the CTM is supplied from three sources. Circuit F12 supplies power to the CTM in the START and RUN position. This circuit is protected by a 10 Amp fuse located in the junction block. Power is also supplied to the CTM on circuit F35. This circuit is HOT at all times and protected by a 20 Amp fuse located in the junction block. In the RUN position circuit V6 provides battery power to the CTM. This circuit is protected by a 20 Amp fuse located in the junction block. Ground for the ECM is provided by circuits Z1 and Z2. CCD Bus interface is accomplished on circuits D1 and D2. The D1 circuit is used for Bus (+), and D2 is for Bus (-). SYSTEM OPERATION Central Timer Module Two versions of the Central Timer Module (CTM) are available on this vehicle, a base version and a high-line version. The base version of the CTM is used on base models of the vehicle. The base version of the CTM combines the functions of a chime/buzzer module, an intermittent wipe module, and an ignition lamp time delay relay in a single unit. The high-line version of the CTM is used on highline vehicles. The high-line CTM provides all of the functions of the base version CTM, but also is used to control and integrate many of the additional electronic functions and features included on the high- line models. The high-line version of the CTM contains a central processing unit and interfaces with other modules in the vehicle on the Chrysler Collision Detection (CCD) data bus network. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 2914 The CCD data bus network allows the sharing of sensor information. This helps to reduce wire harness complexity, reduce internal controller hardware, and reduce component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. The power lock and Remote Keyless Entry (RKE) systems are two of the systems that the high-line CTM controls. The high-line CTM receives hard-wired inputs from the power lock switches, CCD message inputs from the Powertrain Control Module (PCM) and Airbag Control Module (ACM), and coded radio signal inputs from the RKE transmitters. In response to those inputs, the internal programming of the CTM sends the proper outputs to control the power lock motors, the horn relay, and the courtesy lamps. Some of the features and functions of the power lock and Remote Keyless Entry (RKE) systems made possible because of the communication of the CTM on the CCD data bus network include: - A door-lock inhibit feature which prevents the power lock system from being energized with a power door lock switch if the key is in the ignition and/or the headlamps are on. However, the locks can still be operated manually with a key or energized with the RKE transmitter. - An enhanced accident response feature will prevent the doors from locking, then unlock both doors after receiving a CCD message from the ACM indicating a frontal impact requiring airbag deployment. This feature will also turn on the courtesy lamps ten seconds after receiving the ACM deployment message, if the CCD vehicle speed message from the PCM indicates the vehicle is not moving. Of course, these responses are dependent upon functional battery power and wiring circuitry following the impact. - Rolling door locks is a programmable feature of the power lock system. This feature will automatically lock all of the doors after the vehicle reaches a speed of about 24 kilometers-per-hour (15 miles-per-hour) or greater. This feature will also lock the doors if a door is opened, then closed again at any speed above 24 kilometers-per-hour (15 miles-per-hour). This feature can be enabled or disabled using the DRB scan tool and the proper Diagnostic Procedures. - A programmable feature of the RKE system is the enabling or disabling of the horn chirp following the RKE Lock function. This feature can be enabled or disabled using the DRB scan tool and the proper Diagnostic Procedures. The horn relay is one of the outputs that the high-line CTM can control. The high-line CTM is programmed to energize or de-energize the horn relay in response to certain inputs from the Vehicle Theft Security System (VTSS) and the Remote Keyless Entry (RKE) system. One of the features that the high-line CTM supports and controls is the Vehicle Theft Security System (VTSS). In the VTSS, the CTM receives hard-wired inputs from the door jamb, door lock cylinder, and ignition switches. The programming in the CTM allows it to process the information from these inputs and send control outputs to energize or de-energize the headlamp relay, horn relay, and the Security lamp. The CTM also sends CCD data bus messages to the Powertrain Control Module (PCM) to control the engine no-run feature of the VTSS The CTM also contains the receiver and control logic for the power lock and Remote Keyless Entry (RKE) systems, which are integrated into the arming, disarming, and triggering functions of the VTSS. Both versions of the CTM are mounted under the passenger side end of the instrument panel, behind the instrument panel top cover and outboard of the glove box opening. For diagnosis of the base version of the CTM, refer to Wiper and Washer Systems or Chime/Buzzer Warning Systems. For diagnosis of the high-line version of the CTM or the CCD data bus, a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. Chime System CHIME SYSTEM The chime system is built into the CTM. The system also supports an external chime request from the instrument cluster. This feature allows the instrument cluster to request a chime from the CTM for gauge problems and tell-tale warnings. There are two chime rates, Low; 50 chimes per minute for reminders and High; 180 chimes per minute for serious conditions that require immediate attention. The high rate chime sounds when the key is left in the ignition and the doors are open or the headlights are left on. The low rate chime sounds for any of the other conditions. There is a variable rate feature that allows the chime to sound continuously for key-in and headlamp warning as long as the door is open. The seat belt warning chime is activated for six seconds, and all other chime conditions will activate the chime once at the time the warning light on the cluster is illuminated. The chime will sound for the following conditions: - Ignition oft, key in ignition, driver's door open - Ignition oft, headlamps on, driver's door open - Seat belt warning - Check engine lamp illuminated (after prove-out) - Airbag lamp illuminated (after prove-out) - Anti-lock lamp illuminated (after prove-out if equipped) - Check gauges lamp illuminated - Low fuel - Low washer fluid - Engine temp critical - Engine oil press too low Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 2915 CIRCUIT OPERATION Seat Belt Warning Chime The seat belt chime is used to indicate to the operator that the seat belt is not fastened when the ignition switch is in the RUN position. The seat belt switch is normally OPEN with the seat belt buckled. Circuit G10 is connected between the Central Timer Module (CTM) and the switch. Ground for the switch is provided on circuit Z1. Exterior Lamp-On Warning Chime The exterior lamp ON chime is used to indicate to the operator that the lamps are ON with the drivers door OPEN and the key removed from the ignition. The Central Timer Module (CTM) uses information from circuit G26 to determine if the lamps are ON, and circuit G16 for drivers door ajar. Key-In Ignition Warning Chime The Key-In chime is used to indicate to the operator that the key is in the ignition with the driver's door OPEN. If the key is in the ignition, a ground path is completed from the G26 circuit at the Central Timer Module (CTM), through the CLOSED switch, to the Z1 circuit. The Z1 circuit is the ground circuit. When the driver's door is open the normally OPEN door ajar switch CLOSES completing a path to ground on circuit G16. The CTM processes this information and turns on the chime. Compass Mini-Trip Computer (CMTC) SYSTEM OPERATION A mini trip computer is available on this model to provide several electronic functions and features. The trip computer contains a central processing unit and interfaces with other modules in the vehicle on the Chrysler Collision Detection (CCD) data bus network. The CCD data bus network allows the sharing of sensor information. This helps to reduce wire harness complexity, reduce internal controller hardware, and reduce component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. Some of the functions and features that the trip computer supports and/or controls, include the following display options: Compass and temperature - Trip odometer (ODO) - Average fuel economy (AVG ECO) - Instant fuel economy (ECO) - Distance to empty (DTE) - Elapsed time (ET) - Blank display Momentarily depressing and releasing the Step button when the ignition switch is in the On position will cause the overhead console display to step sequentially through the listed display options. Momentarily depressing and releasing the U.S./Metric button toggles the display between U.S. and Metric measurements. For more information on the trip computer features and functions, refer to the owner 5 manual in the vehicle glove box. The push button (Step and U.S./Metric) switches and the compass flux-gate unit are integral to the trip computer, compass, and thermometer display module unit. The ambient temperature sensor is hard-wired to the module. Data input for all other trip computer functions is received through CCD data bus messages. The trip computer uses its internal programming and all of these inputs to calculate and display the requested data. If the data displayed is incorrect, perform the self-diagnostic tests as described. If these tests prove inconclusive, the use of a DRB scan tool and the proper Diagnostic Procedures are recommended for further testing of the trip computer and the CCD data bus. The trip computer, compass, and thermometer display module cannot be repaired, and are only available for service as a unit. If faulty or damaged, the complete module must be replaced. COMPASS MINI-TRIP COMPUTER (CMTC) This system, located in the overhead console, displays information on outside temperature, compass direction and trip information. Compass And Temperature Display This display provides the outside temperature and one of eight compass readings to indicate the direction the vehicle is facing. Trip Odometer (ODO) Shows the distance travelled since the last reset. Average Fuel Economy (AVE ECO) Shows the average fuel economy in MPG (miles per gallon) or L/100Km since the last reset. Instantaneous Fuel Economy Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 2916 Shows the fuel economy for the last few seconds in MPG or L/100Km. Distance to Empty (DTE) Shows the estimated distance that can be travelled with the fuel remaining in the tank. This is calibrated using the MPG for the last few minutes. Elapsed Time (ET) Shows the accumulated ignition on time since the last reset. Step Button Press this button to cycle through all the mini-trip computer displays. US/M Button Press this button to convert all vehicle displays from US to metric to US. To Reset the Display Press the Step and US/M buttons simultaneously for at least two seconds and all resettable conditions will be rest. This will occur only if a resettable function (AVG ECO, ECO, ET) is currently being displayed. Automatic Compass Calibration This compass is self-calibrating which eliminates the need to manually set the compass. When the vehicle is new, the compass may appear erratic and the CAL symbol will be displayed. After completing three 360° turns in an area free from large metal or metallic objects, the CAL symbol will turn off and the compass will function normally. Compass Variance Compass Variance is the difference between Magnetic North and Geographic North. In some areas of the country, the difference between Magnetic and Geographic North is great enough to cause the compass to give false readings. If this occurs, the compass variance must be set. Enhanced Accident Response (Highline CTM only) If the Airbag Control Module (ACM) deploys the airbags, a message is transmitted over the CCD bus to the CTM module to unlock the doors. The interior lights will be turned on when the vehicle speed message on the CCD bus indicates 0 mph or the message is not present. In addition to unlocking the doors, the door lock feature will be disabled for a predetermined amount of time following the deployment. Once the ignition key has been cycled to the "off" position, normal operation will resume. Disclaimers DISCLAIMERS All information, illustrations, and specifications contained in this database are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice. Glossary of Terms/Acronyms GLOSSARY OF ACRONYMS ACM ..................................................................................................................................................... ....................................... Airbag Control Module CAB ........................................................................ ................................................................................................................ Controller Anti-lock Brake CCD ................................................................................................................................... Chrysler Collision Detection (Vehicle Communications Bus) CMTC ................................................................. ................................................................................................................ Compass/mini-trip Computer CTM .................................................................................................................................... .......................................................... Central Timer Module DAB ....................................................... ...................................................................................................................................................... Driver Airbag DLC ............................................................................................................................... ................................................................... Data Link Connector DTC ............................................... ............................................................................................................................................ Diagnostic Trouble Code MIC ............................................................................................................................... ................................................... Mechanical Instrument Cluster PAB ................................................ ........................................................................................................................................................ Passenger Airbag PCM ....................................................................................................................... ................................................................ Powertrain Control Module PDC ........................................ .................................................................................................................................................. Power Distribution Center RKE ...................................................................................................................... ......................................................................... Remote Keyless Entry SQUIB ................................................................................................................................... Also Called Initiator (Located In Rear Of Airbag Module) VTSS ............................................................................ ..................................................................................................... Vehicle Theft Security System Introduction SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION The body system consists of four modules that communicate over the (CCD) bus (Chrysler Collision Detection multiplex system). There are two additional modules, the Powertrain Control Module (PCM) and the Controller Anti-lock Brake (CAB) that are not part of the body system, but do utilize the CCD bus for communication. The CAB also utilizes the bus for diagnostics. The PCM sends and receives messages on the CCD bus, Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 2917 however diagnostics are performed through the Serial Communication Interface or (SCI), the same as last year. All of the information about the functioning of all the systems is organized, controlled, and communicated by the CCD bus. Through the CCD bus, information about the operation of vehicle components and circuits is relayed quickly to the appropriate module(s). All modules receive all the information transmitted on the bus even though a module may not require all information to perform it's function. It will only respond to messages "addressed" to it through a binary coding process. This method of data transmission significantly reduces the complexity of the wiring in the vehicle and the size of the wiring harnesses. Mechanical Instrument Cluster (MIC) MECHANICAL INSTRUMENT CLUSTER (MIC) The MIC is available in 4 different versions. Two of the versions are Canadian clusters. There is a Highline and a low line cluster available. The difference between Highline and low line is the addition of a tachometer in the Highline. In order to accomplish this, the fuel level gauge is reduced in size and the oil pressure gauge is relocated. The cluster positions it's gauges with bus messages received from the Powertrain Control Module (PCM). The odometer is a Liquid Crystal Display (LCD). The cluster will provide bus bias and the PCM provides termination. The MIC has an internal self-test routine that can be accessed by pushing and holding the trip odometer and rotating the key to the on position. The cluster will then place all the gauges at their calibration points and will light all the CCD driven tell-tales. It will also light all the segments of the LCD display for a visual verification check. All of the red warning symbols are non-replaceable LED's, amber tell-tales are serviceable incandescent bulbs. The MIC is not addressable with the DRB. All diagnostics are performed with the on-board sequence described above. If there are faults found during the diagnostic routine, the cluster will report them on the LCD odometer display. For further information about the diagnostic routine and the explanation of faults, please refer to Powertrain Management/Computers and Control Systems/Testing and Inspection/. Power Door Lock System POWER DOOR LOCKS The CTM controls the door lock actuator assemblies to handle locking and unlocking with the key fob or interior switch. There is also a door lock inhibit feature that prevents power locking of the doors if the ignition is off and the key is in the ignition. Automatic or "rolling locks" are included as a DRB programmable feature. If the vehicle is moving approximately 15 mph and approximately 10 degrees of throttle opening is seen by the PCM, (the PCM will send this info to the CTM via the CCD bus) indicating acceleration, the CTM will cycle the lock actuators. Remote Keyless Entry (RKE) /Vehicle Theft Security System (VTSS) INTRODUCTION Remote Keyless Entry System The Remote Keyless Entry (RKE) system is a radio frequency system that allows the use of a remote transmitter to control the power lock and illuminated entry systems. If the vehicle is so equipped, the RKE transmitter can also control the vehicle theft alarm system. The RKE system consists of the remote key fob transmitter and a receiver with program logic, which is integral to the high-line version of the Central Timer Module (CTM). The RKE system can retain the vehicle access codes of up to four transmitters. The transmitter codes are retained in memory, even if the battery is disconnected. If a transmitter is faulty or lost, new transmitter vehicle access codes can be programmed into the system using a DRE scan tool and the proper Diagnostic Procedures. The high line Central Timer Module (CTM) provides for Remote Keyless Entry (RKE) and the Vehicle Theft Security System (VTSS). The base CTM is not able to provide these functions. The presence of either of these options dictates that the vehicle be equipped with a Highline CTM. The VTSS system monitors the door jamb switches and ignition switch to detect unauthorized entry into the vehicle. Once the vehicle is "armed", any one of these inputs can cause the VTSS system to be tripped. Once tripped, the horn and lights will pulse for 3 minutes and if an attempt is made to start the engine, it will start and stall. If the trigger condition is still present, the lights will continue to flash for an additional 15 minutes. After 15 minutes the system will stop pulsing the lights and return to the "armed" state. The cause of the last 4 alarm triggers is stored by the CTM and may be retrieved by the DRB. The system may be disarmed by either an unlock command from a valid RKE key fob or by using a key in either door. Both front door key cylinders are equipped with disarm switches. There is also a VTSS lamp on the dash that provides information to the driver about the state of the vehicle theft system. The RKE system is placed in the programming mode by the DRB. The system will stores up to four key fob codes. Through the DRB, programming of one key fob without deleting the others is possible. If the key fob is stolen, all the fob codes stored previously may be erased to provide the owner of the vehicle with an extra sense of security. Wiper System SPEED SENSITIVE INTERMITTENT WIPERS The Dakota trucks equipped with a Highline Central Timer Module (CTM) will utilize speed sensitive intermittent wipers. Only a Highline CTM will be able to support this feature. A base CTM will provide for intermittent wipers without the speed sensitive feature. The low and high speeds Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 2918 are controlled through the wiper stalk switch. The intermittent portion of the wiper control is handled by the CTM through the intermittent wiper relay. When the module detects a decrease in delay time as selected by the driver, an immediate wipe of the windshield takes place and the new delay interval is implemented. This feature is present only on the Highline CTM. hen the vehicle is moving at speeds at or below 10 mph, the delay time ranges from 1 to 36 seconds. When the speed rises above 10 mph, the delay times are cut in half for a range of 1/2 to 18 seconds. The speed signal is provided to the CTM from the PCM over the CCD bus. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Central Timer Module ( CTM ) High Option: Initial Inspection and Diagnostic Overview VEHICLE COMMUNICATION The Chrysler Collision Detection multiplex system (CCD bus) consists of a twisted pair of wires. These wires run from one module to another. They receive and deliver coded information between the modules. The information is coded to identify the message as well as the importance of the message. When there are multiple messages trying to access the CCD bus at one time, the code determines the message that has higher priority, and is then allowed to access the bus first. The two wires of the twisted pair that make up the CCD multiplex system are called "bus+" (bus plus) and "bus-" (bus minus) respectively. Each wire has a measurable voltage level of roughly 2.5 volts. In order to maintain the 2.5 volts on each line and provide a means of transportation for the coded messages, there is a "voltage divider network" located in the module that supplies bus bias or voltage. Along with the module that supplies bias, some modules provide termination. Bias is the voltage necessary to make the bus operational. At least one point of termination is necessary, some systems use more than one. Some modules are capable of biasing and terminating the bus by themselves. Termination in the circuitry (a 120 ohm resistor placed across the bus) is required to complete the voltage divider network and also provides some electromagnetic protection for the bus. In this vehicle, the bias is supplied by the instrument cluster and termination is provided by the Powertrain Control Module (PCM). Without termination, voltage on the bus goes to approximately 5 volts on one wire and 0 volts on the other wire. In this application, the instrument cluster supplies bus bias and termination and the PCM supplies an additional point of termination. NOTE: Communication over the bus is essential to the proper operation of the vehicle's on-board diagnostic systems and the DRB. Problems with the operation of the bus or DRB must be corrected before proceeding with diagnostic testing. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2921 Central Timer Module ( CTM ) High Option: Component Tests and General Diagnostics DIAGNOSTICS The Central Timer Module (CTM) is fully addressable with DRB III and it is the recommended method for diagnosis. The CTM reports 6 Diagnostic Trouble Codes. All of the inputs to the CTM can be read with DRB and the outputs can be actuated. If the inputs are OK and the outputs can be cycled with the DRB, the problem is "USUALLY" the Central Timer Module. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2922 Central Timer Module ( CTM ) High Option: Scan Tool Testing and Procedures DRB III Does Not Power Up (Blank Screen) DRB III ERROR MESSAGES AND BLANK SCREEN Under normal operation, the DRB will display one of only two error messages: - User-Requested WARM Boot - User-Requested COLD Boot If the DRB should display any other error message, record the entire display and call the MDS Hotline, or call for information and assistance at 1-800-825-8737. This is a sample of such an error message display: VER: 2.14 date: 26 Jul93 file: key_itf.cc date: Jul 26 1993 line: 548 err. Ox1 User-Requested COLD boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. DRB III DOES NOT POWER UP (BLANK SCREEN) 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. If all connection are proper between the DRB and the Vehicle or other devices, and the vehicle battery is fully charged, an inoperative DRB may be the result of faulty cable of vehicle wiring. Perform Vehicle Communication TEST 1A. DRB III Safety Limits WARNING: Never exceed DRBIII safety limits! Display Is Not Visible DISPLAY IS NOT VISIBLE Low temperatures will effect the visibility of the display. Adjust the contrast to compensate for this condition. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Adjustments > Setting the Compass Central Timer Module ( CTM ) High Option: Adjustments Setting the Compass SETTING THE COMPASS The compass/mini-trip module is self-calibrated and requires no adjustment. The word CAL will be displayed to indicate that the compass is in the fast calibrating mode. CAL will turn off after the vehicle has gone in three complete circles without stopping, in an area free of magnetic disturbance. If the module displays the temperature while the compass is blank or shows a false reading, the vehicle must be demagnetized. If the compass still goes blank after the vehicle is demagnetized, the compass/mini-trip module must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Adjustments > Setting the Compass > Page 2925 Central Timer Module ( CTM ) High Option: Adjustments Setting the Variance SETTING THE VARIANCE Setting The Variance Variance is the difference between magnetic north and geographic north. To determine the variance for the area you are in, refer to the zone map provided. The number shown for your area is the variance number for your area. 1. Set the Compass/Mini-Trip Console (CMTC) to compass/temperature mode. 2. Press and hold down the reset button for 5 seconds. NOTE: If the buttons are held for 10 seconds instead of 5, the CMTC will set the variance to 8 and enter the fast calibration mode. 3. The VAR light will come on and the last variance setting will be displayed. 4. Press the STEP button to set the zone number. 5. Press the US/M button and resume normal operation. NOTE: Do not attach any magnetic device such as a magnetic CB antenna to the vehicle. This can cause the compass to give false readings. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Service and Repair > Maintenance and Service Information Central Timer Module ( CTM ) High Option: Service and Repair Maintenance and Service Information MAINTENANCE AND SERVICE INFORMATION When replacing a blown fuse, it is important to use only a fuse having the correct amperage rating. The use of a fuse with a rating other than indicated may result in a dangerous electrical system overload. If a properly rated fuse continues to blow, it indicates a problem in the circuit that must be corrected. When replacing any bulbs, do not touch the new bulb with your fingers. Oil contamination will severely shorten bulb life. If the bulb comes in contact with an oily surface, clean the bulb with rubbing alcohol. WARNING: Failure to have the airbag system properly serviced by an authorized dealer may lead to possible injury in the event of an accident. Aside from the maintenance required in response to the airbag lamp conditions, an inspection of the mechanical and electrical components of the system is included in the regular maintenance service recommended for every 3 years or 30,000 miles. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Service and Repair > Maintenance and Service Information > Page 2928 Central Timer Module ( CTM ) High Option: Service and Repair Setting the Compass SETTING THE COMPASS The compass/mini-trip module is self-calibrated and requires no adjustment. The word CAL will be displayed to indicate that the compass is in the fast calibrating mode. CAL will turn off after the vehicle has gone in three complete circles without stopping, in an area free of magnetic disturbance. If the module displays the temperature while the compass is blank or shows a false reading, the vehicle must be demagnetized. If the compass still goes blank after the vehicle is demagnetized, the compass/mini-trip module must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Service and Repair > Maintenance and Service Information > Page 2929 Central Timer Module ( CTM ) High Option: Service and Repair Setting the Variance SETTING THE VARIANCE Setting The Variance Variance is the difference between magnetic north and geographic north. To determine the variance for the area you are in, refer to the zone map provided. The number shown for your area is the variance number for your area. 1. Set the Compass/Mini-Trip Console (CMTC) to compass/temperature mode. 2. Press and hold down the reset button for 5 seconds. NOTE: If the buttons are held for 10 seconds instead of 5, the CMTC will set the variance to 8 and enter the fast calibration mode. 3. The VAR light will come on and the last variance setting will be displayed. 4. Press the STEP button to set the zone number. 5. Press the US/M button and resume normal operation. NOTE: Do not attach any magnetic device such as a magnetic CB antenna to the vehicle. This can cause the compass to give false readings. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Service and Repair > Page 2930 Central Timer Module ( CTM ) High Option: Tools and Equipment REQUIRED TOOLS AND EQUIPMENT DRB III (diagnostic read-out box) Jumper Wires Ohmmeter Voltmeter Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 18-13-97A > Jun > 97 > PCM - Cold Engine Idle Fluctuation Powertrain Control Module: Customer Interest PCM - Cold Engine Idle Fluctuation NO: 18-13-97 Rev.A GROUP: Vehicle Performance DATE: Jun. 13, 1997 SUBJECT: Cold Engine Idle Fluctuation THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-13-97 DATED MAR. 14, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL CHANGES ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES PART NUMBER AND MODEL ADDITIONS. MODELS: **1997 (AB) Ram Van/Wagon ** 1997 (AN) Dakota **1997 (BR) Ram Truck** NOTE: THIS BULLETIN APPLIES TO 1997 VEHICLES WITH A 3.9L ENGINE BUILT PRIOR TO THE FOLLOWING DATES: (AB) JUN. 2, 1997 (MDH 0602XX), (AN) FEB. 19, 1997 (MDH 0219XX) (BR) JUN. 2, 1997 (MDH 0602XX). SYMPTOM/CONDITION: The vehicle may exhibit an idle fluctuation following a cold engine start. This condition is most noticeable while the transmission selector is in either the park or neutral position. The incidence for idle fluctuation increases with lower engine start temperatures and is less likely to occur in a warm engine. DIAGNOSIS: Verify that the vehicle engine and powertrain control module are close to ambient temperature. Set the vehicle parking brake, place the transmission selector in Park or Neutral, and start the engine. Without giving the engine any throttle assist, allow time for the fuel system to enter "closed loop" fuel control and warm to normal operating temperatures. The engine idle speed should gradually decrease as the engine warms. If the engine exhibits idle fluctuation during engine warm-up, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves replacing the Powertrain Control Module (PCM) with revised parts. 1. Following service manual procedures, replace the PCM. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 18-13-97A > Jun > 97 > PCM - Cold Engine Idle Fluctuation > Page 2939 2. Type the necessary information on the Authorized Modification Label p/n 04275086. Attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-03-92 0.7 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 18-21-98 > Jun > 98 > Powertrain Control Module - Service Precaution Powertrain Control Module: All Technical Service Bulletins Powertrain Control Module - Service Precaution NO: 18-21-98 GROUP: Vehicle Performance DATE: Jun. 5, 1998 SUBJECT: Powertrain Control Module (PCM) Service Caution MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1997 - 1998 (TJ) Wrangler 1996-1998 (XJ) Cherokee 1996-1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (European Market) DISCUSSION: Whenever any connector on the PCM is disconnected, the ignition switch must be in the "OFF" position for a minimum of 5 seconds before connector removal. It has been found under certain key "ON" or momentary key "OFF" conditions, when the black connector is unplugged, the PCM may attempt to write information to the EEPROM processor within the PCM. Sometimes this inadvertent write will set the target charging voltage to 0 (zero) volts. The result will prevent the charging system from charging the battery. If this occurs, the only correction is PCM replacement. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 18-13-97A > Jun > 97 > PCM Cold Engine Idle Fluctuation Powertrain Control Module: All Technical Service Bulletins PCM - Cold Engine Idle Fluctuation NO: 18-13-97 Rev.A GROUP: Vehicle Performance DATE: Jun. 13, 1997 SUBJECT: Cold Engine Idle Fluctuation THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-13-97 DATED MAR. 14, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL CHANGES ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES PART NUMBER AND MODEL ADDITIONS. MODELS: **1997 (AB) Ram Van/Wagon ** 1997 (AN) Dakota **1997 (BR) Ram Truck** NOTE: THIS BULLETIN APPLIES TO 1997 VEHICLES WITH A 3.9L ENGINE BUILT PRIOR TO THE FOLLOWING DATES: (AB) JUN. 2, 1997 (MDH 0602XX), (AN) FEB. 19, 1997 (MDH 0219XX) (BR) JUN. 2, 1997 (MDH 0602XX). SYMPTOM/CONDITION: The vehicle may exhibit an idle fluctuation following a cold engine start. This condition is most noticeable while the transmission selector is in either the park or neutral position. The incidence for idle fluctuation increases with lower engine start temperatures and is less likely to occur in a warm engine. DIAGNOSIS: Verify that the vehicle engine and powertrain control module are close to ambient temperature. Set the vehicle parking brake, place the transmission selector in Park or Neutral, and start the engine. Without giving the engine any throttle assist, allow time for the fuel system to enter "closed loop" fuel control and warm to normal operating temperatures. The engine idle speed should gradually decrease as the engine warms. If the engine exhibits idle fluctuation during engine warm-up, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves replacing the Powertrain Control Module (PCM) with revised parts. 1. Following service manual procedures, replace the PCM. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 18-13-97A > Jun > 97 > PCM Cold Engine Idle Fluctuation > Page 2949 2. Type the necessary information on the Authorized Modification Label p/n 04275086. Attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-03-92 0.7 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 080197 > Feb > 97 > PCM Wire Harness Connector Repair Package Technical Service Bulletin # 080197 Date: 970203 Discussion NO: 08-01-97 GROUP: Electrical EFFECTIVE DATE: Feb. 3, 1997 SUBJECT: JTEC Powertrain Control Module Wiring Harness Connector Repair Packages MODELS: 1996 - 1997 (AB) Ram Van 1996 - 1997 (AN) Dakota 1996 - 1997 (BR) Ram Truck 1996 - 1997 (SR) Viper/Viper GTS 1997 (TJ) Wrangler 1996-1997 (XJ) Cherokee 1996-1997 (ZJ) Grand Cherokee 1996 - 1997 (ZG) Grand Cherokee (International Markets) DISCUSSION: The following Jeep/Truck Engine Controller (JTEC) Powertrain Control Module (PCM) electrical connector and terminal repair components are available to aid in powertrain electrical wiring repairs. These components allow repairs of individual wiring circuits without the need to replace the entire engine harness. If you have determined that a powertrain customer complaint could be related to a poor electrical connection, the PCM connectors should be inspected. The following diagnosis and inspection can be utilized to determine the condition of the PCM connectors and their terminals. Diagnosis Inspection of the connector begins with a thorough inspection of the insulator. 1. Record the radio station presets. 2. Disconnect and isolate the battery negative cable (both batteries should be disconnected if the vehicle is equipped with a 5.9L Cummins Diesel). 3. Disconnect the connector from the PCM. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 080197 > Feb > 97 > PCM Wire Harness Connector Repair Package > Page 2954 4. Inspect the connector lock tab on the side of the insulator (Figure 1) for damage and replace the insulator if damaged is identified. 5. Gently pull on the wires of the connector one at a time. The initial and final locks will need to be inspected if the wire pulls out of the insulator. 6. Push in the single lock tab on the side of the insulator (Figure 2). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 080197 > Feb > 97 > PCM Wire Harness Connector Repair Package > Page 2955 7. Then, insert the probe of special tool 6934 (Figure 3) into the back of the insulator cavity. 8. Grasp the wire and tool 6934 and slowly remove the wire and terminal from the insulator (Figure 4). Then, remove the strain relief and wire seal (Figure 1). 9. Inspect the initial and final locks of the insulator (Figure 1) for damage. Replace the insulator if there are any signs of damage. 10. Inspect all wire terminals for corrosion. If corrosion is evident, replace the terminal ends and the insulator. 11. To verify how secure the cavity of the terminal fits onto the PCM pins, insert and remove the wire end terminal onto the mating pin of the PGM. Then, rotate the terminal 90°, 180°, and 270° while inserting and removing the terminal from the pin. If any connection is loose, replace the wire end terminal. 12. Inspect and replace the PCM connector cover or connector plug if the locking tabs are damaged. Perform the following Repair Procedure if damage or wear is identified in any component of the insulator or terminals (including corrosion on the terminal). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 080197 > Feb > 97 > PCM Wire Harness Connector Repair Package > Page 2956 PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves replacing either the insulator or terminals of the PCM connectors. Insulator Replacement NOTE: THIS PROCEDURE ASSUMES THAT THE WIRE END TERMINALS WERE ALREADY REMOVED WHEN THE DIAGNOSIS WAS PERFORMED. 1. Utilizing the appropriate insulator (see Parts Required list), install the wire and terminal into the appropriate cavities of the insulator. Refer to the appropriate Service Manual, Group 8W-80, for proper terminal-to-cavity locations in the connector. Fully seat all terminals into the insulator. 2. Push in the two lock tabs on the side of the connector (Figure 5). 3. Install the connector into the proper cavity of the PCM. 4. Connect the battery negative cable (both batteries should be connected if the vehicle is equipped with a 5.9L Cummins Diesel). 5. Reset the clock and reprogram the radio stations to the presets recorded in step 1 of the Diagnosis. Wire End Terminal Replacement NOTE: THIS PROCEDURE ASSUMES THAT THE DAMAGED OR CORRODED WIRE END TERMINAL WAS ALREADY REMOVED WHEN THE DIAGNOSIS WAS PERFORMED. 1. The wire of the terminal end that needs repaired will need to be cut and discarded. Measure approximately three inches down the wire from the end of the terminal and cut the wire. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 080197 > Feb > 97 > PCM Wire Harness Connector Repair Package > Page 2957 2. Cut one of the wires with terminal ends from package P/N 04882087 in half. This action will allow for two repairs if necessary. 3. Remove approximately one inch of insulation from the wires that are being spliced together. 4. Place a piece of heat shrink tubing over one of the wires. Make sure the tubing will be long enough to cover and seal the entire repair. 5. Spread the strands of the wire apart on each part of the exposed wire (Example 1) (Figure 6). 6. Push the ends of the two wires together until the strands of wire are close to the insulation (Example 2) (Figure 6). 7. Twist the wires together (Example 3) (Figure 6). 8. Solder the connection together using rosin core type solder only. Do not use acid core solder. 9. Center the heat shrink tubing over the joint and heat the tubing using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 10. Secure the wires to the existing harness to prevent chafing or damage to the insulation. 11. Install the wire terminal end into the appropriate cavity of the insulator. Fully seat all terminals into the insulator. 12. Push in the single lock tab on the side of the connector (Figure 5). 13. Install the connector into the proper cavity of the PCM. 14. Connect the battery negative cable (both batteries should be connected if the vehicle is equipped with a 5.9L Cummins Diesel). 15. Reset the clock and reprogram the radio stations to the presets recorded in step 1 of the Diagnosis. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 18-21-98 > Jun > 98 > Powertrain Control Module - Service Precaution Powertrain Control Module: All Technical Service Bulletins Powertrain Control Module - Service Precaution NO: 18-21-98 GROUP: Vehicle Performance DATE: Jun. 5, 1998 SUBJECT: Powertrain Control Module (PCM) Service Caution MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1997 - 1998 (TJ) Wrangler 1996-1998 (XJ) Cherokee 1996-1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (European Market) DISCUSSION: Whenever any connector on the PCM is disconnected, the ignition switch must be in the "OFF" position for a minimum of 5 seconds before connector removal. It has been found under certain key "ON" or momentary key "OFF" conditions, when the black connector is unplugged, the PCM may attempt to write information to the EEPROM processor within the PCM. Sometimes this inadvertent write will set the target charging voltage to 0 (zero) volts. The result will prevent the charging system from charging the battery. If this occurs, the only correction is PCM replacement. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 080197 > Feb > 97 > PCM - Wire Harness Connector Repair Package Technical Service Bulletin # 080197 Date: 970203 Discussion NO: 08-01-97 GROUP: Electrical EFFECTIVE DATE: Feb. 3, 1997 SUBJECT: JTEC Powertrain Control Module Wiring Harness Connector Repair Packages MODELS: 1996 - 1997 (AB) Ram Van 1996 - 1997 (AN) Dakota 1996 - 1997 (BR) Ram Truck 1996 - 1997 (SR) Viper/Viper GTS 1997 (TJ) Wrangler 1996-1997 (XJ) Cherokee 1996-1997 (ZJ) Grand Cherokee 1996 - 1997 (ZG) Grand Cherokee (International Markets) DISCUSSION: The following Jeep/Truck Engine Controller (JTEC) Powertrain Control Module (PCM) electrical connector and terminal repair components are available to aid in powertrain electrical wiring repairs. These components allow repairs of individual wiring circuits without the need to replace the entire engine harness. If you have determined that a powertrain customer complaint could be related to a poor electrical connection, the PCM connectors should be inspected. The following diagnosis and inspection can be utilized to determine the condition of the PCM connectors and their terminals. Diagnosis Inspection of the connector begins with a thorough inspection of the insulator. 1. Record the radio station presets. 2. Disconnect and isolate the battery negative cable (both batteries should be disconnected if the vehicle is equipped with a 5.9L Cummins Diesel). 3. Disconnect the connector from the PCM. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 080197 > Feb > 97 > PCM - Wire Harness Connector Repair Package > Page 2967 4. Inspect the connector lock tab on the side of the insulator (Figure 1) for damage and replace the insulator if damaged is identified. 5. Gently pull on the wires of the connector one at a time. The initial and final locks will need to be inspected if the wire pulls out of the insulator. 6. Push in the single lock tab on the side of the insulator (Figure 2). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 080197 > Feb > 97 > PCM - Wire Harness Connector Repair Package > Page 2968 7. Then, insert the probe of special tool 6934 (Figure 3) into the back of the insulator cavity. 8. Grasp the wire and tool 6934 and slowly remove the wire and terminal from the insulator (Figure 4). Then, remove the strain relief and wire seal (Figure 1). 9. Inspect the initial and final locks of the insulator (Figure 1) for damage. Replace the insulator if there are any signs of damage. 10. Inspect all wire terminals for corrosion. If corrosion is evident, replace the terminal ends and the insulator. 11. To verify how secure the cavity of the terminal fits onto the PCM pins, insert and remove the wire end terminal onto the mating pin of the PGM. Then, rotate the terminal 90°, 180°, and 270° while inserting and removing the terminal from the pin. If any connection is loose, replace the wire end terminal. 12. Inspect and replace the PCM connector cover or connector plug if the locking tabs are damaged. Perform the following Repair Procedure if damage or wear is identified in any component of the insulator or terminals (including corrosion on the terminal). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 080197 > Feb > 97 > PCM - Wire Harness Connector Repair Package > Page 2969 PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves replacing either the insulator or terminals of the PCM connectors. Insulator Replacement NOTE: THIS PROCEDURE ASSUMES THAT THE WIRE END TERMINALS WERE ALREADY REMOVED WHEN THE DIAGNOSIS WAS PERFORMED. 1. Utilizing the appropriate insulator (see Parts Required list), install the wire and terminal into the appropriate cavities of the insulator. Refer to the appropriate Service Manual, Group 8W-80, for proper terminal-to-cavity locations in the connector. Fully seat all terminals into the insulator. 2. Push in the two lock tabs on the side of the connector (Figure 5). 3. Install the connector into the proper cavity of the PCM. 4. Connect the battery negative cable (both batteries should be connected if the vehicle is equipped with a 5.9L Cummins Diesel). 5. Reset the clock and reprogram the radio stations to the presets recorded in step 1 of the Diagnosis. Wire End Terminal Replacement NOTE: THIS PROCEDURE ASSUMES THAT THE DAMAGED OR CORRODED WIRE END TERMINAL WAS ALREADY REMOVED WHEN THE DIAGNOSIS WAS PERFORMED. 1. The wire of the terminal end that needs repaired will need to be cut and discarded. Measure approximately three inches down the wire from the end of the terminal and cut the wire. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 080197 > Feb > 97 > PCM - Wire Harness Connector Repair Package > Page 2970 2. Cut one of the wires with terminal ends from package P/N 04882087 in half. This action will allow for two repairs if necessary. 3. Remove approximately one inch of insulation from the wires that are being spliced together. 4. Place a piece of heat shrink tubing over one of the wires. Make sure the tubing will be long enough to cover and seal the entire repair. 5. Spread the strands of the wire apart on each part of the exposed wire (Example 1) (Figure 6). 6. Push the ends of the two wires together until the strands of wire are close to the insulation (Example 2) (Figure 6). 7. Twist the wires together (Example 3) (Figure 6). 8. Solder the connection together using rosin core type solder only. Do not use acid core solder. 9. Center the heat shrink tubing over the joint and heat the tubing using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 10. Secure the wires to the existing harness to prevent chafing or damage to the insulation. 11. Install the wire terminal end into the appropriate cavity of the insulator. Fully seat all terminals into the insulator. 12. Push in the single lock tab on the side of the connector (Figure 5). 13. Install the connector into the proper cavity of the PCM. 14. Connect the battery negative cable (both batteries should be connected if the vehicle is equipped with a 5.9L Cummins Diesel). 15. Reset the clock and reprogram the radio stations to the presets recorded in step 1 of the Diagnosis. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 2971 Powertrain Control Module: Specifications DESCRIPTION .................................................................................................................................... .............................................................. TORQUE Powertrain Control Module Mounting Screws ..................................................................................................................................... 3-5 Nm (30-40 in lb) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 2972 Powertrain Control Module: Locations Powertrain Control Module (PCM) The Powertrain Control Module (PCM) is mounted in the engine compartment. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2975 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 Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2976 Electrostatic Discharge Symbol All Electrostatic Discharge (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, especially 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. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2977 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2978 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2979 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2980 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2981 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2982 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2983 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2984 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. 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. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2985 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2986 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2987 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2988 Powertrain Control Module: Diagnostic Aids 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 in 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 and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2989 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. 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 every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. 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 fuse circuit. 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 the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2990 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools 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 - This instrument is 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 vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. 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 non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2991 PCM Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Five Volt Sensor Supply-Primary Powertrain Control Module: Description and Operation Five Volt Sensor Supply-Primary Supplies the required 5 volt power source to the crankshaft position sensor, camshaft position sensor, Manifold Absolute Pressure (MAP) sensor and throttle position sensor. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Five Volt Sensor Supply-Primary > Page 2994 Powertrain Control Module: Description and Operation Five Volt Sensor Supply-Secondary Supplies the required 5 volt power source to the transmission pressure sensor and the vehicle speed sensor. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Five Volt Sensor Supply-Primary > Page 2995 Powertrain Control Module: Description and Operation Power Grounds The power ground is used to control ground circuits for the following powertrain control module (PCM) loads: Generator field winding - Fuel injectors - Ignition coil - Certain relays/solenoids Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Five Volt Sensor Supply-Primary > Page 2996 Powertrain Control Module: Description and Operation Sensor Return-PCM Input Sensor Return provides a low noise ground reference for all system sensors. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Five Volt Sensor Supply-Primary > Page 2997 Powertrain Control Module: Description and Operation Five Volt Sensor Supply-Primary Supplies the required 5 volt power source to the crankshaft position sensor, camshaft position sensor, Manifold Absolute Pressure (MAP) sensor and throttle position sensor. Five Volt Sensor Supply-Secondary Supplies the required 5 volt power source to the transmission pressure sensor and the vehicle speed sensor. Power Grounds The power ground is used to control ground circuits for the following powertrain control module (PCM) loads: Generator field winding - Fuel injectors - Ignition coil - Certain relays/solenoids Sensor Return-PCM Input Sensor Return provides a low noise ground reference for all system sensors. Signal Ground-PCM Input Signal ground provides a low noise ground to the data link connector. System Description Fig 1 Powertrain Control Module (PCM) SYSTEM DIAGNOSIS The Powertrain Control Module (PCM) can test many of its own input and output circuits. If the PCM senses a fault in a major system, it stores a Diagnostic Trouble Code (DTC) in its memory. Technicians can display stored DTC's with different methods. One way is using the DRB scan tool. Another way is using the malfunction indicator (check engine) lamp. On certain models the vehicle odometer can be used to display the numeric DTC. POWERTRAIN CONTROL MODULE (PCM) The powertrain control module (PCM) (Fig. 1) operates the fuel system. The PCM was formerly referred to as the SBEC or engine controller. The PCM is a pre-programmed, dual microprocessor digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, certain transmission features, speed control, air conditioning compressor clutch engagement and idle speed. The PCM can adapt its programming to meet changing operating conditions. The PCM receives input signals from various switches and sensors. Based on these inputs, the PCM regulates various engine and vehicle operations through different system components. These components are referred to as Powertrain Control Module (PCM) Outputs. The sensors and switches that provide inputs to the PCM are considered Powertrain Control Module (PCM) Inputs. The PCM adjusts ignition timing based upon inputs it receives from sensors that react to: engine rpm, manifold absolute pressure, engine coolant temperature, throttle position, transmission gear selection (automatic transmission), vehicle speed and the brake switch. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Five Volt Sensor Supply-Primary > Page 2998 The PCM adjusts idle speed based on inputs it receives from sensors that react to: throttle position, vehicle speed, transmission gear selection, engine coolant temperature and from inputs it receives from the air conditioning clutch switch and brake switch. Based on inputs that it receives, the PCM adjusts ignition coil dwell. The PCM also adjusts the generator charge rate through control of the generator field and provides speed control operation. PCM INPUTS: - A/C request (if equipped with factory A/C) - A/C select (if equipped with factory A/C) - Auto shutdown (ASD) sense - Battery temperature - Battery voltage - Brake switch - CCD bus (+) circuits - CCD bus (-) circuits - Camshaft position sensor signal - Crankshaft position sensor - Data link connection for DRB scan tool - Engine coolant temperature sensor - Fuel level - Generator (battery voltage) output - Ignition circuit sense (ignition switch in on/of/ crank/run position) - Intake manifold air temperature sensor - Leak detection pump (switch) sense (if equipped) - Manifold absolute pressure (MAP) sensor - Oil pressure - Output shaft speed sensor - Overdrive/override switch - Oxygen sensors - Park/neutral switch (auto. trans. only) - Power ground - Sensor return - Signal ground - Speed control multiplexed single wire input - Throttle position sensor - Transmission governor pressure sensor - Transmission temperature sensor - Vehicle speed sensor PCM OUTPUTS: - A/C clutch relay - Auto shutdown (ASD) relay - CCD bus (+) circuits - CCD bus (-) circuits - Data link connection for DRB scan tool - EGR valve control solenoid (if equipped) - EVAP canister purge solenoid - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel injectors - Fuel pump relay - Generator field driver (-) - Generator field driver (+) - Generator lamp (if equipped) - Idle air control (IAC) motor - Ignition coil - Leak detection pump - Malfunction indicator lamp (Check engine lamp) -- Driven through CCD circuits. - Overdrive indicator lamp (if equipped) - Speed control vacuum solenoid - Speed control vent solenoid - Tachometer (if equipped). Driven through CCD circuits. - Transmission convertor clutch circuit - Transmission 3-4 shift solenoid - Transmission relay Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Five Volt Sensor Supply-Primary > Page 2999 - Transmission temperature lamp (if equipped) - Transmission variable force solenoid The powertrain control module (PCM) contains a voltage convertor. This converts battery voltage to a regulated 5.0 volts. It is used to power the crankshaft position sensor, camshaft position sensor and vehicle speed sensor. The PCM also provides a five (5) volt supply for the manifold absolute pressure (MAP) sensor and throttle position sensor (TPS). SPEED CONTROL SYSTEM OPERATION The speed control electronic control circuitry is integrated into the Powertrain Control Module (PCM). The PCM is located in the engine compartment. The PCM speed control functions are monitored by the On-Board Diagnostics (OBD). All OBD-sensed systems are monitored by the PCM. Each monitored circuit is assigned a Diagnostic Trouble Code (DTC). The PCM will store a DTC in electronic memory for certain failures it detects. See Starting and Charging/Charging System/Testing and Inspection/Procedures/On-Board Diagnostic Test For Speed Control System for more information. The PCM cannot be repaired and must be replaced if faulty. CIRCUIT OPERATION Battery Feed Circuit A14 from the Power Distribution Center (PDC) supplies battery voltage to cavity A22 of the Powertrain Control Module (PCM). A 30 amp fuse in cavity 1 of the PDC protects circuit A14. Ignition Feed Circuit F18 provides an input to the Powertrain Control Module (PCM). This circuit is HOT in the START and RUN position and protected by a 10 amp fuse located in the junction block. Power for the fuse is supplied by circuit A21 from the ignition switch. Transmission Control The Powertrain Control Module (PCM) controls operation of the converter clutch, overdrive clutch, and governor pressure solenoid. The control module determines transmission shift points based on input signals from the transmission thermistor, transmission output shaft speed sensor, crankshaft position sensor, vehicle speed sensor, throttle position sensor, and battery temperature sensor. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Powertrain Control Module: Initial Inspection and Diagnostic Overview Battery Feed - Check the 20 amp fuse located in cavity 1 of the PDC Ignition Feed - Check the 10 amp fuse located in the junction block Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Testing and Inspection > Page 3002 Powertrain Control Module: Service and Repair Powertrain Control Module (PCM) REMOVAL 1. Disconnect the negative battery cable at battery. 2. Carefully unplug the three 32-way connectors from PCM. 3. Remove three Powertrain Control Module (PCM) mounting bolts and remove PCM from vehicle. INSTALLATION 1. Install PCM and mounting bolts to vehicle. 2. Tighten bolts to 3-5 Nm (30-40 in lb). 3. Check pin connectors in the PCM and the three 32-way connectors for corrosion or damage. Repair as necessary 4. Install three 32-way connectors. 5. Install battery cable. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates Automatic Shut Down (ASD) Relay: Technical Service Bulletins Engine Controls/Emissions/A/T Manual Updates NUMBER: 26-06-98 GROUP: Miscellaneous DATE: June, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 2.5L, 3.9L, 5.2L, 5.9L 8.0L SFI/CNG/Diesel Diagnostic Manual - Publication Number 81-699-96041 DESCRIPTION OF CHANGES Revision to the diagnostic trouble codes Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3007 56 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3008 57 Revisions to the Throttle Position Sensor test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3009 162 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3010 166 Revisions to the Evap. Purge Flow Monitor tests Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3011 374 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3012 375 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3013 377 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3014 379 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3015 379A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3016 379B Revision to the EGR system Failure tests Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3017 432 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3018 433 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3019 434 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3020 435 Revision to the torque convertor clutch - no drop at lock up test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3021 465 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3022 467 Revision to the no temp rise seen at intake heater test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3023 514 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3024 515 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3025 516 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3026 517 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3027 518 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3028 519 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3029 520 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3030 521 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3031 521A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3032 521B Revision to the 12 volt supply relay test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3033 571 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Page 3034 Automatic Shut Down (ASD) Relay: Locations Power Distribution Center Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Page 3035 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Page 3036 Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Page 3037 Automatic Shut Down (ASD) Relay: Description and Operation CIRCUIT OPERATION Automatic Shut Down (ASD) Relay Circuit A16 from the Power Distribution Center (PDC) supplies battery voltage to the contact side of the Automatic Shut Down (ASD) relay. In the START or RUN position, the ignition switch connects circuit F18 from the 10 amp fuse in the junction block to the coil side of the ASD relay. The Powertrain Control Module (PCM) provides the ground path for the coil side of the relay on circuit K51. Circuit K51 connects to cavity C3 of the PCM. When the ASD relay energizes, it connects circuit A16 and circuit A142. Circuit A142 splices to supply voltage to the fuel injectors, ignition coil, and heated oxygen sensors. Circuit A142 also splices to cavity C12 of the PCM. This input tells the PCM the ASD relay has energized. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Relay Tests Automatic Shut Down (ASD) Relay: Testing and Inspection Relay Tests Fig 91 ASD And Fuel Pump Relay Terminals ASD and Fuel Pump Relay Test The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relay. The terminals on the bottom of each relay are numbered (Fig. 91). RELAY OPERATION Terminal 30: Connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. Terminal 85: The PCM grounds the coil side of the relay through this terminal. Terminal 86: Supplies voltage to the coil side of the relay. Terminal 87A: 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. Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TESTING 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 between 70 - 80 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. CAUTION: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter should now show continuity between relay terminals 87 and 30. - The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. - If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Relay Tests > Page 3040 Automatic Shut Down (ASD) Relay: Testing and Inspection Helpful Information - Check the 30 amp fuse located in the PDC - Check the 10 amp fuse located in the junction block Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Page 3041 Automatic Shut Down (ASD) Relay: Service and Repair Power Distribution Center NOTE: The Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). The PDC is located in the engine compartment. Refer to label on PDC cover for relay location. REMOVAL 1. Remove the PDC cover. 2. Remove the relay by lifting straight up. INSTALLATION 1. Check condition of relay terminals at PDC for corrosion or damage. - Also check the heights of relay terminal pins at PDC. Pin height should be same for all pins. - Repair as necessary before installing relay. 2. Push the relay into the connector. 3. Install the relay cover. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations > Page 3046 MAP Connector Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Battery Temp. Sensor Location Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 3050 Battery Temp. Sensor Connector Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 3051 Battery Temperature Sensor: Service Precautions WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN . Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 3052 Battery Temperature Sensor: Description and Operation SYSTEM OPERATION The battery temperature sensor 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. CIRCUIT OPERATION The Powertrain Control Module (PCM) determines battery temperature on circuit K118. Circuit K118 connects the PCM to the battery temperature sensor. Circuit K4 provides ground for the sensor. Circuit K118 connects to cavity C15 of the PCM. Circuit K4 connects to cavity A4. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Testing Battery Temperature Sensor: Testing and Inspection Testing To perform a complete test of this sensor and its circuitry, refer to the appropriate Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Charts Procedures. To test the sensor only, refer to the following: Battery Temperature Sensor 1. The sensor is located under the battery and is attached to the battery tray. A two-wire pigtail harness is attached directly to the sensor. The opposite end of this harness connects the sensor to the engine wiring harness. 2. Disconnect the two-wire pigtail harness from the engine harness. 3. Attach ohmmeter leads to the wire terminals of the pigtail harness. 4. At room temperature of 25 °C (75 - 80 °F), an ohmmeter reading of 9,000 (9K) to 11,000 (11K) ohms should be observed. 5. If reading is above or below the specification, replace the sensor. 6. Refer to the Removal and Installation for procedures. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Page 3055 Battery Temperature Sensor: Service and Repair Battery Temperature Sensor The battery temperature sensor is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray. The sensor is located under the battery on drivers side of vehicle. REMOVAL 1. Remove battery. 2. Disconnect sensor pigtail harness from engine wire harness. 3. Pry sensor straight up from battery tray mounting hole. INSTALLATION 1. Feed pigtail harness through mounting hole in top of battery tray and press sensor into top of tray (snaps in). 2. Connect pigtail harness. 3. Install battery. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Component Locations Camshaft Position Sensor: Component Locations Camshaft Position Sensor The Camshaft Position (CMP) Sensor is mounted in the distributor housing. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 3060 Distributor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3061 CPS Connector Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3062 Camshaft Position Sensor: Description and Operation LOCATION The camshaft position sensor is located in the distributor on all engines. DESCRIPTION The sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft. The pulse ring rotates 180 degrees through the sync signal generator. Its signal is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. OPERATION When the leading edge of the pulse ring (shutter) enters the sync signal generator, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a sync signal of approximately 5 volts. When the trailing edge of the pulse ring (shutter) leaves the sync signal generator, the change of the magnetic field causes the sync signal voltage to switch low to 0 volts. CIRCUIT OPERATION The camshaft position sensor is located internal to the distributor on all engine applications. The Powertrain Control Module (PCM) supplies 5 Volts to the camshaft position sensor on circuit K6. Circuit K6 connects to cavity A17 of the PCM. The PCM receives the camshaft position sensor signal on circuit K44. Circuit K44 connects to cavity A18 of the PCM. The PCM provides a ground for the camshaft position sensor (circuit K44) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3063 Camshaft Position Sensor: Testing and Inspection Circuit K6 splices to supply 5 Volts to the crankshaft position sensor, manifold absolute pressure sensor, and throttle position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Crankshaft position sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3064 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor NOTE: Distributor removal is not necessary to remove camshaft position sensor. REMOVAL 1. Remove air cleaner assembly 2. Disconnect negative cable from battery 3. Remove distributor cap from distributor (two screws). 4. Disconnect camshaft position sensor wiring harness from main engine wiring harness. 5. Remove distributor rotor from distributor shaft. 6. Lift the camshaft position sensor assembly from the distributor housing. INSTALLATION 1. Install camshaft position sensor to distributor. Align sensor into notch on distributor housing. 2. Connect wiring harness. 3. Install rotor 4. Install distributor cap. Tighten mounting screws. 5. Install air cleaner assembly. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications DESCRIPTION .................................................................................................................................... .............................................................. TORQUE Engine Coolant Temperature Sensor ........................................................................................................................................................... 11 Nm (96 in lb) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3068 Fig 6 Engine Coolant Temperature Sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3069 ECT Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3070 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig 6 Engine Coolant Temperature Sensor DESCRIPTION The engine coolant temperature sensor is installed in the intake manifold next to the thermostat housing. OPERATION The sensor provides an input voltage to the powertrain control module (PCM) relating coolant temperature. The PCM uses this input along with inputs from other sensors to determine injector pulse width and ignition timing. As coolant temperature varies, the coolant temperature sensor resistance will change. This change in resistance results in a different input voltage to the PCM. 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. CIRCUIT OPERATION The engine coolant temperature (ECT) sensor provides an input to the Powertrain Control Module (PCM) on circuit K2. From circuit K2, the engine coolant temperature sensor draws up to 5 Volts from the PCM. The sensor is a variable resistor. As coolant temperature changes, the resistance in the sensor changes, causing a change in current draw. The K2 circuit connects to cavity A16 of the PCM. The PCM provides a ground for the engine coolant temperature sensor signal (circuit K2) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Testing Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Component Testing Fig 57 Engine Coolant Temperature Sensor - Typical Sensor Resistance Chart (OHMS) To perform a complete test of the engine coolant temperature sensor and its circuitry, refer to Powertrain Management/Computers and Controls/Testing and Inspection/Procedures/Diagnostic Charts. To test the sensor only, refer to the following: 1. Disconnect wire harness connector from coolant temperature sensor (Fig. 57). 2. Engines with air conditioning: - When removing the connector from sensor, do not pull directly on wiring harness. - Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). - Place the hook part of tool under the connector for removal. - The connector is snapped onto the sensor. - It is not equipped with a lock type tab. 3. Test the resistance of the sensor with a high input impedance (digital) volt-ohmmeter. - The resistance (as measured across the sensor terminals) should be as shown in the Coolant Temperature Sensor/Intake Air Temperature Sensor resistance chart. - Replace the sensor if it is not within the range of resistance specified in the chart. 4. Test continuity of the wire harness between the PCM wire harness connector and the coolant sensor connector terminals. - Diagrams/Electrical/Connector Views for terminal/cavity locations. - Repair the wire harness if an open circuit is indicated. 5. After tests are completed, connect electrical connector to sensor. - The sensor connector is symmetrical (not indexed). - It can be installed to the sensor in either direction. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Component Testing > Page 3073 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Crankshaft position sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Testing and Inspection > Page 3074 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig. 66 Engine Coolant Temperature Sensor WARNING: Hot, pressurized coolant can cause injury by scalding. cooling system must be partially drained before removing the coolant temperature sensor. REMOVAL 1. Partially drain cooling system. 2. Remove air cleaner assembly 3. Disconnect electrical connector from sensor. 4. Engines with air conditioning: - When removing the connector from sensor, do not pull directly on wiring harness. - Fabricate an L-shaped hook tool from a coat hanger (approximately eight inches long). - Place the hook part of tool under the connector for removal. - The connector is snapped onto the sensor. - It is not equipped with a lock type tab. 5. Remove sensor from intake manifold. INSTALLATION 1. Install sensor. 2. Tighten to 11 Nm (8 ft lb) torque. 3. Connect electrical connector to sensor. - The sensor connector is symmetrical (not indexed). - It can be installed to the sensor in either direction. 4. Install air cleaner assembly 5. Replace any lost engine coolant. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications DESCRIPTION .................................................................................................................................... .............................................................. TORQUE Crankshaft Position Sensor ................................................................................................................. .......................................................... 8 Nm (70 in lb) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3078 Crankshaft Position Sensor: Locations Crankshaft Position Sensor The sensor is located on the top of cylinder block near the rear of right cylinder head. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3079 CKP Connector Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3080 Crankshaft Position Sensor: Description and Operation Fig. 4 Sensor Operation DESCRIPTION The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. The flywheel/drive plate has groups of notches at its outer edge. there are three sets of double notches and three sets of single notches. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. OPERATION Engine speed and crankshaft position are provided through the 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. CIRCUIT OPERATION The Powertrain Control Module (PCM) supplies 5 Volts to the crankshaft position sensor on circuit K6. Circuit K6 connects to cavity A17 of the PCM. The PCM receives the crankshaft position sensor signal on circuit K24. Circuit K24 connects to cavity A8 of the PCM. The PCM provides a ground for the crankshaft position sensor (circuit K24) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector. NOTE: The engine will not operate if the PCM does not receive a crankshaft position sensor input. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3081 Crankshaft Position Sensor: Testing and Inspection Circuit K6 splices to supply 5 Volts to the camshaft position sensor, manifold absolute pressure sensor, and throttle position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3082 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor NOTE: The sensor is bolted to the top of the cylinder block near the rear of right cylinder head. The sensor is accessed by removing the right front fender liner. REMOVAL 1. Remove right front tire and right front wheelhouse liner. 2. Disconnect crankshaft position sensor pigtail harness from main wiring harness. 3. Remove two sensor (recessed hex head) mounting bolts. 4. Remove sensor from engine. INSTALLATION 1. Position crankshaft position sensor to engine. 2. Install mounting bolts and tighten to 8 Nm (70 in lb) torque. 3. Connect main harness electrical connector to sensor. 4. Install right front tire and right front wheelhouse liner. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation The fuel level sensor (fuel gauge sending unit) sends a signal to the PCM to indicate fuel level. The purpose of this feature is to prevent a false setting of misfire and fuel system monitor trouble codes if the fuel level is less than approximately 15 percent of its rated capacity It is also used to send a signal for fuel gauge operation via the CCD bus circuits. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications Intake Air Temperature Sensor: Specifications DESCRIPTION .................................................................................................................................... .............................................................. TORQUE Intake Manifold Air Temp. Sensor ............................................................................................................................................................. 28 Nm (20 ft lb) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 3089 Fig 59 Intake Manifold Air Temperature Sensor - Typical Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 3090 IAT Connector Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 3091 Intake Air Temperature Sensor: Description and Operation Fig 8 Intake Manifold Air Temperature Sensor PURPOSE The sensor provides an input voltage to the powertrain control module (PCM) indicating intake manifold air temperature. The input is used along with inputs from other sensors to determine injector pulse width. OPERATION As the temperature of the air-fuel stream in the manifold varies, the sensor resistance changes. This results in a different input voltage to the PCM. CIRCUIT OPERATION The intake air temperature sensor provides an input to the Powertrain Control Module (PCM) on circuit K21. Circuit K21 connects to cavity A15 of the PCM. From circuit K21, the intake air temperature sensor draws voltage from the PCM. The sensor is a variable resistor. As intake air temperature changes, the resistance in the sensor changes, causing a change in current draw. The PCM provides a ground for the intake air temperature sensor signal (circuit K21) through circuit K4. Circuit K4 connects to cavity A4 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Sensor Test Intake Air Temperature Sensor: Testing and Inspection Sensor Test Fig 59 Intake Manifold Air Temperature Sensor - Typical Sensor Resistance Chart (OHMS) To perform a complete test of the intake manifold air temperature sensor and its circuitry, refer to Powertrain Management/Computers and Controls/Testing and Inspection/Diagnostic Charts. To test the sensor only, refer to the following; 1. Disconnect the wire harness connector from the intake manifold air temperature sensor (Fig. 59). 2. Test the resistance of the sensor with an input impedance (digital) volt-ohmmeter. - The resistance (as measured across the sensor terminals) should be as shown in the Sensor Resistance Chart. - Replace the sensor if it is not within the range of resistance specified in the chart. 3. Test the resistance of the wire harness. - Do this between the PCM wire harness connector A-15 and the sensor connector terminal. - Also check between PCM connector A-4 to the sensor connector terminal. - Repair the wire harness as necessary if the resistance is greater than 1 ohm. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Sensor Test > Page 3094 Intake Air Temperature Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Crankshaft position sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Page 3095 Intake Air Temperature Sensor: Service and Repair Fig 88 Intake Manifold Air Temperature Sensor - Typical The intake manifold air temperature sensor is located in the front/side of the intake manifold (Fig. 88). REMOVAL 1. Remove air duct at throttle body. 2. Disconnect electrical connector at sensor (Fig. 88). 3. Remove sensor from intake manifold. INSTALLATION 1. Install sensor to intake manifold. Tighten to 28 Nm (20 ft lb) torque. 2. Install electrical connector. 3. Install air duct at throttle body. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications Manifold Pressure/Vacuum Sensor: Specifications DESCRIPTION .................................................................................................................................... .............................................................. TORQUE MAP Sensor Mounting Screws ............................................................................................................ ......................................................... 3 Nm (25 in lb) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 3099 Manifold Pressure/Vacuum Sensor: Locations Fig 10 MAP And Throttle Position Sensor Location - Typical The MAP sensor is mounted into the right side of the intake manifold. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 3100 Manifold Pressure/Vacuum Sensor: Description and Operation Fig 10 MAP And Throttle Position Sensor Location - Typical DESCRIPTION The Manifold Absolute Pressure (MAP) sensor reacts to absolute pressure in the intake manifold. It provides an input voltage to the powertrain control module (PCM). The MAP sensor is mounted into the right side of the intake manifold. OPERATION As engine load changes, manifold pressure varies. The change in manifold pressure causes MAP sensor voltage to change. The change in MAP sensor voltage results in a different input voltage to the PCM. The input voltage level supplies the PCM with information about ambient barometric pressure during engine start-up (cranking) and engine load while the engine is running. The PCM uses this input along with inputs from other sensors to adjust air-fuel mixture. CIRCUIT OPERATION From the Powertrain Control Module (PCM), circuit K6 supplies 5 Volts to the Manifold Absolute Pressure (MAP) sensor Circuit K6 connects to cavity A17 of the PCM. Circuit K1 delivers the MAP signal to the PCM. Circuit K1 connects to cavity A27 of the PCM. The PCM provides a ground for the MAP sensor signal (circuit K1) through circuit K4. Circuit K4 connects to cavity A4 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Helpful Information Manifold Pressure/Vacuum Sensor: Testing and Inspection Helpful Information Circuit K6 splices to supply 5 Volts to the Throttle Position Sensor (TPS), camshaft position sensor, and crankshaft position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Crankshaft position sensor - Intake air temperature sensor - Throttle position sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Helpful Information > Page 3103 Manifold Pressure/Vacuum Sensor: Testing and Inspection Component Test Fig 49 MAP Sensor - Typical NOTE: To perform a complete test of MAP sensor (Fig. 49) and its circuitry, refer to Powertrain Management/Computers and Controls/Testing and Inspection/Diagnostic Charts. To test the MAP sensor only, refer to the following: Fig 50 Rubber L-Shaped Fitting - MAP Sensor-to-Throttle Body 1. Inspect the rubber L-shaped fitting from the MAP sensor to the throttle body (Fig. 50). Repair as necessary. CAUTION: When testing the MAP sensor, be sure that the harness wires are not damaged by the test meter probes. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Helpful Information > Page 3104 Fig 51 MAP Sensor Connector Terminals - Typical 2. Test the MAP sensor output voltage at the MAP sensor connector between terminals A and B (Fig. 51). With the ignition switch ON and the engine OFF output voltage should be 4-to-5 volts. The voltage should drop to 1.5-to-2.1 volts with a hot, neutral idle speed condition. 3. Test powertrain control module (PCM) cavity A-27 for the same voltage described above to verify the wire harness condition. Repair as necessary 4. Test MAP sensor supply voltage at sensor connector between terminals A and C (Fig. 51) with the ignition ON. - The voltage should be approximately 5 volts (+/- 0.5V). - Five volts (+/- 0.5V) should also be at cavity A-17 of the PCM wire harness connector. - Repair or replace the wire harness as necessary. 5. Test the MAP sensor ground circuit at sensor connector terminal A (Fig. 51) and PCM connector A-4. - Repair the wire harness if necessary Refer to Diagrams/Electrical/Connector Views for cavity locations. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Testing and Inspection > Page 3105 Manifold Pressure/Vacuum Sensor: Service and Repair Fig 77 MAP Sensor Location Fig 78 MAP Sensor L-Shaped Rubber Fitting The MAP sensor is located on the front of the throttle body (Fig. 77). An L-shaped rubber fitting is used to connect the MAP sensor to throttle body (Fig. 78). REMOVAL 1. Remove air duct at throttle body 2. Remove two MAP sensor mounting bolts (screws) (Fig. 77). 3. While removing MAP sensor, slide the vacuum rubber L-shaped fitting (Fig. 78) from the throttle body 4. Remove rubber L-shaped fitting from MAP sensor. INSTALLATION 1. Install rubber L-shaped fitting to MAP sensor. 2. Position sensor to throttle body while guiding rubber fitting over throttle body vacuum nipple. 3. Install MAP sensor mounting bolts (screws). Tighten screws to 3 Nm (25 in lb) torque 4. Install air duct at throttle body. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Description and Operation Oil Pressure Sensor: Description and Operation Sends a signal from the oil pressure sending unit to the Powertrain Control Module (PCM) relating to engine oil pressure. CIRCUIT OPERATION The engine oil pressure sensor is a variable resistor. As engine oil pressure changes the resistance on circuit G60 changes. The G60 circuit connects to cavity B23 of the Powertrain Control Module (PCM) connector. Ground for the sensor is supplied on circuit K4. This circuit connects to cavity A4 of the PCM connector. This circuit is the ground circuit for many of the components in the fuel/ignition system. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Specifications Oxygen Sensor: Specifications Oxygen Sensor .................................................................................................................................... ......................................................... 30 Nm (22 ft lb) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations Oxygen Sensor: Locations Oxygen Sensor Bank Locations Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 3114 Oxygen Sensor: Locations Oxygen Sensor Location Fig 82 Upstream Oxygen Sensor Locations Fig 83 Downstream Oxygen Sensor Location The upstream and downstream Oxygen (02S) sensors are located at the inlet and outlet ends of the catalytic converter. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations > Page 3115 Oxygen Sensor Configuration Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 3116 Oxygen Sensor: Diagrams Pinout Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 3117 Oxygen Sensor: Application and ID Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 3118 Oxygen Sensor: Description and Operation OXYGEN SENSOR (O2S)-PCM INPUT Two heated O2S sensors are used. The sensors produce voltages from 0 to 1 volt, depending upon the oxygen content of the exhaust gas in the exhaust manifold. When a large amount of oxygen is present (caused by a lean air/fuel mixture), the sensors produces a low voltage. When there is a lesser amount present (rich air/fuel mixture) it produces a higher voltage. By monitoring the oxygen content and converting it to electrical voltage, the sensors act as a rich-lean switch. In Closed Loop operation, the PCM monitors the O2S sensor input (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. The oxygen sensors are equipped with a heating element that keeps the sensors at proper operating temperature during all operating modes. 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. The Automatic Shutdown (ASD) relay supplies battery voltage to both the upstream and downstream heated oxygen sensors. The oxygen sensors are equipped with a heating element. The heating elements reduce the time required for the sensors to reach operating temperature. UPSTREAM HEATED OXYGEN SENSOR The upstream O2S sensor is located near the inlet end of the catalytic converter. It 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 the air/fuel ratio by adjusting injector pulse width. DOWNSTREAM HEATED OXYGEN SENSOR The downstream heated oxygen sensor is located near the outlet end of the catalytic converter The downstream heated oxygen sensor input is used to detect catalytic convertor deterioration. As the convertor deteriorates, the input from the downstream sensor begins to match the upstream sensor input except for a slight time delay By comparing the downstream heated oxygen sensor input to the input from the upstream sensor, the PCM calculates catalytic convertor efficiency. When the catalytic converter efficiency drops below emission standards, the PCM stores a diagnostic trouble code and illuminates the Malfunction Indicator Lamp (MIL). For more information, refer to Emission Control Systems. CIRCUIT OPERATION When the Automatic Shut Down (ASD) relay contacts CLOSE, they connect circuits A16 and A142. Circuit A142 splices to supply voltage to the heated oxygen sensors. Circuit K141 delivers the signal from the center heated oxygen sensor to the PCM. Circuit K141 connects to cavity A24 of the Powertrain Control Module (PCM). Circuit K341 delivers the signal from the rear sensor and connects to cavity A25 of the PCM. Circuit K241 delivers the signal from the right heated oxygen sensor to the PCM. Circuit K241 connects to cavity A26 of the Powertrain Control Module (PCM). Circuit K441 delivers the signal from the left sensor and connects to cavity A25 of the PCM. The PCM provides a ground for the heated oxygen sensor signals (circuits K141 and K341) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector. Circuit Z1 provides a ground for the heater circuit in the sensors. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Helpful Information Oxygen Sensor: Testing and Inspection Helpful Information Circuit A142 splices to supply voltage to the fuel injectors and ignition coil. Circuit K4 splices to supply ground for the signals from the following: - Camshaft position sensor - Crankshaft position sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Helpful Information > Page 3121 Oxygen Sensor: Testing and Inspection Sensor Heating Element Test Fig 82 Upstream Oxygen Sensor Locations Fig 83 Downstream Oxygen Sensor Location The upstream O2S sensor is located in the exhaust downpipe. The downstream sensor is located near outlet end of catalytic converter. Refer to (Fig. 82) or (Fig. 83). WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. REMOVAL 1. Raise and support the vehicle. 2. Disconnect the wire connector from the O2S sensor. CAUTION: When disconnecting the sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove the O2S sensor. Snap-On oxygen sensor wrench (number YA 8875) may be used for removal and installation. NOTE: Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to the threads of a new oxygen sensor. INSTALLATION 1. Install the 02S sensor. Tighten to 30 Nm (22 ft lb) torque. 2. Connect the O2S sensor wire connector. 3. Lower the vehicle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Page 3122 Oxygen Sensor: Service and Repair Fig 82 Upstream Oxygen Sensor Locations Fig 83 Downstream Oxygen Sensor Location NOTE: The upstream and downstream Oxygen (02S) sensors are located at the inlet and outlet ends of the catalytic converter. REMOVAL WARNING: The exhaust manifold, exhaust pipes and catalytic converter become very hot during engine operation. Allow engine to cool before removing oxygen sensor. 1. Raise and support the vehicle. 2. Disconnect the wire connector from the 02S sensor. CAUTION: When disconnecting the sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove the O2S sensor. Snap-On oxygen sensor wrench (number YA 8875) may be used for removal and installation. INSTALLATION Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to the threads of a new oxygen sensor. 1. Install the 02S sensor. Tighten to 30 Nm (22 ft lb) torque. 2. Connect the 02S sensor wire connector. 3. Lower the vehicle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Power Steering - Pressure Switch Torque Revisions Power Steering Pressure Switch: Technical Service Bulletins Power Steering - Pressure Switch Torque Revisions NUMBER: 26-10-96B GROUP: Miscellaneous DATE: October, 1996 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 Dakota - Publication Number 81-270-7146 DESCRIPTION OF CHANGES Revised power steering pressure switch torque (124-195 In. Lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Power Steering - Pressure Switch Torque Revisions > Page 3127 14-65 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Power Steering - Pressure Switch Torque Revisions > Page 3128 14-66 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Page 3129 Power Steering Pressure Switch: Specifications The content of this article reflects changes called for in TSB 26-10-96. Power Steering Pressure Switch ................................................................................................................................................ 14-22 Nm (124-195 in.lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates Throttle Position Sensor: Technical Service Bulletins Engine Controls/Emissions/A/T - Manual Updates NUMBER: 26-06-98 GROUP: Miscellaneous DATE: June, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 2.5L, 3.9L, 5.2L, 5.9L 8.0L SFI/CNG/Diesel Diagnostic Manual - Publication Number 81-699-96041 DESCRIPTION OF CHANGES Revision to the diagnostic trouble codes Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3134 56 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3135 57 Revisions to the Throttle Position Sensor test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3136 162 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3137 166 Revisions to the Evap. Purge Flow Monitor tests Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3138 374 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3139 375 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3140 377 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3141 379 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3142 379A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3143 379B Revision to the EGR system Failure tests Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3144 432 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3145 433 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3146 434 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3147 435 Revision to the torque convertor clutch - no drop at lock up test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3148 465 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3149 467 Revision to the no temp rise seen at intake heater test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3150 514 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3151 515 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3152 516 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3153 517 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3154 518 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3155 519 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3156 520 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3157 521 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3158 521A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3159 521B Revision to the 12 volt supply relay test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3160 571 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3161 Throttle Position Sensor: Technical Service Bulletins Fuel/Engine Controls - Injector Circuit/TPS Revisions NUMBER: 26-05-98F GROUP: Miscellaneous DATE: May, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 2.5L, 3.9L, 5.2L, 5.9L Truck Powertrain Diagnostic Manual - Publication Number 81-699-96041 DESCRIPTION OF CHANGES Revision to the injector connector diagram Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3162 224 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3163 225 Revision to the throttle position sensor test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3164 164 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3165 165 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3166 168 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3167 169 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3168 169A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3169 169B Revision to the TPS voltage test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3170 422 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3171 423 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3172 Throttle Position Sensor: Specifications DESCRIPTION .................................................................................................................................... .............................................................. TORQUE Throttle Position Sensor Mounting Screws ................................................................................................................................................... 7 Nm (60 in lb) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3173 Throttle Position Sensor: Locations Fig. 15 MAP And Throttle Position Sensor Location - Typical The TPS is mounted on the throttle body. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3174 Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3175 Throttle Position Sensor: Description and Operation DESCRIPTION The Throttle Position Sensor (TPS) is a variable resistor that provides the powertrain control module (PCM) with an input signal (voltage) that represents throttle blade position. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the resistance of the TPS changes. OPERATION 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 1 volt at minimum throttle opening (idle), to 4 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. This input signal is also used to determine overdrive and converter clutch shift schedule and to select the proper governor curve. Fig. 15 MAP And Throttle Position Sensor Location - Typical LOCATION The TPS is mounted on the throttle body. CIRCUIT OPERATION From the Powertrain Control Module (PCM), circuit K6 supplies 5 Volts to the Throttle Position Sensor (TPS). Circuit K6 connects to cavity A17 of the PCM. Circuit K22 delivers the TPS signal to the PCM. Circuit K22 connects to cavity A23 of the PCM. The PCM provides a ground for the TPS signal (circuit K22) through circuit K4. Circuit K4 connects to cavity A4 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Component Test Throttle Position Sensor: Testing and Inspection Component Test Fig 62 TPS To perform a complete test of the TPS and its circuitry, refer to Powertrain Management/Computers and Controls/Testing and Inspection/Diagnostic Charts. To test the TPS only, refer to the following: The TPS (Fig. 62) can be tested with a digital voltmeter. The center electrical terminal of the TPS is the output terminal. With the ignition key in the ON position, check the TPS output voltage at the center terminal wire of the connector. Check this at idle (throttle plate closed) and at wide open throttle (WOT). At idle, TPS output voltage should be greater than 0.350 millivolts but less than 900 millivolts. At wide open throttle, TPS output voltage must be less than 4.5 volts. The output voltage should increase gradually as the throttle plate is slowly opened from idle to WOT. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Component Test > Page 3178 Throttle Position Sensor: Testing and Inspection Helpful Information Circuit K6 splices to supply 5 Volts to the manifold absolute pressure sensor, crankshaft position sensor and camshaft position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Crankshaft position sensor - Intake air temperature sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Page 3179 Throttle Position Sensor: Service and Repair Fig 71 TPS Mounting Bolts Fig 72 Installation - Typical REMOVAL 1. Remove air duct at throttle body. 2. Disconnect TPS electrical connector. 3. Remove two TPS mounting bolts (Fig. 71). 4. Remove TPS from throttle body. NOTES: - The throttle shaft end of the throttle body slides into a socket in the TPS (Fig. 72). - The TPS must be installed so that it can be rotated a few degrees. - If the sensor will not rotate, install the sensor with the throttle shaft on the other side of the socket tangs. - The TPS will be under slight tension when rotated. INSTALLATION 1. Install the TPS and two retaining bolts. 2. Tighten bolts to 7 Nm (60 in lb) torque. 3. Manually operate the throttle control lever by hand to check for any binding of the TPS. 4. Connect TPS electrical connector to TPS. 5. Install air duct at throttle body. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3183 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. 4. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 5. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 6. Test continuity of new switch with 12V test lamp. 7. Connect switch wires and lower vehicle. 8. Top off transmission fluid level. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications Vehicle Speed Sensor: Specifications DESCRIPTION .................................................................................................................................... .............................................................. TORQUE Vehicle Speed Sensor Mounting Bolt ......................................................................................................................................................... 2.2 Nm (20 in lb) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 3187 Vehicle Speed Sensor: Locations Fig 13 Vehicle Speed Sensor Location - 2WD - Typical Fig 14 Vehicle Speed Sensor Location - 4WD - Typical Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3190 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 Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3191 Electrostatic Discharge Symbol All Electrostatic Discharge (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, especially 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. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3192 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3193 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3194 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3195 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3196 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3197 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3198 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3199 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. 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. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3200 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3201 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3202 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3203 Vehicle Speed Sensor: Diagnostic Aids 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 in 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 and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3204 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. 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 every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. 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 fuse circuit. 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 the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3205 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools 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 - This instrument is 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 vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. 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 non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3206 Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Circuit Operation Vehicle Speed Sensor: Description and Operation Circuit Operation CIRCUIT OPERATION The Powertrain Control Module (PCM) supplies 5 Volts to the vehicle speed sensor on circuit K7. Circuit K7 connects B31 of the PCM. Circuit G7 from the vehicle speed sensor provides an input signal to the PCM. The G7 circuit connects to cavity B27 of the PCM. The PCM provides a ground for the vehicle speed sensor signal (circuit G7) through circuit K4. Circuit K4 connects to cavity A4 of the PCM. HELPFUL INFORMATION Circuit K4 also provides ground for the signals from the following: Heated oxygen sensors - Crankshaft position sensor - Camshaft position sensor - Engine coolant temperature sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Circuit Operation > Page 3209 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor Operation Fig 13 Vehicle Speed Sensor Location - 2WD - Typical Fig 14 Vehicle Speed Sensor Location - 4WD - Typical DESCRIPTION The sensor input is used by the powertrain control module (PCM) to determine vehicle speed and distance traveled. OPERATION The speed sensor generates 8 pulses per sensor revolution. These signals, in conjunction with a closed throttle signal from the throttle position sensor, indicate a closed throttle deceleration to the PCM. When the vehicle is stopped at idle, a closed throttle signal is received by the PCM (but a speed sensor signal is not received). Under deceleration conditions, the PCM adjusts the idle air control (IAC) motor to maintain a desired Manifold Absolute Pressure (MAP) value. Under idle conditions, the PCM adjusts the IAC motor to maintain a desired engine speed. The vehicle speed sensor is located on the speedometer pinion gear adapter. The pinion gear adapter is located on the extension housing of the transmission (drivers side). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Component Test Vehicle Speed Sensor: Testing and Inspection Component Test To perform a complete test of the idle air control motor and circuits see Computers and System Diagnosis/Testing and Inspection/Diagnostic Charts. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Component Test > Page 3212 Vehicle Speed Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Crankshaft position sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Intake air temperature sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Page 3213 Vehicle Speed Sensor: Service and Repair Fig 91 Vehicle Speed Sensor Location - 2WD - Typical Fig 92 Vehicle Speed Sensor Location - 4WD - Typical The vehicle speed sensor is located on the speedometer pinion gear adapter (Fig. 91) or (Fig. 92). The pinion gear adapter is located on the extension housing of the transmission (drivers side). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Page 3214 Fig 93 Sensor Removal/Installation REMOVAL 1. Raise and support vehicle. 2. Disconnect the electrical connector from the sensor. 3. Remove the sensor mounting bolt (Fig. 93). 4. Remove the sensor (pull straight out) from the speedometer pinion gear adapter (Fig. 93). - Do not remove the gear adapter from the transmission. INSTALLATION 1. Clean the inside of speedometer pinion gear adapter before installing speed sensor. 2. Install sensor into speedometer gear adapter and install mounting bolt. - Before tightening bolt, verify speed sensor is fully seated (mounted flush) to speedometer pinion gear adapter. 3. Tighten sensor mounting bolt to 2.2 Nm (20 in lb) torque. 4. Connect electrical connector to sensor. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates Throttle Position Sensor: Technical Service Bulletins Engine Controls/Emissions/A/T - Manual Updates NUMBER: 26-06-98 GROUP: Miscellaneous DATE: June, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 2.5L, 3.9L, 5.2L, 5.9L 8.0L SFI/CNG/Diesel Diagnostic Manual - Publication Number 81-699-96041 DESCRIPTION OF CHANGES Revision to the diagnostic trouble codes Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3219 56 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3220 57 Revisions to the Throttle Position Sensor test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3221 162 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3222 166 Revisions to the Evap. Purge Flow Monitor tests Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3223 374 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3224 375 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3225 377 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3226 379 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3227 379A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3228 379B Revision to the EGR system Failure tests Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3229 432 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3230 433 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3231 434 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3232 435 Revision to the torque convertor clutch - no drop at lock up test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3233 465 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3234 467 Revision to the no temp rise seen at intake heater test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3235 514 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3236 515 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3237 516 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3238 517 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3239 518 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3240 519 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3241 520 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3242 521 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3243 521A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3244 521B Revision to the 12 volt supply relay test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3245 571 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3246 Throttle Position Sensor: Technical Service Bulletins Fuel/Engine Controls - Injector Circuit/TPS Revisions NUMBER: 26-05-98F GROUP: Miscellaneous DATE: May, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 2.5L, 3.9L, 5.2L, 5.9L Truck Powertrain Diagnostic Manual - Publication Number 81-699-96041 DESCRIPTION OF CHANGES Revision to the injector connector diagram Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3247 224 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3248 225 Revision to the throttle position sensor test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3249 164 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3250 165 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3251 168 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3252 169 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3253 169A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3254 169B Revision to the TPS voltage test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3255 422 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3256 423 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3257 Throttle Position Sensor: Specifications DESCRIPTION .................................................................................................................................... .............................................................. TORQUE Throttle Position Sensor Mounting Screws ................................................................................................................................................... 7 Nm (60 in lb) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3258 Throttle Position Sensor: Locations Fig. 15 MAP And Throttle Position Sensor Location - Typical The TPS is mounted on the throttle body. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3259 Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3260 Throttle Position Sensor: Description and Operation DESCRIPTION The Throttle Position Sensor (TPS) is a variable resistor that provides the powertrain control module (PCM) with an input signal (voltage) that represents throttle blade position. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the resistance of the TPS changes. OPERATION 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 1 volt at minimum throttle opening (idle), to 4 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. This input signal is also used to determine overdrive and converter clutch shift schedule and to select the proper governor curve. Fig. 15 MAP And Throttle Position Sensor Location - Typical LOCATION The TPS is mounted on the throttle body. CIRCUIT OPERATION From the Powertrain Control Module (PCM), circuit K6 supplies 5 Volts to the Throttle Position Sensor (TPS). Circuit K6 connects to cavity A17 of the PCM. Circuit K22 delivers the TPS signal to the PCM. Circuit K22 connects to cavity A23 of the PCM. The PCM provides a ground for the TPS signal (circuit K22) through circuit K4. Circuit K4 connects to cavity A4 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Component Test Throttle Position Sensor: Testing and Inspection Component Test Fig 62 TPS To perform a complete test of the TPS and its circuitry, refer to Powertrain Management/Computers and Controls/Testing and Inspection/Diagnostic Charts. To test the TPS only, refer to the following: The TPS (Fig. 62) can be tested with a digital voltmeter. The center electrical terminal of the TPS is the output terminal. With the ignition key in the ON position, check the TPS output voltage at the center terminal wire of the connector. Check this at idle (throttle plate closed) and at wide open throttle (WOT). At idle, TPS output voltage should be greater than 0.350 millivolts but less than 900 millivolts. At wide open throttle, TPS output voltage must be less than 4.5 volts. The output voltage should increase gradually as the throttle plate is slowly opened from idle to WOT. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Component Test > Page 3263 Throttle Position Sensor: Testing and Inspection Helpful Information Circuit K6 splices to supply 5 Volts to the manifold absolute pressure sensor, crankshaft position sensor and camshaft position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Crankshaft position sensor - Intake air temperature sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Testing and Inspection > Page 3264 Throttle Position Sensor: Service and Repair Fig 71 TPS Mounting Bolts Fig 72 Installation - Typical REMOVAL 1. Remove air duct at throttle body. 2. Disconnect TPS electrical connector. 3. Remove two TPS mounting bolts (Fig. 71). 4. Remove TPS from throttle body. NOTES: - The throttle shaft end of the throttle body slides into a socket in the TPS (Fig. 72). - The TPS must be installed so that it can be rotated a few degrees. - If the sensor will not rotate, install the sensor with the throttle shaft on the other side of the socket tangs. - The TPS will be under slight tension when rotated. INSTALLATION 1. Install the TPS and two retaining bolts. 2. Tighten bolts to 7 Nm (60 in lb) torque. 3. Manually operate the throttle control lever by hand to check for any binding of the TPS. 4. Connect TPS electrical connector to TPS. 5. Install air duct at throttle body. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3268 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. 4. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 5. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 6. Test continuity of new switch with 12V test lamp. 7. Connect switch wires and lower vehicle. 8. Top off transmission fluid level. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications Vehicle Speed Sensor: Specifications DESCRIPTION .................................................................................................................................... .............................................................. TORQUE Vehicle Speed Sensor Mounting Bolt ......................................................................................................................................................... 2.2 Nm (20 in lb) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 3272 Vehicle Speed Sensor: Locations Fig 13 Vehicle Speed Sensor Location - 2WD - Typical Fig 14 Vehicle Speed Sensor Location - 4WD - Typical Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3275 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 Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3276 Electrostatic Discharge Symbol All Electrostatic Discharge (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, especially 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. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3277 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3278 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3279 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3280 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3281 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3282 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3283 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3284 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. 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. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3285 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3286 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3287 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3288 Vehicle Speed Sensor: Diagnostic Aids 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 in 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 and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3289 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. 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 every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. 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 fuse circuit. 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 the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3290 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools 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 - This instrument is 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 vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. 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 non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3291 Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Circuit Operation Vehicle Speed Sensor: Description and Operation Circuit Operation CIRCUIT OPERATION The Powertrain Control Module (PCM) supplies 5 Volts to the vehicle speed sensor on circuit K7. Circuit K7 connects B31 of the PCM. Circuit G7 from the vehicle speed sensor provides an input signal to the PCM. The G7 circuit connects to cavity B27 of the PCM. The PCM provides a ground for the vehicle speed sensor signal (circuit G7) through circuit K4. Circuit K4 connects to cavity A4 of the PCM. HELPFUL INFORMATION Circuit K4 also provides ground for the signals from the following: Heated oxygen sensors - Crankshaft position sensor - Camshaft position sensor - Engine coolant temperature sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Circuit Operation > Page 3294 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor Operation Fig 13 Vehicle Speed Sensor Location - 2WD - Typical Fig 14 Vehicle Speed Sensor Location - 4WD - Typical DESCRIPTION The sensor input is used by the powertrain control module (PCM) to determine vehicle speed and distance traveled. OPERATION The speed sensor generates 8 pulses per sensor revolution. These signals, in conjunction with a closed throttle signal from the throttle position sensor, indicate a closed throttle deceleration to the PCM. When the vehicle is stopped at idle, a closed throttle signal is received by the PCM (but a speed sensor signal is not received). Under deceleration conditions, the PCM adjusts the idle air control (IAC) motor to maintain a desired Manifold Absolute Pressure (MAP) value. Under idle conditions, the PCM adjusts the IAC motor to maintain a desired engine speed. The vehicle speed sensor is located on the speedometer pinion gear adapter. The pinion gear adapter is located on the extension housing of the transmission (drivers side). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Component Test Vehicle Speed Sensor: Testing and Inspection Component Test To perform a complete test of the idle air control motor and circuits see Computers and System Diagnosis/Testing and Inspection/Diagnostic Charts. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Component Test > Page 3297 Vehicle Speed Sensor: Testing and Inspection Helpful Information Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Crankshaft position sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Intake air temperature sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Page 3298 Vehicle Speed Sensor: Service and Repair Fig 91 Vehicle Speed Sensor Location - 2WD - Typical Fig 92 Vehicle Speed Sensor Location - 4WD - Typical The vehicle speed sensor is located on the speedometer pinion gear adapter (Fig. 91) or (Fig. 92). The pinion gear adapter is located on the extension housing of the transmission (drivers side). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Page 3299 Fig 93 Sensor Removal/Installation REMOVAL 1. Raise and support vehicle. 2. Disconnect the electrical connector from the sensor. 3. Remove the sensor mounting bolt (Fig. 93). 4. Remove the sensor (pull straight out) from the speedometer pinion gear adapter (Fig. 93). - Do not remove the gear adapter from the transmission. INSTALLATION 1. Clean the inside of speedometer pinion gear adapter before installing speed sensor. 2. Install sensor into speedometer gear adapter and install mounting bolt. - Before tightening bolt, verify speed sensor is fully seated (mounted flush) to speedometer pinion gear adapter. 3. Tighten sensor mounting bolt to 2.2 Nm (20 in lb) torque. 4. Connect electrical connector to sensor. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component Information > Description and Operation Voltage Signal: Description and Operation PURPOSE The engine controller continuously monitors battery voltage inputs, and since battery voltage always fluctuates, the engine controller will constantly be making changes to the injector pulse width and alternator field. OPERATION The engine controller monitors battery voltage to determine the proper injector pulse width and to control the alternator field voltage. If the engine controller sees low battery voltage, it will increase the injector pulse width to compensate for lack of voltage which could cause a lean air/fuel mixture. A higher voltage signal will be sent to the alternator field so that the alternator will increase its charging output to the battery. When the alternator increases its charging rate it will bring the battery up to its normal state of charge. Once the battery is fully charged, the engine controller reduces the injector pulse width so that the air/fuel mixture doesn't go excessively rich. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst Shield > Component Information > Description and Operation Catalyst Shield: Description and Operation Heat shields are needed to protect both the vehicle and the environment from the high temperatures developed by the catalytic converter. The catalytic converter releases additional heat into the exhaust system. Under severe operating conditions, the temperature increases in the area of the converter. Such conditions can exist when the engine misfires or otherwise does not operate at peak efficiency. NOTE: Avoid application of rust prevention compounds or undercoating materials to exhaust system floor pan heat shields. Light overspray near the edges is permitted. Application of coating will result in excessive floor pan temperatures and objectionable fumes. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst Shield > Component Information > Description and Operation > Page 3308 Catalyst Shield: Service and Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst Shield > Component Information > Description and Operation > Page 3309 REMOVAL 1. Raise and support the vehicle. 2. Remove the screws and nuts holding the heat shields to the frame and floorpan. 3. When removing muffler heat shield, the muffler front support bracket must be removed first. 4. Slide the shield out around the exhaust system. INSTALLATION 1. Position the heat shields to the floor pan or the frame and install the screws and nuts. 2. Tighten the nuts to 5 Nm (45 inch lbs.) torque. Tighten the screws to the rear frame heat shield to 9 Nm (80 inch lbs.) torque. Tighten the other screws to 10 Nm (90 inch lbs.) torque. 3. Lower the vehicle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Specifications Canister Purge Solenoid: Specifications EVAP Canister Purge Solenoid Mounting Bolt ........................................................................................................................................... 11 Nm (95 in lb) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Specifications > Page 3314 Canister Purge Solenoid: Locations Fig 3 Duty Cycle EVAP Purge Solenoid The solenoid attaches to a bracket located at the rear of the intake manifold. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Specifications > Page 3315 EVAP Solenoid Connector Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Specifications > Page 3316 Canister Purge Solenoid: Description and Operation Fig 3 Duty Cycle EVAP Purge Solenoid PURPOSE The solenoid regulates the rate of vapor flow from the EVAP canister to the intake manifold. OPERATION A duty cycle EVAP canister purge solenoid is used. The PCM operates the solenoid. During the cold start warm-up period and the hot start time delay, the PCM does not energize the solenoid. When de-energized, no vapors are purged. The PCM de-energizes the solenoid during open loop operation. The engine enters closed loop operation after it reaches a specified temperature and the time delay ends. During closed loop operation, the PCM cycles (energizes and de-energizes) the solenoid 5 or 10 times per second, depending upon operating conditions. The PCM varies the vapor flow rate by changing solenoid pulse width. Pulse width is the amount of time that the solenoid is energized. The PCM adjusts solenoid pulse width based on engine operating condition. CIRCUIT OPERATION The Powertrain Control Module (PCM) operates the EVAP/Purge solenoid by providing a ground path on circuit K52. Circuit K52 connects to PCM cavity C20. Circuit A21 supplies battery voltage to the EVAP/Purge solenoid. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Specifications > Page 3317 Canister Purge Solenoid: Testing and Inspection - In the RUN or START position, the ignition switch connects circuit A1 from the Power Distribution Center (PDC) and circuit A21. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Specifications > Page 3318 Canister Purge Solenoid: Service and Repair Fig 16 Duty Cycle EVAP Canister Purge Solenoid NOTE: The duty cycle EVAP canister purge solenoid is located at the rear of the intake manifold (Fig. 16). REMOVAL 1. Remove air cleaner housing. 2. Disconnect electrical wiring connector at solenoid (Fig. 16). 3. Disconnect vacuum harness at solenoid (Fig. 16). 4. Remove support bracket mounting bolt at intake manifold. 5. Remove solenoid and its support bracket from intake manifold. INSTALLATION 1. Install EVAP canister purge solenoid and its mounting bracket to intake manifold. Tighten mounting bolt to 11 Nm (95 in lb) torque. 2. Connect vacuum harness and wiring connector. 3. Install air cleaner housing. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Specifications Evaporative Emission Control Canister: Specifications EVAP Canister Mounting Nut ...................................................................................................................................................... 17-24 Nm (150-210 in lb) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Specifications > Page 3322 Evaporative Emission Control Canister: Locations Fig 2 EVAP Canister Location The EVAP canister is located under the vehicle, inside the left frame rail, in front of the fuel tank. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Specifications > Page 3323 Evaporative Emission Control Canister: Description and Operation Fig 2 EVAP Canister Location PURPOSE The charcoal canister contains activated charcoal granules which absorb and store fuel vapors until they can be consumed during combustion. OPERATION A maintenance free, EVAP canister is used on all vehicles. The EVAP canister is located under the vehicle, inside the left frame rail, in front of the fuel tank (Fig. 2). The EVAP canister is filled with granules of an activated carbon mixture. Fuel tank pressure vents into the EVAP canister. Fuel vapors are temporarily held in the canister until they can be drawn into the intake manifold. The duty cycle EVAP canister purge solenoid allows the EVAP canister to be purged at predetermined times and at certain engine operating conditions. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Specifications > Page 3324 Evaporative Emission Control Canister: Service and Repair Fig 15 EVAP Canister Location NOTE The EVAP canister is located below the vehicle, inside the left frame rail, in front of the fuel tank. REMOVAL 1. Raise vehicle. 2. Disconnect vacuum lines at EVAP canister. - Note location of lines before removal. 3. Remove canister mounting nut. 4. Remove canister from mounting bracket. INSTALLATION 1. Position canister locating pins into mounting bracket grommets (Fig. 15) and install mounting nut. 2. Tighten mounting nut to 17-24 Nm (150-210 in lb) torque. 3. Connect vacuum lines at canister. 4. Lower vehicle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > EVAP System - Leak Detection Pump Misdiagnosis Leak Detection Pump: Technical Service Bulletins EVAP System - Leak Detection Pump Misdiagnosis NUMBER: 18-01-00 GROUP: Vehicle Performance DATE: Feb. 4, 2000 SUBJECT: Misdiagnosed Leak Detection Pump Systems With DTC P1494, P0442, P0455, OR P0456 MODELS: 1997 - 2000 (AB) Ram Van 1997 - 2000 (AN) Dakota 1997 - 2000 (BR/BE) Ram truck 1998 - 2000 (DN) Durango 1997 - 2000 (FJ) Avenger/Sebring/Talon 1997 - 2000 (JA) Cirrus/Stratus/Breeze 1997 - 2000 (JX) Sebring Convertible 1997 - 2000 (LH) Concorde/Intrepid/LHS/3OOMNision 1997 - 2000 (NS) Town & Country/CaravanNoyager 1997 2000 (PL) Neon 1997 - 2000 (PR) Prowler 1997 - 2000 (SR) ViperNiper GIS 1997 - 2000 (TJ) Wrangler 1999 - 2000 (WJ) Grand Cherokee 1997 - 2000 (XJ) Cherokee 1997 - 1998 (ZJ) GrandCherokee DISCUSSION: During evaporative system diagnosis, Leak Detection Pumps have mistakenly been replaced. A thorough inspection for pinched, kinked, or disconnected supply vacuum lines (as currently listed in the Powertrain Diagnostic Procedures) is a critical step in diagnosing DTC P1494 (LDP SW OR MECHANICAL FAULT). Additionally, the other evaporative leak faults (DTC P0442 SMALL LEAK, P0455 - LARGE LEAK, and P0456 - VERY SMALL LEAK) should have the supply vacuum lines examined for pinches or kinks prior to any LDP component replacement. The supply vacuum lines should be checked from the engine compartment all the way to the fuel tank, including the LDP and purge system. NOTE: VERIFY ALL RELATED SUPPLY VACUUM LINE ROUTINGS FOR PINCHES, KINKS, OR DISCONNECTION'S BEFORE REPLACING LDP SYSTEM COMPONENTS. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates Purge Flow Sensor: Technical Service Bulletins Engine Controls/Emissions/A/T - Manual Updates NUMBER: 26-06-98 GROUP: Miscellaneous DATE: June, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 2.5L, 3.9L, 5.2L, 5.9L 8.0L SFI/CNG/Diesel Diagnostic Manual - Publication Number 81-699-96041 DESCRIPTION OF CHANGES Revision to the diagnostic trouble codes Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3333 56 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3334 57 Revisions to the Throttle Position Sensor test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3335 162 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3336 166 Revisions to the Evap. Purge Flow Monitor tests Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3337 374 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3338 375 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3339 377 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3340 379 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3341 379A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3342 379B Revision to the EGR system Failure tests Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3343 432 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3344 433 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3345 434 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3346 435 Revision to the torque convertor clutch - no drop at lock up test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3347 465 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3348 467 Revision to the no temp rise seen at intake heater test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3349 514 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3350 515 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3351 516 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3352 517 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3353 518 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3354 519 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3355 520 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3356 521 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3357 521A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3358 521B Revision to the 12 volt supply relay test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3359 571 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates Exhaust Gas Recirculation: Technical Service Bulletins Engine Controls/Emissions/A/T - Manual Updates NUMBER: 26-06-98 GROUP: Miscellaneous DATE: June, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 2.5L, 3.9L, 5.2L, 5.9L 8.0L SFI/CNG/Diesel Diagnostic Manual - Publication Number 81-699-96041 DESCRIPTION OF CHANGES Revision to the diagnostic trouble codes Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3364 56 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3365 57 Revisions to the Throttle Position Sensor test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3366 162 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3367 166 Revisions to the Evap. Purge Flow Monitor tests Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3368 374 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3369 375 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3370 377 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3371 379 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3372 379A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3373 379B Revision to the EGR system Failure tests Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3374 432 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3375 433 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3376 434 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3377 435 Revision to the torque convertor clutch - no drop at lock up test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3378 465 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3379 467 Revision to the no temp rise seen at intake heater test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3380 514 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3381 515 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3382 516 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3383 517 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3384 518 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3385 519 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3386 520 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3387 521 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3388 521A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3389 521B Revision to the 12 volt supply relay test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > System Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3390 571 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Description and Operation Positive Crankcase Ventilation: Description and Operation Fig 5 PCV Valve/Hose - Typical Fig 6 Typical Closed Crankcase Ventilation System NOTE: This engine is equipped with a closed crankcase ventilation system and a positive crankcase ventilation (PCV) valve. PURPOSE The purpose of the PCV system is to reduce hydrocarbon (HC) and carbon monoxide (CO) emissions created by engine blow-by. Also the PCV system is used to prevent sludge build up in crankcase CONSTRUCTION This system consists of a PCV valve mounted on the cylinder head (valve) cover with a hose extending from the valve to the intake manifold. Another hose connects the opposite cylinder head (valve) cover to the air cleaner housing to provide a source of clean air for the system. A separate crankcase breather/filter is not used. OPERATION The PCV system operates by engine intake manifold vacuum (Fig. 6). Filtered air is routed into the crankcase through the air cleaner hose. The metered air, along with crankcase vapors, are drawn through the PCV valve and into a passage in the intake manifold. The PCV system manages crankcase pressure and meters blow by gases to the intake system, reducing engine sludge formation. The PCV valve contains a spring loaded plunger. This plunger meters the amount of crankcase vapors routed into the combustion chamber based on intake manifold vacuum. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Description and Operation > Page 3394 Engine Off Or Engine Pop-Back - No Vapor Flow When the engine is not operating or during an engine pop-back, the spring forces the plunger back against the seat. This will prevent vapors from flowing through the valve. High Intake Manifold Vacuum - Minimal Vapor Flow During periods of high manifold vacuum, such as idle or cruising speeds, vacuum is sufficient to completely compress spring. It will then pull the plunger to the top of the valve (Fig. 8). In this position there is minimal vapor flow through the valve. Moderate Intake Manifold Vacuum - Maximum Vapor Flow During periods of moderate manifold vacuum, the plunger is only pulled part way back from inlet. This results in maximum vapor flow through the valve (Fig. 9). CRANKCASE BREATHER/FILTER The crankcase breather/filter is no longer used. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Description and Operation > Page 3395 Positive Crankcase Ventilation: Testing and Inspection Fig 12 Vacuum Check At PCV Valve - Typical 1. With engine idling, remove the PCV valve from cylinder head (valve) cover. If the valve is not plugged, a hissing noise will be heard as air passes through the valve. Also, a strong vacuum should be felt at the valve inlet (Fig. 12). Fig 13 Vacuum Check At Valve Cover Opening 2. Return the PCV valve into the valve cover. Remove the fitting and air hose at the opposite valve cover. Loosely hold a piece of stiff paper, such as a parts tag, over the opening (rubber grommet) at the valve cover (Fig. 13). 3. The paper should be drawn against the opening in the valve cover with noticeable force. This will be after allowing approximately one minute for crankcase pressure to reduce. Fig 14 Shake PCV Valve - Typical Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Description and Operation > Page 3396 4. Turn engine off and remove PCV valve from valve cover. The valve should rattle when shaken (Fig. 14). 5. Replace the PCV valve and retest the system if it does not operate as described in the preceding tests. Do not attempt to clean the old PCV valve. 6. If the paper is not held against the opening in valve cover after new valve is installed, the PCV valve hose may be restricted and must be replaced. The passage in the intake manifold must also be checked and cleaned. 7. To clean the intake manifold fitting, turn a 1/4 inch drill (by hand) through the fitting to dislodge any solid particles. - Blow out the fitting with shop air. - If necessary, use a smaller drill to avoid removing any metal from the fitting. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates Purge Flow Sensor: Technical Service Bulletins Engine Controls/Emissions/A/T - Manual Updates NUMBER: 26-06-98 GROUP: Miscellaneous DATE: June, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 2.5L, 3.9L, 5.2L, 5.9L 8.0L SFI/CNG/Diesel Diagnostic Manual - Publication Number 81-699-96041 DESCRIPTION OF CHANGES Revision to the diagnostic trouble codes Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3402 56 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3403 57 Revisions to the Throttle Position Sensor test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3404 162 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3405 166 Revisions to the Evap. Purge Flow Monitor tests Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3406 374 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3407 375 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3408 377 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3409 379 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3410 379A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3411 379B Revision to the EGR system Failure tests Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3412 432 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3413 433 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3414 434 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3415 435 Revision to the torque convertor clutch - no drop at lock up test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3416 465 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3417 467 Revision to the no temp rise seen at intake heater test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3418 514 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3419 515 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3420 516 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3421 517 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3422 518 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3423 519 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3424 520 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3425 521 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3426 521A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3427 521B Revision to the 12 volt supply relay test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Purge Flow Sensor, Evaporative System > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3428 571 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Technical Service Bulletins > Fuel Pressure Gauge Adapter - Usage Fuel Pressure: Technical Service Bulletins Fuel Pressure Gauge Adapter - Usage NO: 14-03-98 GROUP: Fuel DATE: May 1, 1998 SUBJECT: Fuel Pressure Gauge Adapter Usage MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) DISCUSSION: Currently, four different fuel pressure adapters are required, depending on application, to attach a fuel gauge for pressure testing. The matrix lists the adapter part numbers and their application. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Pressure, Vacuum and Temperature Specifications Fuel Pressure: Pressure, Vacuum and Temperature Specifications Fuel Pressure Engine at curb idle ............................................................................................................................... ........................................ 339 ± 34 kPa (49.2 ± 5 psi) Pressure Leakdown (fuel pump not engaged) ................................................................................................................. Not fall below 30 psi for 5 minutes Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Pressure, Vacuum and Temperature Specifications > Page 3436 Fuel Pressure: Capacity Specifications NOTE: Before performing this test, vent fuel pump pressure by performing the Fuel Pump Pressure Test. Use this test in conjunction with the Fuel Pressure Leak Down Test. 1. Release fuel system pressure. Refer to the Fuel Pressure Release Procedure. 2. Disconnect fuel supply line at fuel rail. Some engines may require air cleaner housing removal before line disconnection. 3. Connect appropriate Fuel Line Pressure Test Adapter Tool Hose (number 6631, 6923, 6541 or 6539) into disconnected fuel supply line. Insert other end of Adaptor Tool hose into a graduated container. 4. Remove fuel fill cap. 5. To activate fuel pump and pressurize system, obtain DRB scan tool and actuate ASD Fuel System Test. 6. A good fuel pump will deliver at least 1/4 liter of fuel in 7 seconds. Do not operate fuel pump for longer than 7 seconds with fuel line disconnected as fuel pump module reservoir may run empty. a. If capacity is lower than specification, but fuel pump can be heard operating through fuel fill cap opening, check for a kinked/damaged fuel supply line somewhere between fuel rail and fuel pump module. b. If line is not kinked/damaged, and fuel pressure is OK, but capacity is low, replace fuel filter/ fuel pressure regulator. The filter/regulator may be serviced separately on certain applications. Refer to Fuel Filter/Fuel Pressure Regulator Removal/Installation for additional information. c. If both fuel pressure and capacity are low, replace fuel pump module assembly Refer to Fuel Pump Module Removal/Installation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test Fuel Pressure: Testing and Inspection Fuel Pressure Leak Down Test Fig 11 Connecting Adapter Tool - Typical Fig 12 Connecting Adapter Tool - Typical NOTE: Use this test in conjunction with the Fuel Pump Pressure Test and Fuel Pump Capacity Test. Check Valve Operation: The electric fuel pump outlet contains a one-way check valve to prevent fuel flow back into the tank and to maintain fuel supply line pressure (engine warm) when pump is not operational. It is also used to keep the fuel supply line full of gasoline when pump is not operational. After the vehicle has cooled down, fuel pressure may drop to 0 psi (cold fluid contracts), but liquid gasoline will remain in fuel supply line between the check valve and fuel injectors. Fuel pressure that has dropped to 0 psi on a cooled down vehicle (engine off) is a normal condition. when the electric fuel pump is activated, fuel pressure should immediately rise to specification. Abnormally long periods of cranking to restart a hot engine that has been shut down for a short period of time may be caused by: ^ Fuel pressure bleeding past a fuel injector(s). ^ Fuel pressure bleeding past the check valve in the fuel pump module. Procedure 1. Disconnect the fuel inlet line at fuel rail. - On some engines, air cleaner housing removal may be necessary before fuel line disconnection. 2. Connect the appropriate Fuel Line Pressure Test Adapter Tool (number 6539, 6631, 6541 or 6923) between the disconnected fuel line and fuel rail (Fig. 11) or (Fig. 12). 3. Connect the 0-414 kPa (0-60 psi) fuel pressure test gauge (from Gauge Set 5069) to the test port on the appropriate Adaptor Tool. - The fittings on both tools must be in good condition and free from any small leaks before performing the proceeding test. 4. Start engine and bring to normal operating temperature. 5. Observe test gauge. Normal operating pressure should be 339 kPa +/- 34 kPa (49.2 psi +/- 5 psi). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 3439 6. Shut engine off. 7. Pressure should not fall below 30 psi for five minutes. 8. If pressure falls below 30 psi, it must be determined if a fuel injector, the check valve within the fuel pump module, or a fuel tube/line is leaking. 9. Again, start engine and bring to normal operating temperature. 10. Shut engine off. 11. Testing for fuel injector or fuel rail leakage: - Clamp off the rubber hose portion of Adaptor Tool between the fuel rail and the test port "T" on Adapter Tool. - If pressure now holds at or above 30 psi, a fuel injector or the fuel rail is leaking. 12. Testing for fuel pump check valve, filter/ regulator check valve or fuel tube/line leakage: - Clamp off the rubber hose portion of Adaptor Tool between the vehicle fuel line and test port "T" on Adapter Tool. - If pressure now holds at or above 30 psi, a leak may be found at a fuel tube/line. - If no leaks are found at fuel tubes or lines, one of the check valves in either the electric fuel pump or filter/ regulator may be leaking. NOTE: A quick loss of pressure usually indicates a defective check valve in the filter/regulator. A slow loss of pressure usually indicates a defective check valve in the electric fuel pump. The electric fuel pump is not serviced separately. Replace the fuel pump module assembly. The filter/regulator may be replaced separately on certain applications. Refer to Fuel Filter/Fuel Pressure Regulator Removal/Installation for additional information. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 3440 Fuel Pressure: Testing and Inspection Fuel Pressure Test - With Test Port Fig 8 Fuel Pressure Test Port - Typical WARNING: THE FUEL SYSTEM IS UNDER CONSTANT FUEL PRESSURE EVEN WITH THE ENGINE OFF. BEFORE DISCONNECTING FUEL LINE AT FUEL RAIL, THIS PRESSURE MUST BE RELEASED. REFER TO THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE. NOTE: Use this test in conjunction with the Fuel Pump Capacity Test and Fuel Pressure Leak Down Test found elsewhere. Check Valve Operation: The electric fuel pump outlet contains a one-way check valve to prevent fuel flow back into the tank and to maintain fuel supply line pressure (engine warm) when pump is not operational. - It is also used to keep the fuel supply line full of gasoline when pump is not operational. After the vehicle has cooled down, fuel pressure may drop to 0 psi (cold fluid contracts), but liquid gasoline will remain in fuel supply line between the check valve and fuel injectors. Fuel pressure that has dropped to 0 psi on a cooled down vehicle (engine off) is a normal condition. When the electric fuel pump is activated, fuel pressure should immediately rise to specification. NOTE: The fuel pressure test port is used on certain engines only. The test port is located on the fuel rail near the throttle position sensor (Fig. 8). A sealing cap is screwed onto the test port. All fuel systems are equipped with a fuel tank module mounted, combination fuel filter/fuel pressure regulator. The fuel pressure regulator is not controlled by engine vacuum. Procedure 1. Remove protective cap at fuel rail test port. Connect the 0-414 kPa (0-60 psi) fuel pressure gauge (from gauge set 5069) to test port pressure fitting on fuel rail. 2. Start and warm engine and note pressure gauge reading. Fuel pressure should be 339 kPa +/34 kPa (49.2 psi +/- 5 psi) at idle. 3. If engine runs but pressure is below 44.2 psi, check for a kinked fuel supply line somewhere between fuel rail and fuel pump module. If line is not kinked, replace fuel pump module assembly. Refer to Fuel Pump Module Removal/Installation. 4. If operating pressure is above 54.2 psi, electric fuel pump is OK, but fuel pressure regulator is defective. - Replace fuel filter/fuel pressure regulator. - Certain filter/regulators may be serviced separately and some require the replacement of the fuel pump module assembly Refer to Fuel Filter /Fuel Pressure Regulator Removal/Installation for more information. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 3441 Fuel Pressure: Testing and Inspection Fuel Pressure Test - Without Test Port Fig 10 Installing Adapter Tool And Pressure Gauge WARNING: THE FUEL SYSTEM IS UNDER CONSTANT FUEL PRESSURE EVEN WITH THE ENGINE OFF. BEFORE DISCONNECTING FUEL LINE AT FUEL RAIL, THIS PRESSURE MUST BE RELEASED. REFER TO THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE. NOTE: Use this test in conjunction with the Fuel Pump Capacity Test and Fuel Pressure Leak Down Test. Check Valve Operation: The electric fuel pump outlet contains a one-way check valve to prevent fuel flow back into the tank and to maintain fuel supply line pressure (engine warm) when pump is not operational. It is also used to keep the fuel supply line full of gasoline when pump is not operational. After the vehicle has cooled down, fuel pressure may drop to 0 psi (cold fluid contracts), but liquid gasoline will remain in fuel supply line between the check valve and fuel injectors. Fuel pressure that has dropped to 0 psi on a cooled down vehicle (engine off) is a normal condition. When the electric fuel pump is activated, fuel pressure should immediately rise to specification. All fuel systems are equipped with a fuel tank module mounted, combination fuel filter/fuel pressure regulator. The fuel pressure regulator is not controlled by engine vacuum. Procedure 1. Release fuel pressure. Refer to the Fuel System Pressure Release Procedure-Without Pressure Test Port. 2. Disconnect latch clip and fuel line at fuel rail. Refer to Quick-Connect Fittings for procedures. 3. Connect adapter tool number 6923 into the fuel rail (Fig. 10). Be sure adapter tool is fully seated into fuel rail. 4. Install latch clip to fuel rail. If latch clip can not be fully seated into fuel rail, check for adapter tool not fully seated to fuel rail. 5. Connect vehicle fuel line into adapter tool 6923 (Fig. 10). Be sure fuel line is fully seated into adapter tool 6923. 6. Remove protective cap at test port "T" on adapter tool number 6923. 7. Connect the 0-414 kPa (0-60 psi) fuel pressure gauge (from gauge set 5069) to the test port "T" (Fig. 10). 8. Start engine and note pressure gauge reading. Fuel pressure should be 339 kPa +/- 34 kPa (49.2 psi +/5 psi) at idle. 9. If engine runs but pressure is below 44.2 psi, check for a kinked fuel supply line somewhere between fuel rail and fuel pump module. If line is not kinked, replace fuel pump module assembly. Refer to Fuel Pump Module Removal/Installation. 10. If operating pressure is above 54.2 psi, electric fuel pump is OK, but fuel pressure regulator is defective. Replace fuel filter/fuel pressure regulator. Certain filter/regulators may be serviced separately and some require the replacement of the fuel pump module assembly. Refer to Fuel Filter/Fuel Pressure Regulator Removal/Installation for more information. 11. After performing pressure test, install fuel line into fuel rail. Install latch clip into fuel rail. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 3442 Fuel Pressure: Testing and Inspection Fuel Pump Capacity Test NOTE: Before performing this test, vent fuel pump pressure by performing the Fuel Pump Pressure Test. Use this test in conjunction with the Fuel Pressure Leak Down Test. 1. Release fuel system pressure. Refer to the Fuel Pressure Release Procedure. 2. Disconnect fuel supply line at fuel rail. Some engines may require air cleaner housing removal before line disconnection. 3. Connect appropriate Fuel Line Pressure Test Adapter Tool Hose (number 6631, 6923, 6541 or 6539) into disconnected fuel supply line. Insert other end of Adaptor Tool hose into a graduated container. 4. Remove fuel fill cap. 5. To activate fuel pump and pressurize system, obtain DRB scan tool and actuate ASD Fuel System Test. 6. A good fuel pump will deliver at least 1/4 liter of fuel in 7 seconds. Do not operate fuel pump for longer than 7 seconds with fuel line disconnected as fuel pump module reservoir may run empty. a. If capacity is lower than specification, but fuel pump can be heard operating through fuel fill cap opening, check for a kinked/damaged fuel supply line somewhere between fuel rail and fuel pump module. b. If line is not kinked/damaged, and fuel pressure is OK, but capacity is low, replace fuel filter/ fuel pressure regulator. The filter/regulator may be serviced separately on certain applications. Refer to Fuel Filter/Fuel Pressure Regulator Removal/Installation for additional information. c. If both fuel pressure and capacity are low, replace fuel pump module assembly Refer to Fuel Pump Module Removal/Installation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > With Pressure Test Port Fuel Pressure Release: Service and Repair With Pressure Test Port WARNING: BECAUSE THE FUEL SYSTEM IS UNDER CONSTANT FUEL PRESSURE, IT MUST BE RELEASED BEFORE SERVICING ANY FUEL SYSTEM COMPONENT THIS DOES NOT APPLY TO THROTTLE BODY REMOVAL. NOTE: The fuel pressure test port is used on certain engines only. If equipped, the test port will be located on fuel rail. A sealing cap is screwed onto test port. - The fuel system is under constant fuel pressure (even with engine off). 1. Disconnect negative battery cable. 2. Remove fuel tank filler tube cap to release fuel tank pressure. 3. Remove protective cap from pressure test port on fuel rail. This is located on top of fuel rail. WARNING: DO NOT ALLOW FUEL TO SPILL ONTO ENGINE INTAKE OR EXHAUST MANIFOLDS. PLACE SHOP TOWELS UNDER AND AROUND PRESSURE PORT TO ABSORB FUEL WHEN PRESSURE IS RELEASED FROM FUEL RAIL. WARNING: WEAR PROPER EYE PROTECTION WHEN RELEASING FUEL SYSTEM PRESSURE. 4. Obtain fuel pressure gauge/hose assembly from fuel pressure gauge tool set 5069. Remove gauge from hose. 5. Place one end of hose (gauge end) into an approved gasoline container. 6. Place a shop towel under test port. 7. To release fuel pressure, screw other end of hose onto fuel pressure test port. 8. After fuel pressure has been released, remove hose from test port. 9. Install protective cap to fuel test port. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > With Pressure Test Port > Page 3447 Fuel Pressure Release: Service and Repair Without Pressure Test Port NOTE: Use the following procedure if the fuel rail is not equipped with a fuel pressure test port. 1. Remove the Fuel Pump relay from the Power Distribution Center (PDC). For location of the relay, refer to the label on the underside of the PDC cover. 2. Start and run engine until it stalls. 3. Attempt restarting engine until it will no longer run. 4. Turn ignition key to OFF position. CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within the fuel rail. Do not attempt to use the following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber. 5. Unplug connector from any injector. 6. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 7. Connect the other end of the jumper wire to the positive side of the battery 8. Connect one end of a second jumper wire to the remaining injector terminal. CAUTION: Supplying power to an injector for more than 4 seconds will permanently damage the injector. Do not leave the injector connected to power for more than 4 seconds. 9. Momentarily touch the other end of this jumper wire to the negative terminal of the battery for no more than 4 seconds. 10. Place a rag or towel below the fuel line at the quick connect to the rail. 11. Disconnect the quick connect fitting to the rail. Refer to Quick-Connect Fittings. 12. Return the fuel pump relay to the PDC. 13. One or more Diagnostic Trouble Codes (DTC's) may have been stored in the PCM memory due to fuel pump relay removal. The DRB scan tool must be used to erase a DTC. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications Minimum Air Flow Idle ......................................................................................................................... ......................................................... 500 to 900 rpm Note: Idle speed range achieved through Minimum Air Flow Idle Test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications > Page 3451 Idle Speed: Testing and Inspection The following test procedure has been developed to check throttle body calibrations for correct idle conditions. The procedure should be used to diagnose the throttle body for conditions that may cause idle problems. This procedure should be used only after normal diagnostic procedures have failed to produce results that indicate a throttle body related problem. Be sure to check for proper operation of the idle air control motor before performing this test. Fig. 73 Fixed Orifice Tool A special fixed orifice tool (number 6714) must be used for the following test. 1. Start the engine and bring to operating temperature. Be sure all accessories are off before performing this test. 2. Shut off the engine and remove the air cleaner element housing. Fig. 74 Install Orifice Tool 3. Disconnect the vacuum line at the PCV valve. 4. Install the 0.185 inch orifice tool (number 6714) into the disconnected vacuum line in place of the PCV valve. Fig. 75 Idle Purge Line Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications > Page 3452 5. Disconnect the idle purge vacuum line from fitting at throttle body This vacuum line is located on the front of throttle body next to the MAP sensor. Cap the fitting at throttle body after vacuum line has been removed. 6. Connect the DRB scan tool to the 16-way data link connector. This connector is located under the instrument panel to the left of the steering column. 7. Start the engine. 8. Using the DRB scan tool, scroll through the menus as follows: select-System, select-Engine, select-Fuel and Ignition, select-Actuator Tests, select Engine rpm and select-Minimum Air Flow. 9. The DRB scan tool will count down to stabilize the idle rpm and display the minimum air flow idle rpm. The idle rpm should be between 500 and 900 rpm. If the idle speed is outside of these specifications, replace the throttle body. 10. Disconnect the DRB scan tool from the vehicle. 11. Remove cap from idle purge fitting at throttle body and install vacuum line. 12. Remove orifice tool and connect vacuum line to PCV valve. 13. Install air cleaner element housing. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications > Page 3453 Idle Speed: Adjustments Idle speed is electronically controlled by the Powertrain Control Module (PCM) through the Idle Air Control (IAC) motor, and is not adjustable. CAUTION: This vehicle is equipped with a factory adjusted throttle plate position set screw. Never attempt to adjust idle speed using this screw, unless directed to do so in a service procedure. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications Accelerator Pedal: Specifications Accelerator Pedal Bracket Mounting Nuts .................................................................................................................................................... 7 Nm (65 in lb) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications > Page 3457 Accelerator Pedal: Service and Repair Fig 44 Accelerator Pedal - Removal Or Installation NOTE: All engines are equipped with torsion return springs located on the throttle body shaft. Engines equipped with a manual transmission have an additional pedal return spring on the throttle body linkage. CAUTION: Be careful not to damage or kink the cable core wire (within the cable sheathing) while servicing accelerator pedal or cables. REMOVAL 1. From inside the vehicle, hold up accelerator pedal. Remove plastic cable retainer and throttle cable core wire from upper end of pedal arm (Fig. 44). Plastic cable retainer snaps into pedal arm. 2. Remove two accelerator pedal/bracket nuts (Fig. 44) and remove pedal/bracket assembly from vehicle. INSTALLATION 1. Position pedal/bracket assembly over the two dash panel mounting studs and install retaining nuts. 2. Tighten nuts to 7 Nm (65 in lb) torque. 3. From inside the vehicle, hold up the accelerator pedal. Install the throttle cable core wire and plastic cable retainer into the upper end of the pedal arm. The plastic retainer is snapped into the pedal arm. Fig 45 Index Tab And Slot When installing the plastic retainer to the accelerator pedal arm, note the index tab on the pedal arm (Fig. 45). Align the index slot (Fig. 45) on the Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications > Page 3458 plastic cable retainer to this index tab. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Engine - High Driveability Index Fuels Fuel: Technical Service Bulletins Engine - High Driveability Index Fuels NO: 14-08-97 GROUP: Fuel DATE: Nov. 21, 1997 SUBJECT: Poor Driveability With High DI (Driveability Index) Fuel MODELS: 1996 - 1998 (AB) Ram Van/Wagon 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1996 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1996 - 1998 (PL) Neon 1997 (PR) Prowler 1996 - 1998 (SR) Viper Roadster/Coupe 1997 - 1998 (TJ) Wrangler 1996 - 1998 (XJ) Cherokee 1995 - 1998 (ZJ) Grand Cherokee SYMPTOM/CONDITION: Long cold start times, warm-up sags, hesitations, and driveway die outs. These symptoms are most noticeable and severe at moderate ambient temperatures between 4 - 27 degrees C (40 - 80 degrees F). DISCUSSION: Gasoline with a high Driveability Index (DI) can cause the above described symptoms. DI is a measure of the gasolines total volatility, or tendency to vaporize completely. A high DI number is less volatile than a low DI number. Most premium gasoline sold in the U.S. has a higher (worse) DI index than regular or mid-grade gasoline. Use of premium gasoline is NOT recommended for vehicles designed to run on 87 (R+M)/2 regular or 89 (R+M)/2 midgrade gasoline. High DI gasolines also cause higher emissions for the same reasons they cause driveability problems. For vehicles that require an octane rating of 91 (R+M)/2, premium is recommended, or possibly required. Using premium fuel with a higher than recommended octane rating is not recommended. Owners who experience fuel related cold start and warm up driveability problems should try a gasoline with the recommended octane rating or different brands of gasoline until they find one that provides good performance. The octane quality of gasoline is only a measure of its resistance to spark knock. The use of higher than recommended octane gasoline under normal operating conditions does NOT improve startability, idle quality, fuel economy, driveability, acceleration, engine durability, or emissions. In fact, most higher octane gasolines available in the U.S. have higher DI values than regular gasoline. Customers are most likely to experience poor driveability with premium gasoline than with regular. Some vehicles, such as Viper, Prowler, 5.9L Grand Cherokee, 2.0L Turbo Talon, and 2.0L DOHC Neon have been specifically designed to take advantage of higher octane. These vehicles may have higher compression ratios, and/or more aggressive spark calibrations which provide optimum performance with the specified higher octane. However, other vehicles which are not specifically designed and calibrated to take advantage of higher octane will not benefit from higher octane. Some vehicles may experience light spark knock in situations such as trailer towing or climbing steep sustained grades. Light knock or "ping" under these conditions is not harmful. However, if the customer is concerned about light knock under these circumstances, the use of 89 (R+M)/2 or even 91 (R+M)/2 premium gasoline may be temporarily warranted. If a vehicle is experiencing heavy spark knock on gasoline with its designed octane rating, this may be an indication of excessive combustion chamber deposits, or some other problem. Combustion chamber deposits can be removed with Mopar Combustion Chamber Conditioner p/n 04318001. Standard diagnostic procedures may help in identifying other potential causes of excessive knock. Some gasoline marketers may advertise that their premium gasoline contains extra detergent additives. Under provisions of the Clean Air Act, ALL gasoline sold in the U.S. must contain effective deposit control additives. Nevertheless, if fuel injector or intake valve deposits are suspected of Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Engine - High Driveability Index Fuels > Page 3463 contributing to poor performance, occasional use of Mopar Fuel Injector Clean Up p/n 04549613 is a much less expensive way to maintain engine cleanliness than regular use of premium gasoline. The charts (Figures 1 & 2) show the negative effects of high DI fuel as related to customer satisfaction. If fuel quality is suspected in causing a customers driveability concern, your zone technical office may be able to provide direction on procedures for fuel sample analysis. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Page 3464 Fuel: Specifications FUEL REQUIREMENTS Your vehicle was designed to meet all emission regulations and provide excellent fuel economy when using high quality unleaded gasoline. Use unleaded gasoline having a minimum posted octane of 87. If your vehicle develops occasional light spark knock (ping) at low engine speeds this is not harmful. However; continued heavy knock at high speeds can cause damage and should be reported to your dealer immediately. Engine damage as a result of heavy knock operation may not be covered by the new vehicle warranty. In addition to using unleaded gasoline with the proper octane rating, those that contain detergents, corrosion and stability additives are recommended. Using gasoline that have these additives will help improve fuel economy, reduce emissions, and maintain vehicle performance. Poor quality gasoline can cause problems such as hard starting, stalling, and stumble. If you experience these problems, try another brand of gasoline before considering service for the vehicle. GASOLINE/OXYGENATE BLENDS Some fuel suppliers blend unleaded gasoline with materials that contain oxygen such as alcohol, MTBE (Methyl Tertiary Butyl Ether) and ETBE (Ethyl Tertiary Butyl Ether). Oxygenates are required in some areas of the country during winter months to reduce carbon monoxide emissions. The type and amount of oxygenate used in the blend is important. The following are generally used in gasoline blends: Ethanol - (Ethyl or Grain Alcohol) properly blended, is used as a mixture of 10 percent ethanol and 90 percent gasoline. Gasoline blended with ethanol may be used in your vehicle. MTBE/ETBE - Gasoline and MTBE (Methyl Tertiary Butyl Ether) blends are a mixture of unleaded gasoline and up to 15 percent MTBE. Gasoline and ETBE (Ethyl Tertiary Butyl Ether) are blends of gasoline and up to 17 percent ETBE. Gasoline blended with MTBE or ETBE may be used in your vehicle. Methanol - Methanol (Methyl or Wood Alcohol) is used in a variety of concentrations blended with unleaded gasoline. You may encounter fuels containing 3 percent or more methanol along with other alcohols called cosolvents. DO NOT USE GASOLINE CONTAINING METHANOL Use of methanol/gasoline blends may result in starting and drive ability problems and damage critical fuel system components. Problems that are the result of using methanol/ gasoline blends are not the responsibility of Chrysler Corporation and may not be covered by the vehicle warranty. REFORMULATED GASOLINE Many areas of the country are requiring the use of cleaner-burning fuel referred to as Reformulated Gasoline. Reformulated gasoline are specially blended to reduce vehicle emissions and improve air quality Chrysler Corporation strongly supports the use of reformulated gasoline whenever available. Although your vehicle was designed to provide optimum performance and lowest emissions operating on high quality unleaded gasoline, it will perform equally well and produce even lower emissions when operating on reformulated gasoline. MATERIALS ADDED TO FUEL Indiscriminate use of fuel system cleaning agents should be avoided. Many of these materials intended for gum and varnish removal may contain active solvents of similar ingredients that can be harmful to fuel system gasket and diaphragm materials. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Specifications Fuel Filler Cap: Specifications Filler Cap Pressure Vent Limit ........................................................................................................................................... 6.58 - 8.44 kPa (1.95 - 2.5 psi) Filler Cap Vacuum Vent Limit ............................................................................................................................................ 0.97 - 2.0 kPa (0.14 - 0.29 psi) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Specifications > Page 3468 Fuel Filler Cap: Description and Operation Pressure-Vacuum Filler Cap PURPOSE The fuel filler cap is used to relieve excess fuel tank pressure or vacuum and prevents loss of any fuel or vapor out of the filler neck. OPERATION Relief valves inside cap will release only under significant pressure of 6.58 to 8.44 kPa (1.95 to 2.5 psi). The vacuum release for all gas caps is between 0.97 and 2.0 kPa (0.14 and 0.29 psi). NOTE: This cap must be replaced by a similar unit if replacement is necessary. This is in order for the system to remain effective. NOTE: It is normal to encounter an air pressure release when removing the fuel filler cap. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > With Pressure Test Port Fuel Pressure Release: Service and Repair With Pressure Test Port WARNING: BECAUSE THE FUEL SYSTEM IS UNDER CONSTANT FUEL PRESSURE, IT MUST BE RELEASED BEFORE SERVICING ANY FUEL SYSTEM COMPONENT THIS DOES NOT APPLY TO THROTTLE BODY REMOVAL. NOTE: The fuel pressure test port is used on certain engines only. If equipped, the test port will be located on fuel rail. A sealing cap is screwed onto test port. - The fuel system is under constant fuel pressure (even with engine off). 1. Disconnect negative battery cable. 2. Remove fuel tank filler tube cap to release fuel tank pressure. 3. Remove protective cap from pressure test port on fuel rail. This is located on top of fuel rail. WARNING: DO NOT ALLOW FUEL TO SPILL ONTO ENGINE INTAKE OR EXHAUST MANIFOLDS. PLACE SHOP TOWELS UNDER AND AROUND PRESSURE PORT TO ABSORB FUEL WHEN PRESSURE IS RELEASED FROM FUEL RAIL. WARNING: WEAR PROPER EYE PROTECTION WHEN RELEASING FUEL SYSTEM PRESSURE. 4. Obtain fuel pressure gauge/hose assembly from fuel pressure gauge tool set 5069. Remove gauge from hose. 5. Place one end of hose (gauge end) into an approved gasoline container. 6. Place a shop towel under test port. 7. To release fuel pressure, screw other end of hose onto fuel pressure test port. 8. After fuel pressure has been released, remove hose from test port. 9. Install protective cap to fuel test port. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > With Pressure Test Port > Page 3474 Fuel Pressure Release: Service and Repair Without Pressure Test Port NOTE: Use the following procedure if the fuel rail is not equipped with a fuel pressure test port. 1. Remove the Fuel Pump relay from the Power Distribution Center (PDC). For location of the relay, refer to the label on the underside of the PDC cover. 2. Start and run engine until it stalls. 3. Attempt restarting engine until it will no longer run. 4. Turn ignition key to OFF position. CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within the fuel rail. Do not attempt to use the following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber. 5. Unplug connector from any injector. 6. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 7. Connect the other end of the jumper wire to the positive side of the battery 8. Connect one end of a second jumper wire to the remaining injector terminal. CAUTION: Supplying power to an injector for more than 4 seconds will permanently damage the injector. Do not leave the injector connected to power for more than 4 seconds. 9. Momentarily touch the other end of this jumper wire to the negative terminal of the battery for no more than 4 seconds. 10. Place a rag or towel below the fuel line at the quick connect to the rail. 11. Disconnect the quick connect fitting to the rail. Refer to Quick-Connect Fittings. 12. Return the fuel pump relay to the PDC. 13. One or more Diagnostic Trouble Codes (DTC's) may have been stored in the PCM memory due to fuel pump relay removal. The DRB scan tool must be used to erase a DTC. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Fuel/Engine Controls - Injector Circuit/TPS Revisions Fuel Injector: Technical Service Bulletins Fuel/Engine Controls - Injector Circuit/TPS Revisions NUMBER: 26-05-98F GROUP: Miscellaneous DATE: May, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 2.5L, 3.9L, 5.2L, 5.9L Truck Powertrain Diagnostic Manual - Publication Number 81-699-96041 DESCRIPTION OF CHANGES Revision to the injector connector diagram Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Fuel/Engine Controls - Injector Circuit/TPS Revisions > Page 3479 224 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Fuel/Engine Controls - Injector Circuit/TPS Revisions > Page 3480 225 Revision to the throttle position sensor test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Fuel/Engine Controls - Injector Circuit/TPS Revisions > Page 3481 164 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Fuel/Engine Controls - Injector Circuit/TPS Revisions > Page 3482 165 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Fuel/Engine Controls - Injector Circuit/TPS Revisions > Page 3483 168 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Fuel/Engine Controls - Injector Circuit/TPS Revisions > Page 3484 169 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Fuel/Engine Controls - Injector Circuit/TPS Revisions > Page 3485 169A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Fuel/Engine Controls - Injector Circuit/TPS Revisions > Page 3486 169B Revision to the TPS voltage test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Fuel/Engine Controls - Injector Circuit/TPS Revisions > Page 3487 422 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Fuel/Engine Controls - Injector Circuit/TPS Revisions > Page 3488 423 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Electrical Specifications Fuel Injector: Electrical Specifications Injector Resistance ...................................................................................................................................................... 12 ohms ± 1.2 ohms at 20 ° C (68 ° F) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Electrical Specifications > Page 3491 Fuel Injector: Pressure, Vacuum and Temperature Specifications Fig 8 Fuel Pressure Test Port - Typical WARNING: THE FUEL SYSTEM IS UNDER CONSTANT FUEL PRESSURE EVEN WITH THE ENGINE OFF. BEFORE DISCONNECTING FUEL LINE AT FUEL RAIL, THIS PRESSURE MUST BE RELEASED. REFER TO THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE. NOTE: Use this test in conjunction with the Fuel Pump Capacity Test and Fuel Pressure Leak Down Test found elsewhere. Check Valve Operation: The electric fuel pump outlet contains a one-way check valve to prevent fuel flow back into the tank and to maintain fuel supply line pressure (engine warm) when pump is not operational. - It is also used to keep the fuel supply line full of gasoline when pump is not operational. After the vehicle has cooled down, fuel pressure may drop to 0 psi (cold fluid contracts), but liquid gasoline will remain in fuel supply line between the check valve and fuel injectors. Fuel pressure that has dropped to 0 psi on a cooled down vehicle (engine off) is a normal condition. When the electric fuel pump is activated, fuel pressure should immediately rise to specification. NOTE: The fuel pressure test port is used on certain engines only. The test port is located on the fuel rail near the throttle position sensor (Fig. 8). A sealing cap is screwed onto the test port. All fuel systems are equipped with a fuel tank module mounted, combination fuel filter/fuel pressure regulator. The fuel pressure regulator is not controlled by engine vacuum. Procedure 1. Remove protective cap at fuel rail test port. Connect the 0-414 kPa (0-60 psi) fuel pressure gauge (from gauge set 5069) to test port pressure fitting on fuel rail. 2. Start and warm engine and note pressure gauge reading. Fuel pressure should be 339 kPa +/34 kPa (49.2 psi +/- 5 psi) at idle. 3. If engine runs but pressure is below 44.2 psi, check for a kinked fuel supply line somewhere between fuel rail and fuel pump module. If line is not kinked, replace fuel pump module assembly. Refer to Fuel Pump Module Removal/Installation. 4. If operating pressure is above 54.2 psi, electric fuel pump is OK, but fuel pressure regulator is defective. - Replace fuel filter/fuel pressure regulator. - Certain filter/regulators may be serviced separately and some require the replacement of the fuel pump module assembly Refer to Fuel Filter /Fuel Pressure Regulator Removal/Installation for more information. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 3492 Gas Engine Components Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 3493 Injector Connector Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 3494 Fuel Injector: Description and Operation Fig. 4 Fuel Injectors - Typical DESCRIPTION The nozzle ends of the injectors are positioned into openings in the intake manifold just above the intake valve ports of the cylinder head. The engine wiring harness connector for each fuel injector is equipped with an attached numerical tag (INJ 1, INJ 2 etc.). This is used to identify each fuel injector with its respective cylinder number. OPERATION The injectors are energized individually in a sequential order by the powertrain control module (PCM). The PCM will adjust injector pulse width by switching the ground path to each individual injector on and off. injector pulse width is the period of time that the injector is energized. The PCM will adjust injector pulse width based on various inputs it receives. CIRCUIT OPERATION when the Automatic Shut Down (ASD) relay contacts CLOSE, it connects circuits A16 and A142. Circuit A142 supplies voltage to the fuel injectors. Each injector has a separate ground circuit controlled by the Powertrain Control Module (PCM). Circuit K11 provides ground for injector number one. The K11 circuit connects to cavity B4 of the PCM. Circuit K12 provides ground for injector number two. The K12 circuit connects to cavity B15 of the PCM. Circuit K13 provides ground for injector number three. The K13 circuit connects to cavity E5 of the PCM. Circuit K14 provides ground for injector number four. The K14 circuit connects to cavity B16 of the PCM. Circuit K38 provides ground for injector number five. The K38 circuit connects to cavity B6 of the PCM. Circuit K58 provides ground for injector number six. The K58 circuit connects to cavity B12 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Test Fuel Injector: Testing and Inspection Fuel Injector Test Fig 13 Fuel Injector Internal Components - Typical To perform a complete test of the fuel injectors and their circuitry, refer to DRB scan tool and appropriate Powertrain Diagnostics Procedures. To test the injector only, refer to the following: Disconnect the fuel injector wire harness connector from the injector. Place an ohmmeter across the injector electrical terminals. Resistance reading should be approximately 12 ohms +/- 1.2 ohms at 20°C (68°F). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Test > Page 3497 Fuel Injector: Testing and Inspection Helpful Information - Circuit A142 splices to supply voltage to the fuel injectors, ignition coil, and heated oxygen sensor. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Page 3498 Fuel Injector: Service and Repair Fig 21 Injector Mounting Fig 22 Injector Retaining Clips-typical Injector WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE EVEN WITH ENGINE TURNED OFF. BEFORE SERVICING FUEL INJECTOR(S), FUEL SYSTEM PRESSURE MUST BE RELEASED. NOTE: Prior to beginning procedure -- release fuel pressure, refer to Fuel System Pressure Release Procedure. TIP: To remove one or more fuel injectors, fuel rail assembly must be removed from engine. REMOVAL 1. Remove air cleaner assembly 2. Remove fuel injector rail assembly Refer to Fuel Injector Rail Removal/Installation. 3. Remove clip(s) retaining the injector(s) to fuel rail. 4. Remove injector(s) from fuel rail. INSTALLATION 1. Apply a small amount of clean engine oil to each fuel injector O-ring. - This will help in fuel rail installation. 2. Install injector(s) and injector clip(s) to fuel rail. 3. Install fuel rail assembly Refer to Fuel Injector Rail Removal/Installation. 4. Install air cleaner. 5. Start engine and check for leaks. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Description and Operation Fuel Line Coupler: Description and Operation Different types of quick-connect fittings are used to attach various fuel system components. These are: a single-tab type, a two-tab type or a plastic retainer ring type. Some are equipped with safety latch clips. CAUTION: The interior components (0-rings, spacers) of quick-connect fitting are not serviced separately, but new pull tabs are available for some types. Do not attempt to repair damaged fittings or fuel lines/tubes. If repair is necessary, replace the complete fuel tube assembly. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Fuel Line at Fuel Rail Fuel Line Coupler: Service and Repair Fuel Line at Fuel Rail With Pressure Test Port Fig. 16 Latch Clip Location - Typical A latch clip is used to secure the fuel line to the fuel rail on certain engines. A special tool will be necessary to separate the fuel line from the fuel rail after the latch clip is removed. DISCONNECTION/CONNECTION AT FUEL RAIL 1. Disconnect the negative battery cable from battery. 2. Perform the fuel pressure release procedure. 3. Clean the fitting of any foreign material before disassembly Fig. 17 Latch Clip Removal - Typical 4. Pry up on the latch clip with a screwdriver. 5. Slide the latch clip toward the fuel rail while lifting with the screwdriver. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Fuel Line at Fuel Rail > Page 3504 Fig. 18 Fuel Line Disconnection - Typical 6. Insert special fuel line removal tool (Snap-On number FIH 9055-1 or equivalent) into the fuel line. Use this tool to release the locking fingers in the end of the line. 7. With the special tool still inserted, pull the fuel line from the fuel rail. 8. After disconnection, the locking fingers will remain within the quick-connect fitting at the end of the fuel line. 9. Inspect fuel line fitting, locking fingers and fuel rail fitting for damage. Replace as necessary 10. Prior to connecting the fuel line to the fuel rail, check condition of both fittings. Clean the parts with a lint-free cloth. Lubricate them with clean engine oil. 11. Insert the fuel line onto the fuel rail until a click is felt. 12. Verify a locked condition by firmly pulling on fuel line and fitting (15-30 lbs.). 13. Install latch clip (snaps into position). If the latch clip will not fit, this indicates the fuel line is not properly installed to the fuel rail. Recheck the fuel line connection. 14. Connect negative battery cable to battery 15. Start engine and check for leaks. W/O Pressure Test Port Fig. 19 Latch Clip Removal A special latch clip is used to secure the fuel line to the fuel rail on this particular engine. DISCONNECTION/CONNECTION AT FUEL RAIL 1. Disconnect the negative battery cable from battery. 2. Perform the fuel pressure release procedure. 3. Clean the fitting of any foreign material before disassembly 4. Compress clip fingers and pull clip straight up for removal. 5. Pull the fuel line from the fuel rail. 6. After disconnection the locking fingers will remain within the quick-connect fitting in the fuel rail. 7. Inspect fuel line fitting, locking fingers and fuel rail fitting for damage. Replace as necessary 8. Prior to connecting the fuel line to the fuel rail, check condition of both fittings. Clean the parts with a lint-free cloth. Lubricate them with clean engine oil. 9. Insert the fuel line into the fuel rail. 10. Install latch clip with fingers down (snaps into position). The fingers should protrude below the fuel rail if properly installed. If the latch clip will not fit, this indicates the fuel line is not properly installed to the fuel rail. Recheck the fuel line connection. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Fuel Line at Fuel Rail > Page 3505 11. Verify a locked condition by firmly pulling on fuel line and fitting (15-30 lbs.). 12. Connect negative battery cable to battery 13. Start engine and check for leaks. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Fuel Line at Fuel Rail > Page 3506 Fuel Line Coupler: Service and Repair Plastic Retainer Type Fig. 15 Plastic Retainer Ring Type Fitting This type of fitting can be identified by the use of a full-round plastic retainer ring usually black in color. CAUTION: The interior components (0-rings, spacers, retainers) of this type of quick-connect fitting are not serviced separately. Do not attempt to repair damaged fittings or fuel lines/tubes. If repair is necessary, replace the complete fuel tube assembly. WARNING: The fuel system is under a constant pressure (even with the engine off). Before servicing any fuel system hoses, fittings or lines, the fuel system pressure must be released. Refer to the fuel system pressure release procedure. DISCONNECTION/CONNECTION 1. Disconnect negative battery cable from the battery 2. Perform the fuel pressure release procedure. Refer to the Fuel Pressure Release Procedure. 3. Clean the fitting of any foreign material before disassembly 4. To release the fuel system component from the quick-connect fitting, firmly push the fitting towards the component being serviced while firmly pushing the plastic retainer ring into the fitting. With the plastic ring depressed, pull the fitting from the component. The plastic retainer ring must be pressed squarely into the fitting body. If this retainer is cocked during removal, it may be difficult to disconnect fitting. Use an open-end wrench on the shoulder of the plastic retainer ring to aid in disconnection. 5. After disconnection, the plastic retainer ring will remain with the quick-connect fitting connector body. 6. Inspect fitting connector body, plastic retainer ring and fuel system component for damage. Replace as necessary. 7. Prior to connecting the quick-connect fitting to component being serviced, check condition of fitting and component. Clean the parts with a lint-free cloth. Lubricate them with clean engine oil. 8. Insert the quick-connect fitting into the component being serviced until a click is felt. 9. Verify a locked condition by firmly pulling on fuel tube and fitting (15-30 lbs.). 10. Connect negative battery cable to battery 11. Start engine and check for leaks. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Fuel Line at Fuel Rail > Page 3507 Fuel Line Coupler: Service and Repair Retainer Ring Type Fittings NOTE: Plastic ring type quick connect fittings are not serviced separately. Do not attempt to repair damaged quick connect fittings or tubes. Replace complete fuel tube/quick connect fitting assembly. Fuel Line Quick Connect Fitting REMOVAL 1. Disconnect negative battery cable. 2. Perform fuel pressure release procedure. 3. Push the quick connect fitting toward the fuel tube while depressing the plastic retainer. Then slightly twist the fitting and pull fitting off of fuel tube. The retainer will remain on the fitting. INSTALLATION 1. Using a clean lint free cloth, clean fuel tube nipple and retainer. 2. Using a clean motor oil, lightly lube nipple and retainer. CAUTION: Never install quick connect fitting if retainer ring is damaged or stuck in the release position. Fuel Line Quick Connect Fitting 3. Push fitting over fuel tube until retainer seats and a click is heard. When the fitting is properly plastic retainer should be in the out position. 4. Verify connection by pulling on the fuel tube. If fitting locks in place connection is secure. 5. Use the Automatic Shut Down (ASD) Fuel System Test on the DRB II to pressurize the fuel system and check for leaks. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Fuel Line at Fuel Rail > Page 3508 CAUTION: The ASD relay and the fuel pump relay will remain energized for 7 minutes during this test unless the test is stopped or the ignition switch is turned to the OFF position. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Fuel Line at Fuel Rail > Page 3509 Fuel Line Coupler: Service and Repair Single TAB Type Fittings Fig. 11 Single-Tab Type Fitting This type of fitting is equipped with a single pull tab. The tab is removable. After the tab is removed, the quick-connect fitting can be separated from the fuel system component. CAUTION: The interior components (0-rings, spacers) of this type of quick-connect fitting are not serviced separately, but new pull tabs are available. Do not attempt to repair damaged fittings or fuel lines/tubes. If repair is necessary, replace the complete fuel tube assembly. WARNING: The fuel system is under a constant pressure (even with the engine off). Before servicing any fuel system hoses, fittings or lines, the fuel system pressure must be released. DISCONNECTION/CONNECTION 1. Disconnect negative battery cable from battery. 2. Perform the fuel pressure release procedure. 3. Clean the fitting of any foreign material before disassembly. Fig. 12 Disconnecting Single-Tab Type Fitting 4. Press the release tab on the side of fitting to release pull tab. CAUTION: If this release tab is not pressed prior to releasing the pull tab, the pull tab will be damaged. 5. While pressing the release tab on the side of the fitting, use a screwdriver to pry up the pull tab. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Fuel Line at Fuel Rail > Page 3510 Fig. 13 Removing Pull Tab 6. Raise the pull tab until it separates from the quick-connect fitting. Discard the old pull tab. 7. Disconnect the quick-connect fitting from the fuel system component being serviced. 8. Inspect the quick-connect fitting body and fuel system component for damage. Replace as necessary. 9. Prior to connecting the quick-connect fitting to component being serviced, check condition of fitting and component. Clean the parts with a lint-free cloth. Lubricate them with clean engine oil. 10. Insert the quick-connect fitting into the fuel tube or fuel system component until the built-on stop on the fuel tube or component rests against back of fitting. 11. Obtain a new pull tab. Push the new tab down until it locks into place in the quick-connect fitting. 12. Verify a locked condition by firmly pulling on fuel tube and fitting (15-30 lbs.). 13. Connect negative cable to battery. 14. Start engine and check for leaks. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Fuel Line at Fuel Rail > Page 3511 Fuel Line Coupler: Service and Repair Two TAB Type Fittings Fig. 14 Typical Two-Tab Type Quick-Connect Fitting Fuel Line Quick Connect Fitting Fuel Line Quick Connect Fitting This type of fitting is equipped with tabs located on both sides of the fitting. These tabs are supplied for disconnecting the quick-connect fitting from component being serviced. CAUTION: The interior components (0-rings, spacers) of this type of quick-connect fitting are not serviced separately, but new plastic retainers are available. Do not attempt to repair damaged fittings or fuel lines/tubes. If repair is necessary, replace the complete fuel tube assembly. WARNING: The fuel system is under a constant pressure (even with the engine off). Before servicing any fuel system hoses, fittings or lines, the fuel system pressure must be released. Refer to the fuel pressure release procedure. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Fuel Line at Fuel Rail > Page 3512 DISCONNECTION/CONNECTION 1. Disconnect negative battery cable from the battery 2. Perform the fuel pressure release procedure. Refer to the Fuel Pressure Release Procedure. 3. Clean the fitting of any foreign material before disassembly 4. To disconnect the quick-connect fitting, squeeze the plastic retainer tabs against the sides of the quick-connect fitting with your fingers. Tool use is not required for removal and may damage plastic retainer. Pull the fitting from the fuel system component being serviced. The plastic retainer will remain on the component being serviced after fitting is disconnected. The 0-rings and spacer will remain in the quick- connect fitting connector body. 5. Inspect the quick-connect fitting body and component for damage. Replace as necessary. CAUTION: When the quick-connect fitting was disconnected, the plastic retainer will remain on the component being serviced. If this retainer must be removed, very carefully release the retainer from the component with two small screwdrivers. After removal, inspect the retainer for cracks or any damage. 6. Prior to connecting the quick-connect fitting to component being serviced, check condition of fitting and component. Clean the parts with a lint-free cloth. Lubricate them with clean engine oil. 7. Insert the quick-connect fitting to the component being serviced and into the plastic retainer. when a connection is made, a click will be heard. 8. Verify a locked condition by firmly pulling on fuel tube and fitting (15-30 lbs.). 9. Connect negative cable to battery 10. Start engine and check for leaks. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations Fuel Pressure Regulator: Locations Fig1 Fuel Tank/Fuel Pump Module Fig 3 Side View - Filter/Regulator A combination fuel filter and fuel pressure regulator is pressed into a rubber grommet located on the top of the fuel pump module. A separate frame mounted fuel filter is not used. NOTE: There is also a fuel pump inlet filter on the bottom of the fuel pump module. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Page 3516 Fuel Pressure Regulator: Description and Operation Fig 3 Side View - Filter/Regulator Fuel Filter/fuel Pressure Regulator A combination fuel filter and fuel pressure regulator (Fig. 3) is used on all engines. It is located on the top of the fuel pump module. A separate frame mounted fuel filter is not used with any engine. Both fuel filters (at bottom of fuel pump module and within fuel pressure regulator) are designed for extended service. They do not require normal scheduled maintenance. Filters should only be replaced if a diagnostic procedure indicates to do so. Fuel Pressure Regulator Operation: The pressure regulator is a mechanical device that is not controlled by engine vacuum or the powertrain control module (PCM). The regulator is calibrated to maintain fuel system operating pressure of approximately 339 kPa +/34 kPa (49.2 psi +/- 5 psi) at the fuel injectors. It contains a diaphragm, calibrated springs and a fuel return valve. The internal fuel filter is also part of the assembly. Fuel is supplied to the filter/regulator by the electric fuel pump through an opening tube at the bottom of filter/regulator. The regulator acts as a check valve to maintain some fuel pressure when the engine is not operating. This will help to start the engine. A second check valve is located at the outlet end of the electric fuel pump. Refer to Fuel Pump-Description and Operation for more information. Also refer to the Fuel Pressure Leak Down Test and the Fuel Pump Pressure Tests. See: Fuel Pressure/Testing and Inspection If fuel pressure at the pressure regulator exceeds approximately 49.2 psi, an internal diaphragm opens and excess fuel pressure is routed back into the tank through the bottom of pressure regulator. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Technical Service Bulletins > Fuel Pressure Gauge Adapter - Usage Fuel Pressure: Technical Service Bulletins Fuel Pressure Gauge Adapter - Usage NO: 14-03-98 GROUP: Fuel DATE: May 1, 1998 SUBJECT: Fuel Pressure Gauge Adapter Usage MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) DISCUSSION: Currently, four different fuel pressure adapters are required, depending on application, to attach a fuel gauge for pressure testing. The matrix lists the adapter part numbers and their application. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Pressure, Vacuum and Temperature Specifications Fuel Pressure: Pressure, Vacuum and Temperature Specifications Fuel Pressure Engine at curb idle ............................................................................................................................... ........................................ 339 ± 34 kPa (49.2 ± 5 psi) Pressure Leakdown (fuel pump not engaged) ................................................................................................................. Not fall below 30 psi for 5 minutes Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Pressure, Vacuum and Temperature Specifications > Page 3524 Fuel Pressure: Capacity Specifications NOTE: Before performing this test, vent fuel pump pressure by performing the Fuel Pump Pressure Test. Use this test in conjunction with the Fuel Pressure Leak Down Test. 1. Release fuel system pressure. Refer to the Fuel Pressure Release Procedure. 2. Disconnect fuel supply line at fuel rail. Some engines may require air cleaner housing removal before line disconnection. 3. Connect appropriate Fuel Line Pressure Test Adapter Tool Hose (number 6631, 6923, 6541 or 6539) into disconnected fuel supply line. Insert other end of Adaptor Tool hose into a graduated container. 4. Remove fuel fill cap. 5. To activate fuel pump and pressurize system, obtain DRB scan tool and actuate ASD Fuel System Test. 6. A good fuel pump will deliver at least 1/4 liter of fuel in 7 seconds. Do not operate fuel pump for longer than 7 seconds with fuel line disconnected as fuel pump module reservoir may run empty. a. If capacity is lower than specification, but fuel pump can be heard operating through fuel fill cap opening, check for a kinked/damaged fuel supply line somewhere between fuel rail and fuel pump module. b. If line is not kinked/damaged, and fuel pressure is OK, but capacity is low, replace fuel filter/ fuel pressure regulator. The filter/regulator may be serviced separately on certain applications. Refer to Fuel Filter/Fuel Pressure Regulator Removal/Installation for additional information. c. If both fuel pressure and capacity are low, replace fuel pump module assembly Refer to Fuel Pump Module Removal/Installation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test Fuel Pressure: Testing and Inspection Fuel Pressure Leak Down Test Fig 11 Connecting Adapter Tool - Typical Fig 12 Connecting Adapter Tool - Typical NOTE: Use this test in conjunction with the Fuel Pump Pressure Test and Fuel Pump Capacity Test. Check Valve Operation: The electric fuel pump outlet contains a one-way check valve to prevent fuel flow back into the tank and to maintain fuel supply line pressure (engine warm) when pump is not operational. It is also used to keep the fuel supply line full of gasoline when pump is not operational. After the vehicle has cooled down, fuel pressure may drop to 0 psi (cold fluid contracts), but liquid gasoline will remain in fuel supply line between the check valve and fuel injectors. Fuel pressure that has dropped to 0 psi on a cooled down vehicle (engine off) is a normal condition. when the electric fuel pump is activated, fuel pressure should immediately rise to specification. Abnormally long periods of cranking to restart a hot engine that has been shut down for a short period of time may be caused by: ^ Fuel pressure bleeding past a fuel injector(s). ^ Fuel pressure bleeding past the check valve in the fuel pump module. Procedure 1. Disconnect the fuel inlet line at fuel rail. - On some engines, air cleaner housing removal may be necessary before fuel line disconnection. 2. Connect the appropriate Fuel Line Pressure Test Adapter Tool (number 6539, 6631, 6541 or 6923) between the disconnected fuel line and fuel rail (Fig. 11) or (Fig. 12). 3. Connect the 0-414 kPa (0-60 psi) fuel pressure test gauge (from Gauge Set 5069) to the test port on the appropriate Adaptor Tool. - The fittings on both tools must be in good condition and free from any small leaks before performing the proceeding test. 4. Start engine and bring to normal operating temperature. 5. Observe test gauge. Normal operating pressure should be 339 kPa +/- 34 kPa (49.2 psi +/- 5 psi). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 3527 6. Shut engine off. 7. Pressure should not fall below 30 psi for five minutes. 8. If pressure falls below 30 psi, it must be determined if a fuel injector, the check valve within the fuel pump module, or a fuel tube/line is leaking. 9. Again, start engine and bring to normal operating temperature. 10. Shut engine off. 11. Testing for fuel injector or fuel rail leakage: - Clamp off the rubber hose portion of Adaptor Tool between the fuel rail and the test port "T" on Adapter Tool. - If pressure now holds at or above 30 psi, a fuel injector or the fuel rail is leaking. 12. Testing for fuel pump check valve, filter/ regulator check valve or fuel tube/line leakage: - Clamp off the rubber hose portion of Adaptor Tool between the vehicle fuel line and test port "T" on Adapter Tool. - If pressure now holds at or above 30 psi, a leak may be found at a fuel tube/line. - If no leaks are found at fuel tubes or lines, one of the check valves in either the electric fuel pump or filter/ regulator may be leaking. NOTE: A quick loss of pressure usually indicates a defective check valve in the filter/regulator. A slow loss of pressure usually indicates a defective check valve in the electric fuel pump. The electric fuel pump is not serviced separately. Replace the fuel pump module assembly. The filter/regulator may be replaced separately on certain applications. Refer to Fuel Filter/Fuel Pressure Regulator Removal/Installation for additional information. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 3528 Fuel Pressure: Testing and Inspection Fuel Pressure Test - With Test Port Fig 8 Fuel Pressure Test Port - Typical WARNING: THE FUEL SYSTEM IS UNDER CONSTANT FUEL PRESSURE EVEN WITH THE ENGINE OFF. BEFORE DISCONNECTING FUEL LINE AT FUEL RAIL, THIS PRESSURE MUST BE RELEASED. REFER TO THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE. NOTE: Use this test in conjunction with the Fuel Pump Capacity Test and Fuel Pressure Leak Down Test found elsewhere. Check Valve Operation: The electric fuel pump outlet contains a one-way check valve to prevent fuel flow back into the tank and to maintain fuel supply line pressure (engine warm) when pump is not operational. - It is also used to keep the fuel supply line full of gasoline when pump is not operational. After the vehicle has cooled down, fuel pressure may drop to 0 psi (cold fluid contracts), but liquid gasoline will remain in fuel supply line between the check valve and fuel injectors. Fuel pressure that has dropped to 0 psi on a cooled down vehicle (engine off) is a normal condition. When the electric fuel pump is activated, fuel pressure should immediately rise to specification. NOTE: The fuel pressure test port is used on certain engines only. The test port is located on the fuel rail near the throttle position sensor (Fig. 8). A sealing cap is screwed onto the test port. All fuel systems are equipped with a fuel tank module mounted, combination fuel filter/fuel pressure regulator. The fuel pressure regulator is not controlled by engine vacuum. Procedure 1. Remove protective cap at fuel rail test port. Connect the 0-414 kPa (0-60 psi) fuel pressure gauge (from gauge set 5069) to test port pressure fitting on fuel rail. 2. Start and warm engine and note pressure gauge reading. Fuel pressure should be 339 kPa +/34 kPa (49.2 psi +/- 5 psi) at idle. 3. If engine runs but pressure is below 44.2 psi, check for a kinked fuel supply line somewhere between fuel rail and fuel pump module. If line is not kinked, replace fuel pump module assembly. Refer to Fuel Pump Module Removal/Installation. 4. If operating pressure is above 54.2 psi, electric fuel pump is OK, but fuel pressure regulator is defective. - Replace fuel filter/fuel pressure regulator. - Certain filter/regulators may be serviced separately and some require the replacement of the fuel pump module assembly Refer to Fuel Filter /Fuel Pressure Regulator Removal/Installation for more information. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 3529 Fuel Pressure: Testing and Inspection Fuel Pressure Test - Without Test Port Fig 10 Installing Adapter Tool And Pressure Gauge WARNING: THE FUEL SYSTEM IS UNDER CONSTANT FUEL PRESSURE EVEN WITH THE ENGINE OFF. BEFORE DISCONNECTING FUEL LINE AT FUEL RAIL, THIS PRESSURE MUST BE RELEASED. REFER TO THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE. NOTE: Use this test in conjunction with the Fuel Pump Capacity Test and Fuel Pressure Leak Down Test. Check Valve Operation: The electric fuel pump outlet contains a one-way check valve to prevent fuel flow back into the tank and to maintain fuel supply line pressure (engine warm) when pump is not operational. It is also used to keep the fuel supply line full of gasoline when pump is not operational. After the vehicle has cooled down, fuel pressure may drop to 0 psi (cold fluid contracts), but liquid gasoline will remain in fuel supply line between the check valve and fuel injectors. Fuel pressure that has dropped to 0 psi on a cooled down vehicle (engine off) is a normal condition. When the electric fuel pump is activated, fuel pressure should immediately rise to specification. All fuel systems are equipped with a fuel tank module mounted, combination fuel filter/fuel pressure regulator. The fuel pressure regulator is not controlled by engine vacuum. Procedure 1. Release fuel pressure. Refer to the Fuel System Pressure Release Procedure-Without Pressure Test Port. 2. Disconnect latch clip and fuel line at fuel rail. Refer to Quick-Connect Fittings for procedures. 3. Connect adapter tool number 6923 into the fuel rail (Fig. 10). Be sure adapter tool is fully seated into fuel rail. 4. Install latch clip to fuel rail. If latch clip can not be fully seated into fuel rail, check for adapter tool not fully seated to fuel rail. 5. Connect vehicle fuel line into adapter tool 6923 (Fig. 10). Be sure fuel line is fully seated into adapter tool 6923. 6. Remove protective cap at test port "T" on adapter tool number 6923. 7. Connect the 0-414 kPa (0-60 psi) fuel pressure gauge (from gauge set 5069) to the test port "T" (Fig. 10). 8. Start engine and note pressure gauge reading. Fuel pressure should be 339 kPa +/- 34 kPa (49.2 psi +/5 psi) at idle. 9. If engine runs but pressure is below 44.2 psi, check for a kinked fuel supply line somewhere between fuel rail and fuel pump module. If line is not kinked, replace fuel pump module assembly. Refer to Fuel Pump Module Removal/Installation. 10. If operating pressure is above 54.2 psi, electric fuel pump is OK, but fuel pressure regulator is defective. Replace fuel filter/fuel pressure regulator. Certain filter/regulators may be serviced separately and some require the replacement of the fuel pump module assembly. Refer to Fuel Filter/Fuel Pressure Regulator Removal/Installation for more information. 11. After performing pressure test, install fuel line into fuel rail. Install latch clip into fuel rail. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Leak Down Test > Page 3530 Fuel Pressure: Testing and Inspection Fuel Pump Capacity Test NOTE: Before performing this test, vent fuel pump pressure by performing the Fuel Pump Pressure Test. Use this test in conjunction with the Fuel Pressure Leak Down Test. 1. Release fuel system pressure. Refer to the Fuel Pressure Release Procedure. 2. Disconnect fuel supply line at fuel rail. Some engines may require air cleaner housing removal before line disconnection. 3. Connect appropriate Fuel Line Pressure Test Adapter Tool Hose (number 6631, 6923, 6541 or 6539) into disconnected fuel supply line. Insert other end of Adaptor Tool hose into a graduated container. 4. Remove fuel fill cap. 5. To activate fuel pump and pressurize system, obtain DRB scan tool and actuate ASD Fuel System Test. 6. A good fuel pump will deliver at least 1/4 liter of fuel in 7 seconds. Do not operate fuel pump for longer than 7 seconds with fuel line disconnected as fuel pump module reservoir may run empty. a. If capacity is lower than specification, but fuel pump can be heard operating through fuel fill cap opening, check for a kinked/damaged fuel supply line somewhere between fuel rail and fuel pump module. b. If line is not kinked/damaged, and fuel pressure is OK, but capacity is low, replace fuel filter/ fuel pressure regulator. The filter/regulator may be serviced separately on certain applications. Refer to Fuel Filter/Fuel Pressure Regulator Removal/Installation for additional information. c. If both fuel pressure and capacity are low, replace fuel pump module assembly Refer to Fuel Pump Module Removal/Installation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Control Unit > Component Information > Description and Operation Fuel Pump Control Unit: Description and Operation CIRCUIT OPERATION The in-tank fuel pump module contains the fuel pump motor and fuel level sensor. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Power Distribution Center Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3537 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3538 Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3539 Fuel Pump Relay: Description and Operation CIRCUIT OPERATION Circuit A14 from the Power Distribution Center (PDC) supplies battery voltage to the contact side of the fuel pump relay. In the START or RUN position, the ignition switch connects circuit F18 from the 10 amp fuse in the junction block to the coil side of the fuel pump relay. The Powertrain Control Module (PCM) provides the ground path for the coil side of the relay on circuit K151. Circuit K151 connects to cavity C19 of the PCM. When the fuel pump relay energizes, it connects circuit A14 and circuit A61. Circuit A61 supplies voltage to the fuel pump module. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Testing and Inspection > Helpful Information Fuel Pump Relay: Testing and Inspection Helpful Information - Check the 20 amp fuse located in the PDC Check the 10 amp fuse located in the junction block Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Testing and Inspection > Helpful Information > Page 3542 Fuel Pump Relay: Testing and Inspection Relay Tests Fig 91 ASD And Fuel Pump Relay Terminals ASD and Fuel Pump Relay Test The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relay. The terminals on the bottom of each relay are numbered (Fig. 91). RELAY OPERATION Terminal 30: Connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. Terminal 85: The PCM grounds the coil side of the relay through this terminal. Terminal 86: Supplies voltage to the coil side of the relay. Terminal 87A: 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. Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TESTING 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 between 70 - 80 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. CAUTION: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter should now show continuity between relay terminals 87 and 30. - The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. - If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Testing and Inspection > Page 3543 Fuel Pump Relay: Service and Repair Fig 67 Power Distribution Center (PDC) Location The fuel pump relay is located in the Power Distribution Center (PDC) (Fig. 67). 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 Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications Fuel Rail: Specifications Fuel Rail Mounting bolts ...................................................................................................................... ......................................... 23 Nm (200 in lb) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 3547 Fuel Rail: Description and Operation Fig 6 Fuel Rail - Typical The fuel rail supplies the necessary fuel to each individual fuel injector and is mounted to the intake manifold (Fig. 6). The fuel pressure regulator is no longer mounted to the fuel rail on any engine. It is now located on the fuel tank mounted fuel pump module. Refer to Fuel Filter/Fuel Pressure Regulator in this section of group for information. The fuel rail is not repairable. CAUTION: The left and right sections of the fuel rail are connected with a flexible connecting hose. Do not attempt to separate the rail halves at this connecting hose. Due to the design of this connecting hose, it does not use any clamps. Never attempt to install a clamping device of any kind to the hose. When removing the fuel rail assembly for any reason, be careful not to bend or kink the connecting hose. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 3548 Fuel Rail: Service and Repair Fig. 25 Fuel Rail Assembly - Typical WARNING: The fuel system is under a constant pressure (even with the engine turned off). Before servicing the fuel rail assembly, the fuel system pressure must be released. CAUTION: The left and right fuel rails are replaced as an assembly. Do not attempt to separate the rail halves at the connecting hose. Due to the design of this connecting hose, it does use any clamps. Never attempt to install a clamping device of any kind to the hose. When removing the fuel rail assembly for any reason, be careful not to bend or kink the connecting hose. REMOVAL 1. Remove negative battery cable at battery. 2. Remove air cleaner. 3. Perform the fuel pressure release procedure. 4. Remove throttle body from intake manifold. Fig. 26 A/C Compressor Support Bracket - Typical 5. If equipped with air conditioning, remove the A-shaped A/C compressor-to-intake manifold support bracket (three bolts). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 3549 Fig. 27 Fuel Injector Connectors - Typical 6. Disconnect electrical connectors at all fuel injectors. The factory fuel injection wiring harness is numerically tagged (INJ 1, INJ 2, etc.) for injector position identification. Fig. 28 EVAP Canister Purge Solenoid - Typical 7. Remove duty cycle EVAP canister purge solenoid/bracket assembly from intake manifold. 8. Disconnect fuel tube (line) at side of fuel rail. 9. Remove the remaining fuel rail mounting bolts. 10. Gently rock and pull the left fuel rail until the fuel injectors just start to clear the intake manifold. Gently rock and pull the right fuel rail until the fuel injectors just start to clear the intake manifold. Repeat this procedure (left/right) until all fuel injectors have cleared the intake manifold. 11. Remove fuel rail (with injectors attached) from engine. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications > Page 3550 Fig 37 Fuel Injector Mounting - Typical Fig. 30 Injector Retaining Clips - Typical Injector 12. Remove the clip(s) retaining the injector(s) to fuel rail. INSTALLATION 1. Apply a small amount of engine oil to each fuel injector 0-ring. This will help in fuel rail installation. 2. Install injector(s) and injector clip(s) to fuel rail. 3. Position the fuel rail/fuel injector assembly to the injector openings on the intake manifold. 4. Guide each injector into the intake manifold. Be careful not to tear the injector 0-ring. 5. Push the right fuel rail down until fuel injectors have bottomed on injector shoulder. Push the left fuel rail down until fuel injectors have bottomed on injector shoulder. 6. Install fuel rail mounting bolts. 7. Install EVAP canister purge solenoid to intake manifold. 8. Connect electrical connector to intake manifold air temperature sensor. 9. Connect wiring to all fuel injectors. The injector wiring harness is numerically tagged. 10. Install the A/C support bracket (if equipped). 11. Install throttle body to intake manifold. 12. Install fuel tube (line) at side of fuel rail. 13. Install air cleaner. 14. Connect battery cable to battery. 15. Start engine and check for leaks. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Description and Operation Fuel Gauge Sender: Description and Operation Fig 31 Fuel Gauge Sending Unit Location - Typical Module Fig 32 Fuel Gauge Sending Unit Lock Tab/Tracks 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). The resistor track is used to send electrical signals to the Powertrain Control Module (PCM) for fuel gauge operation and for OBD II emission requirements. For fuel gauge operation: As fuel level increases, the float and arm move up. This decreases the sending unit resistance, causing the fuel gauge to read full. As fuel level decreases, the float and arm move down. This increases the sending unit resistance causing the fuel gauge to read empty. After this fuel level signal is sent to the PCM, the PCM will transmit the data across the CCD bus circuits to the instrument panel. Here it is translated into the appropriate fuel gauge level reading. For OBD II emission requirements: The voltage signal is sent from the resistor track to the PCM to indicate fuel level. The purpose of this feature is to prevent a false setting of misfire and fuel system monitor trouble codes. This is if the fuel level in the tank is less than approximately 15 percent of its rated capacity. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Description and Operation > Page 3555 Fuel Gauge Sender: Testing and Inspection The fuel gauge sending unit contains a variable resistor (track). As the float moves up or down, electrical resistance will change. 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 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 Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Description and Operation > Page 3556 Fuel Gauge Sender: Service and Repair Fig 31 Fuel Gauge Sending Unit Location - Typical Module Fig 32 Fuel Gauge Sending Unit Lock Tab/Tracks The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module. The fuel pump module is located inside of fuel tank. REMOVAL 1. Remove fuel tank. Refer to Fuel Tank Removal/ Installation. 2. Remove fuel pump module. Refer to Fuel Pump Module Removal/Installation. 3. Unplug 6-way electrical connector. 4. Disconnect 2 sending unit wires at 6-way connector. The locking collar of connector must be removed before wires can be released from connector. Note location of wires within 6-way connector. 5. The sending unit is retained to pump module with a small lock tab and notch. Carefully push lock tab to the side and away from notch while sliding sending unit downward on tracks for removal. Note wire routing while removing unit from module. INSTALLATION 1. Position sending unit into tracks. Note wire routing. 2. Push unit on tracks until lock tab snaps into notch. 3. Connect 2 sending unit wires into 6-way connector and install locking collar. 4. Connect 6-way electrical connector to module. 5. Carefully connect lower section of pump module to upper section (3 tabs lock upper section to lower section). 6. Install fuel pump module. Refer to Fuel Pump Module Removal/Installation. 7. Install fuel tank. Refer to Fuel Tank Removal/ Installation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Specifications Fuel Tank Unit: Specifications Fuel pump module locknut .................................................................................................................. ...................................................... 54 Nm (4O ft lb) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Specifications > Page 3560 Fuel Tank Unit: Description and Operation Fig1 Fuel Tank/Fuel Pump Module Fig 2 Fuel Pump Module Components - Typical The fuel pump module on all gas powered engines is installed in the top of the fuel tank. The fuel pump module contains the following: ^ A combination fuel filter/fuel pressure regulator ^ Electric fuel pump ^ Fuel pump reservoir ^ A separate in-tank fuel filter (at bottom of module) ^ Fuel gauge sending unit ^ Fuel supply line connection at filter/regulator A threaded locknut is used to retain the module to fuel tank. The fuel gauge sending unit (fuel level sensor), and pick-up filter (at bottom of module) may be serviced separately. If the electrical fuel pump requires service, the entire fuel pump module must be replaced. The fuel filter/fuel pressure regulator may be serviced separately on certain applications. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Specifications > Page 3561 Fuel Tank Unit: Service and Repair Fig 28 Top View Of Fuel Pump Module Fig 29 Locknut Removal/Installation - Typical WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH ENGINE OFF). BEFORE SERVICING FUEL PUMP MODULE, FUEL SYSTEM PRESSURE MUST BE RELEASED. FUEL PUMP MODULE REMOVAL 1. Drain fuel tank and remove tank. Refer to Fuel Tank Removal/Installation. 2. Thoroughly wash and clean area around pump module to prevent contaminants from entering tank. 3. The fuel pump module locknut is threaded onto fuel tank (Fig. 28). Install Special Tool 6856 to fuel pump module locknut and remove locknut (Fig. 29). 4. Remove module from fuel tank. CAUTION: Whenever fuel pump module is serviced, the module gasket must be replaced. INSTALLATION 1. Using a new gasket, position fuel pump module into opening in fuel tank. - Be sure rubber gasket remains in place. - Rotate module assembly until module alignment arrow is at 7 o'clock position (Fig. 28). - This step must be followed to prevent float/float rod from contacting sides of fuel tank. 2. Position locknut over top of fuel pump module. - Tighten finger tight. 3. Carefully rotate fuel filter/fuel pressure regulator until pointed towards drivers side of vehicle (Fig. 28). 4. Install Special Tool 6856 to locknut. 5. Tighten locknut to 54 Nm (40 ft lb) torque. - While tightening locknut, be sure module has not rotated. 6. Install fuel tank. Refer to Fuel Tank Installation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Specifications > Page 3562 Fig 30 Fuel Pump Inlet Filter FUEL PUMP INLET FILTER NOTE: The fuel pump inlet filter (strainer) is located on the bottom of the fuel pump module (Fig. 30). The fuel pump module is located inside of fuel tank. REMOVAL 1. Remove fuel tank. Refer to Fuel Tank Removal/ Installation. 2. Remove fuel pump module. Refer to Fuel Pump Module Removal/Installation. 3. Remove filter by carefully prying 2 lock tabs at bottom of module with 2 screwdrivers. Filter is snapped to module. 4. Clean bottom of pump module. INSTALLATION 1. Snap new filter to bottom of module. 2. Install fuel pump module. Refer to Fuel Pump Module Removal/Installation. 3. Install fuel tank. Refer to Fuel Tank Removal/ Installation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications Idle Speed/Throttle Actuator - Electronic: Specifications DESCRIPTION .................................................................................................................................... .............................................................. TORQUE IAC Motor-To-Throttle Body Bolts ............................................................................................................................................................. 7 Nm (60 in lb) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 3566 Fig 10 MAP And Throttle Position Sensor Location - Typical Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 3567 IAC Connector Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 3568 Idle Speed/Throttle Actuator - Electronic: Description and Operation Fig 10 MAP And Throttle Position Sensor Location - Typical DESCRIPTION The throttle body has an air control passage that provides air for the engine at idle (the throttle plate is closed). The Idle Air Control (IAC) motor pintle protrudes into the air control passage and regulates air flow through it. OPERATION Based on various sensor inputs, the powertrain control module (PCM) adjusts engine idle speed by moving the IAC motor pintle in and out of the air control passage. The IAC motor is positioned when the ignition key is turned to the On position. A (factory adjusted) set screw is used to mechanically limit the position of the throttle body throttle plate. Never attempt to adjust the engine idle speed using this screw. All idle speed functions are controlled by the PCM. CIRCUIT OPERATION The Powertrain Control Module (PCM) operates the Idle Air Control motor through four circuits; K39, K40, K59, and K60. Each circuit connects to separate cavities in the PCM connector. Circuit K39 connects to cavity A19 of the PCM connector. - Circuit K40 connects to cavity A11 of the PCM connector. - Circuit K59 connects to cavity A20 of the PCM connector. - Circuit K60 connects to cavity A10 of the PCM connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 3569 Idle Speed/Throttle Actuator - Electronic: Testing and Inspection To perform a complete test of the idle air control motor and circuits see Computers and System Diagnosis/Testing and Inspection/Diagnostic Charts. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 3570 Idle Speed/Throttle Actuator - Electronic: Adjustments A (factory adjusted) set screw is used to mechanically limit the position of the throttle body throttle plate. Never attempt to adjust the engine idle speed using this screw. All idle speed functions are controlled by the powertrain control module (PCM). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 3571 Idle Speed/Throttle Actuator - Electronic: Service and Repair Fig 75 Mounting Bolts (Screws) - IAC Motor The IAC motor is located on the back of the throttle body (Fig. 75). REMOVAL 1. Remove air duct at throttle body. 2. Disconnect electrical connector from IAC motor. 3. Remove two mounting bolts (screws) (Fig. 75). 4. Remove IAC motor from throttle body INSTALLATION 1. Install IAC motor to throttle body 2. Install and tighten two mounting bolts (screws) to 7 Nm (60 in lb) torque. 3. Install electrical connector. 4. Install air duct at throttle body Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates Intake Air Heater: Technical Service Bulletins Engine Controls/Emissions/A/T - Manual Updates NUMBER: 26-06-98 GROUP: Miscellaneous DATE: June, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 2.5L, 3.9L, 5.2L, 5.9L 8.0L SFI/CNG/Diesel Diagnostic Manual - Publication Number 81-699-96041 DESCRIPTION OF CHANGES Revision to the diagnostic trouble codes Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3576 56 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3577 57 Revisions to the Throttle Position Sensor test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3578 162 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3579 166 Revisions to the Evap. Purge Flow Monitor tests Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3580 374 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3581 375 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3582 377 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3583 379 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3584 379A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3585 379B Revision to the EGR system Failure tests Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3586 432 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3587 433 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3588 434 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3589 435 Revision to the torque convertor clutch - no drop at lock up test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3590 465 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3591 467 Revision to the no temp rise seen at intake heater test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3592 514 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3593 515 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3594 516 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3595 517 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3596 518 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3597 519 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3598 520 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3599 521 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3600 521A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3601 521B Revision to the 12 volt supply relay test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3602 571 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates Automatic Shut Down (ASD) Relay: Technical Service Bulletins Engine Controls/Emissions/A/T Manual Updates NUMBER: 26-06-98 GROUP: Miscellaneous DATE: June, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 2.5L, 3.9L, 5.2L, 5.9L 8.0L SFI/CNG/Diesel Diagnostic Manual - Publication Number 81-699-96041 DESCRIPTION OF CHANGES Revision to the diagnostic trouble codes Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3607 56 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3608 57 Revisions to the Throttle Position Sensor test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3609 162 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3610 166 Revisions to the Evap. Purge Flow Monitor tests Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3611 374 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3612 375 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3613 377 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3614 379 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3615 379A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3616 379B Revision to the EGR system Failure tests Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3617 432 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3618 433 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3619 434 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3620 435 Revision to the torque convertor clutch - no drop at lock up test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3621 465 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3622 467 Revision to the no temp rise seen at intake heater test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3623 514 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3624 515 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3625 516 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3626 517 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3627 518 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3628 519 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3629 520 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3630 521 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3631 521A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3632 521B Revision to the 12 volt supply relay test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3633 571 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Page 3634 Automatic Shut Down (ASD) Relay: Locations Power Distribution Center Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Page 3635 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Page 3636 Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Page 3637 Automatic Shut Down (ASD) Relay: Description and Operation CIRCUIT OPERATION Automatic Shut Down (ASD) Relay Circuit A16 from the Power Distribution Center (PDC) supplies battery voltage to the contact side of the Automatic Shut Down (ASD) relay. In the START or RUN position, the ignition switch connects circuit F18 from the 10 amp fuse in the junction block to the coil side of the ASD relay. The Powertrain Control Module (PCM) provides the ground path for the coil side of the relay on circuit K51. Circuit K51 connects to cavity C3 of the PCM. When the ASD relay energizes, it connects circuit A16 and circuit A142. Circuit A142 splices to supply voltage to the fuel injectors, ignition coil, and heated oxygen sensors. Circuit A142 also splices to cavity C12 of the PCM. This input tells the PCM the ASD relay has energized. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Relay Tests Automatic Shut Down (ASD) Relay: Testing and Inspection Relay Tests Fig 91 ASD And Fuel Pump Relay Terminals ASD and Fuel Pump Relay Test The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relay. The terminals on the bottom of each relay are numbered (Fig. 91). RELAY OPERATION Terminal 30: Connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. Terminal 85: The PCM grounds the coil side of the relay through this terminal. Terminal 86: Supplies voltage to the coil side of the relay. Terminal 87A: 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. Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TESTING 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 between 70 - 80 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. CAUTION: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter should now show continuity between relay terminals 87 and 30. - The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. - If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Relay Tests > Page 3640 Automatic Shut Down (ASD) Relay: Testing and Inspection Helpful Information - Check the 30 amp fuse located in the PDC - Check the 10 amp fuse located in the junction block Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Page 3641 Automatic Shut Down (ASD) Relay: Service and Repair Power Distribution Center NOTE: The Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). The PDC is located in the engine compartment. Refer to label on PDC cover for relay location. REMOVAL 1. Remove the PDC cover. 2. Remove the relay by lifting straight up. INSTALLATION 1. Check condition of relay terminals at PDC for corrosion or damage. - Also check the heights of relay terminal pins at PDC. Pin height should be same for all pins. - Repair as necessary before installing relay. 2. Push the relay into the connector. 3. Install the relay cover. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Description and Operation Fuel Pump Control Unit: Description and Operation CIRCUIT OPERATION The in-tank fuel pump module contains the fuel pump motor and fuel level sensor. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Power Distribution Center Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3649 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3650 Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3651 Fuel Pump Relay: Description and Operation CIRCUIT OPERATION Circuit A14 from the Power Distribution Center (PDC) supplies battery voltage to the contact side of the fuel pump relay. In the START or RUN position, the ignition switch connects circuit F18 from the 10 amp fuse in the junction block to the coil side of the fuel pump relay. The Powertrain Control Module (PCM) provides the ground path for the coil side of the relay on circuit K151. Circuit K151 connects to cavity C19 of the PCM. When the fuel pump relay energizes, it connects circuit A14 and circuit A61. Circuit A61 supplies voltage to the fuel pump module. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Helpful Information Fuel Pump Relay: Testing and Inspection Helpful Information - Check the 20 amp fuse located in the PDC Check the 10 amp fuse located in the junction block Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Helpful Information > Page 3654 Fuel Pump Relay: Testing and Inspection Relay Tests Fig 91 ASD And Fuel Pump Relay Terminals ASD and Fuel Pump Relay Test The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relay. The terminals on the bottom of each relay are numbered (Fig. 91). RELAY OPERATION Terminal 30: Connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. Terminal 85: The PCM grounds the coil side of the relay through this terminal. Terminal 86: Supplies voltage to the coil side of the relay. Terminal 87A: 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. Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TESTING 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 between 70 - 80 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. CAUTION: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter should now show continuity between relay terminals 87 and 30. - The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. - If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Page 3655 Fuel Pump Relay: Service and Repair Fig 67 Power Distribution Center (PDC) Location The fuel pump relay is located in the Power Distribution Center (PDC) (Fig. 67). 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 Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates Automatic Shut Down (ASD) Relay: Technical Service Bulletins Engine Controls/Emissions/A/T Manual Updates NUMBER: 26-06-98 GROUP: Miscellaneous DATE: June, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 2.5L, 3.9L, 5.2L, 5.9L 8.0L SFI/CNG/Diesel Diagnostic Manual - Publication Number 81-699-96041 DESCRIPTION OF CHANGES Revision to the diagnostic trouble codes Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3660 56 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3661 57 Revisions to the Throttle Position Sensor test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3662 162 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3663 166 Revisions to the Evap. Purge Flow Monitor tests Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3664 374 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3665 375 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3666 377 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3667 379 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3668 379A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3669 379B Revision to the EGR system Failure tests Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3670 432 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3671 433 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3672 434 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3673 435 Revision to the torque convertor clutch - no drop at lock up test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3674 465 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3675 467 Revision to the no temp rise seen at intake heater test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3676 514 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3677 515 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3678 516 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3679 517 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3680 518 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3681 519 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3682 520 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3683 521 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3684 521A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3685 521B Revision to the 12 volt supply relay test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3686 571 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Page 3687 Automatic Shut Down (ASD) Relay: Locations Power Distribution Center Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Page 3688 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Page 3689 Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Technical Service Bulletins > Page 3690 Automatic Shut Down (ASD) Relay: Description and Operation CIRCUIT OPERATION Automatic Shut Down (ASD) Relay Circuit A16 from the Power Distribution Center (PDC) supplies battery voltage to the contact side of the Automatic Shut Down (ASD) relay. In the START or RUN position, the ignition switch connects circuit F18 from the 10 amp fuse in the junction block to the coil side of the ASD relay. The Powertrain Control Module (PCM) provides the ground path for the coil side of the relay on circuit K51. Circuit K51 connects to cavity C3 of the PCM. When the ASD relay energizes, it connects circuit A16 and circuit A142. Circuit A142 splices to supply voltage to the fuel injectors, ignition coil, and heated oxygen sensors. Circuit A142 also splices to cavity C12 of the PCM. This input tells the PCM the ASD relay has energized. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Relay Tests Automatic Shut Down (ASD) Relay: Testing and Inspection Relay Tests Fig 91 ASD And Fuel Pump Relay Terminals ASD and Fuel Pump Relay Test The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relay. The terminals on the bottom of each relay are numbered (Fig. 91). RELAY OPERATION Terminal 30: Connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. Terminal 85: The PCM grounds the coil side of the relay through this terminal. Terminal 86: Supplies voltage to the coil side of the relay. Terminal 87A: 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. Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TESTING 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 between 70 - 80 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. CAUTION: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter should now show continuity between relay terminals 87 and 30. - The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. - If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Relay Tests > Page 3693 Automatic Shut Down (ASD) Relay: Testing and Inspection Helpful Information - Check the 30 amp fuse located in the PDC - Check the 10 amp fuse located in the junction block Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Page 3694 Automatic Shut Down (ASD) Relay: Service and Repair Power Distribution Center NOTE: The Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). The PDC is located in the engine compartment. Refer to label on PDC cover for relay location. REMOVAL 1. Remove the PDC cover. 2. Remove the relay by lifting straight up. INSTALLATION 1. Check condition of relay terminals at PDC for corrosion or damage. - Also check the heights of relay terminal pins at PDC. Pin height should be same for all pins. - Repair as necessary before installing relay. 2. Push the relay into the connector. 3. Install the relay cover. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover Valve, Fuel Tank > Component Information > Description and Operation Rollover Valve: Description and Operation Fig 1 Rollover Valve Location The fuel tank is equipped with a rollover valve. The valve is located on the top of the fuel tank (Fig. 1). The valve will prevent fuel flow through the fuel tank vent (EVAP) hoses in the event of an accidental vehicle rollover. The EVAP canister draws fuel vapors from the fuel tank through this valve. The valve cannot be serviced separately. If replacement is necessary, the fuel tank must be replaced. Refer to Fuel Tank removal and installation in this group. ROLLOVER VALVE(S) The pressure relief/rollover valves(s) are/is molded into the fuel tank and are not serviced separately. If replacement is necessary, the fuel tank must be replaced. Refer to Fuel Tank Removal/Installation in Fuel System for procedures. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates Throttle Position Sensor: Technical Service Bulletins Engine Controls/Emissions/A/T - Manual Updates NUMBER: 26-06-98 GROUP: Miscellaneous DATE: June, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 2.5L, 3.9L, 5.2L, 5.9L 8.0L SFI/CNG/Diesel Diagnostic Manual - Publication Number 81-699-96041 DESCRIPTION OF CHANGES Revision to the diagnostic trouble codes Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3703 56 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3704 57 Revisions to the Throttle Position Sensor test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3705 162 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3706 166 Revisions to the Evap. Purge Flow Monitor tests Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3707 374 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3708 375 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3709 377 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3710 379 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3711 379A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3712 379B Revision to the EGR system Failure tests Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3713 432 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3714 433 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3715 434 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3716 435 Revision to the torque convertor clutch - no drop at lock up test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3717 465 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3718 467 Revision to the no temp rise seen at intake heater test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3719 514 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3720 515 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3721 516 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3722 517 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3723 518 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3724 519 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3725 520 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3726 521 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3727 521A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3728 521B Revision to the 12 volt supply relay test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3729 571 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3730 Throttle Position Sensor: Technical Service Bulletins Fuel/Engine Controls - Injector Circuit/TPS Revisions NUMBER: 26-05-98F GROUP: Miscellaneous DATE: May, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 2.5L, 3.9L, 5.2L, 5.9L Truck Powertrain Diagnostic Manual - Publication Number 81-699-96041 DESCRIPTION OF CHANGES Revision to the injector connector diagram Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3731 224 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3732 225 Revision to the throttle position sensor test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3733 164 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3734 165 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3735 168 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3736 169 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3737 169A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3738 169B Revision to the TPS voltage test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3739 422 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3740 423 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3741 Throttle Position Sensor: Specifications DESCRIPTION .................................................................................................................................... .............................................................. TORQUE Throttle Position Sensor Mounting Screws ................................................................................................................................................... 7 Nm (60 in lb) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3742 Throttle Position Sensor: Locations Fig. 15 MAP And Throttle Position Sensor Location - Typical The TPS is mounted on the throttle body. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3743 Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3744 Throttle Position Sensor: Description and Operation DESCRIPTION The Throttle Position Sensor (TPS) is a variable resistor that provides the powertrain control module (PCM) with an input signal (voltage) that represents throttle blade position. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the resistance of the TPS changes. OPERATION 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 1 volt at minimum throttle opening (idle), to 4 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. This input signal is also used to determine overdrive and converter clutch shift schedule and to select the proper governor curve. Fig. 15 MAP And Throttle Position Sensor Location - Typical LOCATION The TPS is mounted on the throttle body. CIRCUIT OPERATION From the Powertrain Control Module (PCM), circuit K6 supplies 5 Volts to the Throttle Position Sensor (TPS). Circuit K6 connects to cavity A17 of the PCM. Circuit K22 delivers the TPS signal to the PCM. Circuit K22 connects to cavity A23 of the PCM. The PCM provides a ground for the TPS signal (circuit K22) through circuit K4. Circuit K4 connects to cavity A4 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Component Test Throttle Position Sensor: Testing and Inspection Component Test Fig 62 TPS To perform a complete test of the TPS and its circuitry, refer to Powertrain Management/Computers and Controls/Testing and Inspection/Diagnostic Charts. To test the TPS only, refer to the following: The TPS (Fig. 62) can be tested with a digital voltmeter. The center electrical terminal of the TPS is the output terminal. With the ignition key in the ON position, check the TPS output voltage at the center terminal wire of the connector. Check this at idle (throttle plate closed) and at wide open throttle (WOT). At idle, TPS output voltage should be greater than 0.350 millivolts but less than 900 millivolts. At wide open throttle, TPS output voltage must be less than 4.5 volts. The output voltage should increase gradually as the throttle plate is slowly opened from idle to WOT. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Component Test > Page 3747 Throttle Position Sensor: Testing and Inspection Helpful Information Circuit K6 splices to supply 5 Volts to the manifold absolute pressure sensor, crankshaft position sensor and camshaft position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Crankshaft position sensor - Intake air temperature sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Page 3748 Throttle Position Sensor: Service and Repair Fig 71 TPS Mounting Bolts Fig 72 Installation - Typical REMOVAL 1. Remove air duct at throttle body. 2. Disconnect TPS electrical connector. 3. Remove two TPS mounting bolts (Fig. 71). 4. Remove TPS from throttle body. NOTES: - The throttle shaft end of the throttle body slides into a socket in the TPS (Fig. 72). - The TPS must be installed so that it can be rotated a few degrees. - If the sensor will not rotate, install the sensor with the throttle shaft on the other side of the socket tangs. - The TPS will be under slight tension when rotated. INSTALLATION 1. Install the TPS and two retaining bolts. 2. Tighten bolts to 7 Nm (60 in lb) torque. 3. Manually operate the throttle control lever by hand to check for any binding of the TPS. 4. Connect TPS electrical connector to TPS. 5. Install air duct at throttle body. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications Throttle Body: Specifications DESCRIPTION .................................................................................................................................... .............................................................. TORQUE Throttle Body Mounting Bolts .............................................................................................................. .................................................... 23 Nm (200 in lb) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 3752 Throttle Body: Description and Operation Fig 68 Sensor Electric Connectors - Typical Fig 69 Throttle Body Mounting Bolts - Typical DESCRIPTION The throttle position sensor (TPS), idle air control (IAC) motor and manifold absolute pressure sensor (MAP) are attached to the throttle body The accelerator pedal cable, speed control cable and transmission control cable (when equipped) are connected to the throttle arm. A (factory adjusted) set screw is used to mechanically limit the position of the throttle body throttle plate. Never attempt to adjust the engine idle speed using this screw. All idle speed functions are controlled by the Powertrain Control Module (PCM). OPERATION Filtered air from the air cleaner enters the intake manifold through the throttle body. Fuel does not enter the intake manifold through the throttle body. Fuel is sprayed into the manifold by the fuel injectors. The throttle body is mounted on the intake manifold. It contains an air control passage controlled by an idle air control (IAC) motor. The air control passage is used to supply air for idle conditions. A throttle valve (plate) is used to supply air for above idle conditions. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 3753 Throttle Body: Testing and Inspection The following test procedure has been developed to check throttle body calibrations for correct idle conditions. The procedure should be used to diagnose the throttle body for conditions that may cause idle problems. This procedure should be used only after normal diagnostic procedures have failed to produce results that indicate a throttle body related problem. Be sure to check for proper operation of the idle air control motor before performing this test. Fig. 73 Fixed Orifice Tool A special fixed orifice tool (number 6714) must be used for the following test. 1. Start the engine and bring to operating temperature. Be sure all accessories are off before performing this test. 2. Shut off the engine and remove the air cleaner element housing. Fig. 74 Install Orifice Tool 3. Disconnect the vacuum line at the PCV valve. 4. Install the 0.185 inch orifice tool (number 6714) into the disconnected vacuum line in place of the PCV valve. Fig. 75 Idle Purge Line Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 3754 5. Disconnect the idle purge vacuum line from fitting at throttle body This vacuum line is located on the front of throttle body next to the MAP sensor. Cap the fitting at throttle body after vacuum line has been removed. 6. Connect the DRB scan tool to the 16-way data link connector. This connector is located under the instrument panel to the left of the steering column. 7. Start the engine. 8. Using the DRB scan tool, scroll through the menus as follows: select-System, select-Engine, select-Fuel and Ignition, select-Actuator Tests, select Engine rpm and select-Minimum Air Flow. 9. The DRB scan tool will count down to stabilize the idle rpm and display the minimum air flow idle rpm. The idle rpm should be between 500 and 900 rpm. If the idle speed is outside of these specifications, replace the throttle body. 10. Disconnect the DRB scan tool from the vehicle. 11. Remove cap from idle purge fitting at throttle body and install vacuum line. 12. Remove orifice tool and connect vacuum line to PCV valve. 13. Install air cleaner element housing. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 3755 Throttle Body: Service and Repair Fig 68 Sensor Electric Connectors - Typical Fig 69 Throttle Body Mounting Bolts - Typical CAUTION: A (factory adjusted) set screw is used to mechanically limit the position of the throttle body throttle plate. Never attempt to adjust the engine idle speed using this screw. All idle speed functions are controlled by the powertrain control module (PCM). REMOVAL 1. Remove the air duct at throttle body. 2. Disconnect throttle body electrical connectors at MAP sensor, IAC motor and TPS (Fig. 68). 3. Remove vacuum line at throttle body 4. Remove all control cables from throttle body (lever) arm. Refer to the Accelerator Pedal and Throttle Cable for additional information. 5. Remove four throttle body mounting bolts (Fig. 69). 6. Remove throttle body from intake manifold. 7. Discard old throttle body-to-intake manifold gasket. INSTALLATION 1. Clean the mating surfaces of the throttle body and the intake manifold. 2. Install new throttle body-to-intake manifold gasket. 3. Install throttle body to intake manifold. 4. Install four mounting bolts. Tighten bolts to 23 Nm (200 in lb) torque. 5. Install control cables. 6. Install vacuum line to throttle body. 7. Install electrical connectors. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 3756 8. Install air duct at throttle body. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair Throttle Cable/Linkage: Service and Repair Fig 44 Accelerator Pedal - Removal Or Installation Fig 46 Throttle Cable At Throttle Body - Typical CAUTION: Be careful not to damage or kink cable core wire (within cable sheathing) while servicing accelerator pedal or cables. REMOVAL 1. From inside vehicle, hold up accelerator pedal. Remove plastic cable retainer and throttle cable core wire from upper end of pedal arm (Fig. 44). Plastic cable retainer snaps into pedal arm. 2. Remove cable core wire at pedal arm. 3. From inside vehicle, pinch both sides of cable housing retainer at dash panel (Fig. 44). Remove cable housing from dash panel and pull into engine compartment. 4. Remove air tube at top of throttle body. 5. Operate throttle body lever (by hand) to full open throttle position. - Slip cable end rearward from pin on throttle lever (Fig. 46). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Page 3760 Fig 47 Cable Release Tab - Typical 6. Remove cable housing at throttle body mounting bracket by pressing forward on release tab with a small screwdriver (Fig. 47). - To prevent cable housing breakage, press on tab only enough to release cable from bracket. - Lift cable housing straight up from bracket while pressing on release tab. - Remove cable housing. 7. Remove cable from vehicle. INSTALLATION 1. Snap cable end onto lever pin (Fig. 46). 2. Connect cable to throttle body mounting bracket (push down and lock). 3. Install remaining cable housing end into dash panel opening (snaps into position). Fig 46 Throttle Cable At Throttle Body - Typical Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Page 3761 Fig 48 Throttle Cable 4. Install ball end of cable wire through hole in pedal arm. Install plastic cable retainer. The plastic retainer is snapped into pedal arm. When installing retainer to accelerator pedal arm, note index tab on pedal arm (Fig. 45). Align index slot (Fig. 48) on plastic retainer to this index tab. 5. Operate and test throttle before starting engine. 6. Install air tube to throttle body. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates Throttle Position Sensor: Technical Service Bulletins Engine Controls/Emissions/A/T - Manual Updates NUMBER: 26-06-98 GROUP: Miscellaneous DATE: June, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 2.5L, 3.9L, 5.2L, 5.9L 8.0L SFI/CNG/Diesel Diagnostic Manual - Publication Number 81-699-96041 DESCRIPTION OF CHANGES Revision to the diagnostic trouble codes Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3766 56 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3767 57 Revisions to the Throttle Position Sensor test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3768 162 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3769 166 Revisions to the Evap. Purge Flow Monitor tests Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3770 374 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3771 375 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3772 377 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3773 379 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3774 379A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3775 379B Revision to the EGR system Failure tests Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3776 432 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3777 433 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3778 434 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3779 435 Revision to the torque convertor clutch - no drop at lock up test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3780 465 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3781 467 Revision to the no temp rise seen at intake heater test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3782 514 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3783 515 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3784 516 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3785 517 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3786 518 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3787 519 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3788 520 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3789 521 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3790 521A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3791 521B Revision to the 12 volt supply relay test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3792 571 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3793 Throttle Position Sensor: Technical Service Bulletins Fuel/Engine Controls - Injector Circuit/TPS Revisions NUMBER: 26-05-98F GROUP: Miscellaneous DATE: May, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 2.5L, 3.9L, 5.2L, 5.9L Truck Powertrain Diagnostic Manual - Publication Number 81-699-96041 DESCRIPTION OF CHANGES Revision to the injector connector diagram Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3794 224 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3795 225 Revision to the throttle position sensor test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3796 164 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3797 165 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3798 168 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3799 169 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3800 169A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3801 169B Revision to the TPS voltage test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3802 422 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 3803 423 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3804 Throttle Position Sensor: Specifications DESCRIPTION .................................................................................................................................... .............................................................. TORQUE Throttle Position Sensor Mounting Screws ................................................................................................................................................... 7 Nm (60 in lb) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3805 Throttle Position Sensor: Locations Fig. 15 MAP And Throttle Position Sensor Location - Typical The TPS is mounted on the throttle body. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3806 Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3807 Throttle Position Sensor: Description and Operation DESCRIPTION The Throttle Position Sensor (TPS) is a variable resistor that provides the powertrain control module (PCM) with an input signal (voltage) that represents throttle blade position. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the resistance of the TPS changes. OPERATION 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 1 volt at minimum throttle opening (idle), to 4 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. This input signal is also used to determine overdrive and converter clutch shift schedule and to select the proper governor curve. Fig. 15 MAP And Throttle Position Sensor Location - Typical LOCATION The TPS is mounted on the throttle body. CIRCUIT OPERATION From the Powertrain Control Module (PCM), circuit K6 supplies 5 Volts to the Throttle Position Sensor (TPS). Circuit K6 connects to cavity A17 of the PCM. Circuit K22 delivers the TPS signal to the PCM. Circuit K22 connects to cavity A23 of the PCM. The PCM provides a ground for the TPS signal (circuit K22) through circuit K4. Circuit K4 connects to cavity A4 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Component Test Throttle Position Sensor: Testing and Inspection Component Test Fig 62 TPS To perform a complete test of the TPS and its circuitry, refer to Powertrain Management/Computers and Controls/Testing and Inspection/Diagnostic Charts. To test the TPS only, refer to the following: The TPS (Fig. 62) can be tested with a digital voltmeter. The center electrical terminal of the TPS is the output terminal. With the ignition key in the ON position, check the TPS output voltage at the center terminal wire of the connector. Check this at idle (throttle plate closed) and at wide open throttle (WOT). At idle, TPS output voltage should be greater than 0.350 millivolts but less than 900 millivolts. At wide open throttle, TPS output voltage must be less than 4.5 volts. The output voltage should increase gradually as the throttle plate is slowly opened from idle to WOT. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Component Test > Page 3810 Throttle Position Sensor: Testing and Inspection Helpful Information Circuit K6 splices to supply 5 Volts to the manifold absolute pressure sensor, crankshaft position sensor and camshaft position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Crankshaft position sensor - Intake air temperature sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Testing and Inspection > Page 3811 Throttle Position Sensor: Service and Repair Fig 71 TPS Mounting Bolts Fig 72 Installation - Typical REMOVAL 1. Remove air duct at throttle body. 2. Disconnect TPS electrical connector. 3. Remove two TPS mounting bolts (Fig. 71). 4. Remove TPS from throttle body. NOTES: - The throttle shaft end of the throttle body slides into a socket in the TPS (Fig. 72). - The TPS must be installed so that it can be rotated a few degrees. - If the sensor will not rotate, install the sensor with the throttle shaft on the other side of the socket tangs. - The TPS will be under slight tension when rotated. INSTALLATION 1. Install the TPS and two retaining bolts. 2. Tighten bolts to 7 Nm (60 in lb) torque. 3. Manually operate the throttle control lever by hand to check for any binding of the TPS. 4. Connect TPS electrical connector to TPS. 5. Install air duct at throttle body. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations Engine Firing Order - 3.9L Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Timing Marks and Indicators > System Information > Locations Timing Marks and Indicators: Locations Align Timing Marks The timing marks are located on the timing cover, next to the vibration damper. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations Camshaft Position Sensor: Component Locations Camshaft Position Sensor The Camshaft Position (CMP) Sensor is mounted in the distributor housing. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 3824 Distributor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3825 CPS Connector Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3826 Camshaft Position Sensor: Description and Operation LOCATION The camshaft position sensor is located in the distributor on all engines. DESCRIPTION The sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft. The pulse ring rotates 180 degrees through the sync signal generator. Its signal is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. OPERATION When the leading edge of the pulse ring (shutter) enters the sync signal generator, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a sync signal of approximately 5 volts. When the trailing edge of the pulse ring (shutter) leaves the sync signal generator, the change of the magnetic field causes the sync signal voltage to switch low to 0 volts. CIRCUIT OPERATION The camshaft position sensor is located internal to the distributor on all engine applications. The Powertrain Control Module (PCM) supplies 5 Volts to the camshaft position sensor on circuit K6. Circuit K6 connects to cavity A17 of the PCM. The PCM receives the camshaft position sensor signal on circuit K44. Circuit K44 connects to cavity A18 of the PCM. The PCM provides a ground for the camshaft position sensor (circuit K44) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3827 Camshaft Position Sensor: Testing and Inspection Circuit K6 splices to supply 5 Volts to the crankshaft position sensor, manifold absolute pressure sensor, and throttle position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Crankshaft position sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3828 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor NOTE: Distributor removal is not necessary to remove camshaft position sensor. REMOVAL 1. Remove air cleaner assembly 2. Disconnect negative cable from battery 3. Remove distributor cap from distributor (two screws). 4. Disconnect camshaft position sensor wiring harness from main engine wiring harness. 5. Remove distributor rotor from distributor shaft. 6. Lift the camshaft position sensor assembly from the distributor housing. INSTALLATION 1. Install camshaft position sensor to distributor. Align sensor into notch on distributor housing. 2. Connect wiring harness. 3. Install rotor 4. Install distributor cap. Tighten mounting screws. 5. Install air cleaner assembly. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications DESCRIPTION .................................................................................................................................... .............................................................. TORQUE Crankshaft Position Sensor ................................................................................................................. .......................................................... 8 Nm (70 in lb) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3832 Crankshaft Position Sensor: Locations Crankshaft Position Sensor The sensor is located on the top of cylinder block near the rear of right cylinder head. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3833 CKP Connector Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3834 Crankshaft Position Sensor: Description and Operation Fig. 4 Sensor Operation DESCRIPTION The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. The flywheel/drive plate has groups of notches at its outer edge. there are three sets of double notches and three sets of single notches. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. OPERATION Engine speed and crankshaft position are provided through the 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. CIRCUIT OPERATION The Powertrain Control Module (PCM) supplies 5 Volts to the crankshaft position sensor on circuit K6. Circuit K6 connects to cavity A17 of the PCM. The PCM receives the crankshaft position sensor signal on circuit K24. Circuit K24 connects to cavity A8 of the PCM. The PCM provides a ground for the crankshaft position sensor (circuit K24) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector. NOTE: The engine will not operate if the PCM does not receive a crankshaft position sensor input. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3835 Crankshaft Position Sensor: Testing and Inspection Circuit K6 splices to supply 5 Volts to the camshaft position sensor, manifold absolute pressure sensor, and throttle position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3836 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor NOTE: The sensor is bolted to the top of the cylinder block near the rear of right cylinder head. The sensor is accessed by removing the right front fender liner. REMOVAL 1. Remove right front tire and right front wheelhouse liner. 2. Disconnect crankshaft position sensor pigtail harness from main wiring harness. 3. Remove two sensor (recessed hex head) mounting bolts. 4. Remove sensor from engine. INSTALLATION 1. Position crankshaft position sensor to engine. 2. Install mounting bolts and tighten to 8 Nm (70 in lb) torque. 3. Connect main harness electrical connector to sensor. 4. Install right front tire and right front wheelhouse liner. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Distributor Cap > Component Information > Testing and Inspection Distributor Cap: Testing and Inspection Fig. 22 Cap Inspection - External - Typical (V6 Shown) Fig. 23 Cap Inspection - Internal - Typical (V6 Shown) Remove the distributor cap and wipe it clean with a dry lint free cloth. Visually inspect the cap for cracks, carbon paths, broken towers or damaged rotor button. Also check for white deposits on the inside (caused by condensation entering the cap through cracks). Replace any cap that displays charred or eroded terminals. NOTE: A small amount of erosion is expected from normal operation. Examine the terminal ends for evidence of mechanical interference with the rotor tip. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Ignition Rotor > Component Information > Testing and Inspection Ignition Rotor: Testing and Inspection Fig. 24 Rotor Inspection - Typical Visually inspect the rotor for cracks, evidence of corrosion, or the effects of arcing on the metal tip. Also check for evidence of mechanical interference with the cap. Some charring is normal on the end of the metal tip. The silicone-dielectric-varnish-compound applied to the rotor tip for radio interference noise suppression, will appear charred. This is normal. Do not remove the charred compound. Test the spring for insufficient tension. Replace a rotor that displays any of these adverse conditions. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction Technical Service Bulletin # 18-48-98 Date: 981230 Ignition System - Cross Fire/Ignition Wire Induction NO: 18-48-98 GROUP: Vehicle Performance DATE: Dec. 30, 1998 SUBJECT: Ignition System Cross Fire/Secondary Ignition Wire Induction MODELS: 1994 - 1999 (AN) Dakota 1994 - 1999 (BR/BE)Ram Truck 1998 - 1999 (DN) Durango 1995 - 1998 (ZG) Grand Cherokee (International Market) 1994 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 3.9L, 5.2L, OR 5.9L ENGINE. AB MODELS WILL BE ADDED LATER (NEW PARTS REQUIRED). SYMPTOM/CONDITION: Some vehicles may exhibit one or more of the following: Spark knock complaints when the vehicle is under load. Various single cylinder misfire (1, 3, 7), especially 5 and/or 8. Surge in 4th gear with the Electronically Modulated Converter Clutch (EMCC) engaged (around 45 mph). Perceived torque converter EMCC engagement/disengagement around 45 mph. DIAGNOSIS: Using the Mopar Diagnostic System (MDS/MDS 2) or the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If other than mentioned Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present or if the above symptoms/conditions have been described by the customer, perform the Repair Procedure. NOTE: THIS REROUTING PROCEDURE SHOULD BE PERFORMED BEFORE ANY OTHER MISFIRE, SURGE, OR SPARK KNOCK REPAIRS ARE ATTEMPTED. PARTS REQUIRED: 3 56028186 Clip, Single Wire 2 06503441 Clip, Wire To Hose (5.2L & 5.9L) 1 04364375 Convolute, 10 ft Roll POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-12-15-92 - 3.9L (All) 0.2 Hrs. 08-12-15-93 (ZJ) 5.2/5.9L 0.2 Hrs. (AN/DN) 5.2/5.9L 0.3 Hrs. (BR/BE) 5.2/5.9L 0.4 Hrs. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 3852 FAILURE CODE: 9X - Routed Improperly Repair Procedure This bulletin involves rerouting the coil wire for all engines listed and rerouting the 4, 5, 7, and 8 plug wires for the 5.2/5.9L applications to minimize induction effects. NOTE: IF WIRES MUST CROSS DURING THE REROUTE PROCEDURE, THEY MUST CROSS AT A 90° ANGLE. 5.2L and 5.9L Engine Procedures 1. Coil Wire Routing (Figure 1 and 2) A. Remove the coil wire from the distributor cap coil wire tower terminal. B. Remove the coil wire from the rear five-wire clip, the center three-wire clip, and the front one-wire clip located along the lower side of the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover. Use the studs of the valve cover retaining bolts (Figure 1). NOTE: SOME APPLICATIONS MAY ONLY HAVE STUD LOCATIONS FOR 3 OF THE ONE-WIRE CLIPS. D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths 203 mm (8 in.), 101.5 mm (4 in.), and 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the 203 mm (8 in.) and the 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 3853 H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 2). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM AND/OR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. I. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. 2. No.8 Cylinder Plug Wire Routing (Figure 3) A. Remove the No.8 cylinder plug wire from the distributor cap tower terminal. B. Remove the No.8 cylinder plug wire from the five-wire clip located at the lower rear of the valve cover. C. Route the No.8 cylinder plug wire over the rear quarter of the right valve cover (Figure 3). D. Position the original piece convolute from the No.8 cylinder plug wire to prevent chafing at the right valve cover and with other engine components. E. Secure the No.8 cylinder plug wire and its convolute in place with the hose to wire clip p/n 06503441. The small end of the clip is positioned over the convolute. The large end of the clip is fastened to a heater hose (A/C line on ZJ models). NOTE: MAKE SURE THE NO.8 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE COIL WIRE AND THE NO.4 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. F. Install the No.8 cylinder plug wire to its distributor cap terminal. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 3854 3. No.4 Cylinder Plug Wire Routing (Figure 4 and 5) A. Remove the No.4 cylinder plug wire from the distributor cap terminal. B. At the three-wire clip (located at the center of the lower side of the right valve cover), keep the two wires from crossing and chafing each other. Position the No.2 cylinder plug wire in the top wire slot and the No.4 cylinder plug wire in the bottom wire slot. Leave the middle wire slot empty (Figure 5). C. At the five-wire clip (located at the right rear lower side of the valve cover), keep the plug wires from crossing and chafing each other. Position the No.4 cylinder plug wire in a slot that will obtain the maximum amount of distance allowable from the No.8 cylinder plug wire (Figure 6). Remove any slack in the No.4 cylinder plug wire between the three-wire and the five-wire clips. NOTE: EARLIER MODEL FIVE-WIRE CLIPS LOOK SLIGHTLY DIFFERENT BUT THE SAME WIRING LAYOUT APPLIES. D. Route the No.4 cylinder plug wire behind the transmission dipstick tube and heater hoses. On ZJ models this may not be possible due to the location of the bulkhead. NOTE: MAKE SURE THAT THE NO.4 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH AWAY FROM THE NO.8 CYLINDER PLUG WIRE. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 3855 E. Install the No.4 cylinder plug wire to its distributor cap terminal (Figure 7). 4. No.7 Cylinder Plug Wire Routing (Figure 8 and 9) A. Verify that the No.7 cylinder plug wire crosses over the distributor cap and leaves the distributor cap between the No.3 and the No.6 tower terminals (Figure 8). This is the original wire routing for 1998 and prior model years. B. For 1999 M.Y. vehicles the No.7 cylinder plug wire was shortened. Reroute the No.7 cylinder plug wire so that it crosses the distributor cap and leaves the distributor cap between the No.6 and the No.5 tower terminals (Figure 9). NOTE: MAKE SURE THE NO.7 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH, AWAY FROM THE NO.5 CYLINDER PLUG WIRE. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 3856 5. No. 5 Cylinder Plug Wire Routing (Figure 10) A. Remove the No.5 cylinder plug wire from its distributor cap terminal. B. Remove the No.5 cylinder plug wire from the five-wire clip located at the lower rear of the left valve cover. C. Route the No.5 cylinder plug wire over the left valve cover and in front of the breather tube elbow. D. Position the original convolute from the No.5 cylinder plug wire to prevent chafing against the valve cover and any engine components. Secure the small end of the hose to wire clip p/n 06503441 over the convolute. Secure the large end of the hose to wire clip to the breather hose. NOTE: MAKE SURE THE NO.5 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE NO.7 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. 3.9L Engine Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System - Cross Fire/Ignition Wire Induction > Page 3857 1. Coil Wire Routing (Figure 11 and 12) A. Remove the coil wire from the distributor cap tower terminal. B. Remove the coil wire from the right rear five-wire clip, the center three wire clip and the front one-wire clip on the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover studs (Figure 11). D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths. Two (2) at 101.5 mm (4 in.), and one (1) at 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the two 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 12). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM ANDIOR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction Technical Service Bulletin # 18-48-98 Date: 981230 Ignition System - Cross Fire/Ignition Wire Induction NO: 18-48-98 GROUP: Vehicle Performance DATE: Dec. 30, 1998 SUBJECT: Ignition System Cross Fire/Secondary Ignition Wire Induction MODELS: 1994 - 1999 (AN) Dakota 1994 - 1999 (BR/BE)Ram Truck 1998 - 1999 (DN) Durango 1995 - 1998 (ZG) Grand Cherokee (International Market) 1994 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 3.9L, 5.2L, OR 5.9L ENGINE. AB MODELS WILL BE ADDED LATER (NEW PARTS REQUIRED). SYMPTOM/CONDITION: Some vehicles may exhibit one or more of the following: Spark knock complaints when the vehicle is under load. Various single cylinder misfire (1, 3, 7), especially 5 and/or 8. Surge in 4th gear with the Electronically Modulated Converter Clutch (EMCC) engaged (around 45 mph). Perceived torque converter EMCC engagement/disengagement around 45 mph. DIAGNOSIS: Using the Mopar Diagnostic System (MDS/MDS 2) or the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If other than mentioned Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present or if the above symptoms/conditions have been described by the customer, perform the Repair Procedure. NOTE: THIS REROUTING PROCEDURE SHOULD BE PERFORMED BEFORE ANY OTHER MISFIRE, SURGE, OR SPARK KNOCK REPAIRS ARE ATTEMPTED. PARTS REQUIRED: 3 56028186 Clip, Single Wire 2 06503441 Clip, Wire To Hose (5.2L & 5.9L) 1 04364375 Convolute, 10 ft Roll POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-12-15-92 - 3.9L (All) 0.2 Hrs. 08-12-15-93 (ZJ) 5.2/5.9L 0.2 Hrs. (AN/DN) 5.2/5.9L 0.3 Hrs. (BR/BE) 5.2/5.9L 0.4 Hrs. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction > Page 3863 FAILURE CODE: 9X - Routed Improperly Repair Procedure This bulletin involves rerouting the coil wire for all engines listed and rerouting the 4, 5, 7, and 8 plug wires for the 5.2/5.9L applications to minimize induction effects. NOTE: IF WIRES MUST CROSS DURING THE REROUTE PROCEDURE, THEY MUST CROSS AT A 90° ANGLE. 5.2L and 5.9L Engine Procedures 1. Coil Wire Routing (Figure 1 and 2) A. Remove the coil wire from the distributor cap coil wire tower terminal. B. Remove the coil wire from the rear five-wire clip, the center three-wire clip, and the front one-wire clip located along the lower side of the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover. Use the studs of the valve cover retaining bolts (Figure 1). NOTE: SOME APPLICATIONS MAY ONLY HAVE STUD LOCATIONS FOR 3 OF THE ONE-WIRE CLIPS. D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths 203 mm (8 in.), 101.5 mm (4 in.), and 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the 203 mm (8 in.) and the 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction > Page 3864 H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 2). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM AND/OR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. I. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. 2. No.8 Cylinder Plug Wire Routing (Figure 3) A. Remove the No.8 cylinder plug wire from the distributor cap tower terminal. B. Remove the No.8 cylinder plug wire from the five-wire clip located at the lower rear of the valve cover. C. Route the No.8 cylinder plug wire over the rear quarter of the right valve cover (Figure 3). D. Position the original piece convolute from the No.8 cylinder plug wire to prevent chafing at the right valve cover and with other engine components. E. Secure the No.8 cylinder plug wire and its convolute in place with the hose to wire clip p/n 06503441. The small end of the clip is positioned over the convolute. The large end of the clip is fastened to a heater hose (A/C line on ZJ models). NOTE: MAKE SURE THE NO.8 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE COIL WIRE AND THE NO.4 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. F. Install the No.8 cylinder plug wire to its distributor cap terminal. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction > Page 3865 3. No.4 Cylinder Plug Wire Routing (Figure 4 and 5) A. Remove the No.4 cylinder plug wire from the distributor cap terminal. B. At the three-wire clip (located at the center of the lower side of the right valve cover), keep the two wires from crossing and chafing each other. Position the No.2 cylinder plug wire in the top wire slot and the No.4 cylinder plug wire in the bottom wire slot. Leave the middle wire slot empty (Figure 5). C. At the five-wire clip (located at the right rear lower side of the valve cover), keep the plug wires from crossing and chafing each other. Position the No.4 cylinder plug wire in a slot that will obtain the maximum amount of distance allowable from the No.8 cylinder plug wire (Figure 6). Remove any slack in the No.4 cylinder plug wire between the three-wire and the five-wire clips. NOTE: EARLIER MODEL FIVE-WIRE CLIPS LOOK SLIGHTLY DIFFERENT BUT THE SAME WIRING LAYOUT APPLIES. D. Route the No.4 cylinder plug wire behind the transmission dipstick tube and heater hoses. On ZJ models this may not be possible due to the location of the bulkhead. NOTE: MAKE SURE THAT THE NO.4 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH AWAY FROM THE NO.8 CYLINDER PLUG WIRE. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction > Page 3866 E. Install the No.4 cylinder plug wire to its distributor cap terminal (Figure 7). 4. No.7 Cylinder Plug Wire Routing (Figure 8 and 9) A. Verify that the No.7 cylinder plug wire crosses over the distributor cap and leaves the distributor cap between the No.3 and the No.6 tower terminals (Figure 8). This is the original wire routing for 1998 and prior model years. B. For 1999 M.Y. vehicles the No.7 cylinder plug wire was shortened. Reroute the No.7 cylinder plug wire so that it crosses the distributor cap and leaves the distributor cap between the No.6 and the No.5 tower terminals (Figure 9). NOTE: MAKE SURE THE NO.7 CYLINDER PLUG WIRE IS, AT LEAST ONE INCH, AWAY FROM THE NO.5 CYLINDER PLUG WIRE. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction > Page 3867 5. No. 5 Cylinder Plug Wire Routing (Figure 10) A. Remove the No.5 cylinder plug wire from its distributor cap terminal. B. Remove the No.5 cylinder plug wire from the five-wire clip located at the lower rear of the left valve cover. C. Route the No.5 cylinder plug wire over the left valve cover and in front of the breather tube elbow. D. Position the original convolute from the No.5 cylinder plug wire to prevent chafing against the valve cover and any engine components. Secure the small end of the hose to wire clip p/n 06503441 over the convolute. Secure the large end of the hose to wire clip to the breather hose. NOTE: MAKE SURE THE NO.5 CYLINDER PLUG WIRE IS SECURE AND AWAY FROM THE NO.7 CYLINDER PLUG WIRE. MAKE CERTAIN IT WILL NOT FALL DOWN AND CONTACT THE CYLINDER HEAD AND/OR EXHAUST COMPONENTS. 3.9L Engine Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-48-98 > Dec > 98 > Ignition System Cross Fire/Ignition Wire Induction > Page 3868 1. Coil Wire Routing (Figure 11 and 12) A. Remove the coil wire from the distributor cap tower terminal. B. Remove the coil wire from the right rear five-wire clip, the center three wire clip and the front one-wire clip on the right valve cover. C. Install three (3) one-wire clips p/n 56028186 along the top and front of the valve cover studs (Figure 11). D. Route the coil wire starting from the ignition coil toward the distributor. Any excess wire should end up at the distributor end. E. Install the coil wire into the one-wire clips. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the one-wire clips are attached to the valve cover studs). F. Cut the ignition wire convolute p/n 04364375 into three lengths. Two (2) at 101.5 mm (4 in.), and one (1) at 82.5 mm (3.25 in.). G. Slit and install the three sections of convolute onto the coil wire between the one-wire clips. Install the 82.5 mm (3.25 in.) section at the front of the right valve cover. Install the two 101.5 mm (4 in.) sections along the top side of the right valve cover. This procedure may be easier to perform while the coil wire is loose from the valve cover (before the clips are attached to the valve cover studs). H. Route the distributor end of the coil wire down and behind the intake manifold, in front of the oil pressure switch (Figure 12). NOTE: THE COIL WIRE MUST BE A MINIMUM OF ONE (1) INCH AWAY FROM ANY OTHER IGNITION WIRES. THIS MAY REQUIRE THAT THE COIL WIRE BE ROUTED UNDER VACUUM ANDIOR WIRE HARNESSES IN THE RIGHT REAR CORNER OF THE INTAKE MANIFOLD. Route the distributor end of the coil wire up the side of the distributor cap and onto the coil wire tower terminal. J. Position the original piece of coil wire convolute so it protects the wire against chafing with components at the rear of the engine. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Page 3869 Ignition Cable: Specifications Minimum ..................................................................................................................................................... 250 ohms per inch (3,000 ohms per foot) Maximum ............................................................................................................................................... 1,000 ohms per inch (12,000 ohms per foot) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Page 3870 Ignition Cable: Description and Operation DESCRIPTION Spark plug cables are sometimes referred to as secondary ignition wires. The resistive spark plug cables are of nonmetallic construction. OPERATION These cables transfer electrical current from the ignition coil(s) and/or distributor, to individual spark plugs at each cylinder. The cables provide suppression of radio frequency emissions from the ignition system. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Page 3871 Ignition Cable: Service and Repair Fig. 11 Cable Removal CAUTION: When disconnecting a high voltage cable from a spark plug or from the distributor cap, twist the rubber boot slightly (1/2 turn) to break it loose. Grasp the boot (not the cable) and pull it off with a steady, even force. When replacing the spark plug and coil cables, route the cables correctly and secure in the proper retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise. It could also cause cross ignition of the plugs or short circuit the cables to ground. When installing new cables, make sure a positive connection is made. A snap should be felt when a good connection is made between the plug cable and the distributor cap tower. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Electrical Specifications Ignition Coil: Electrical Specifications Toyodenso Coil Primary ................................................................................................................................................ ............................................. 0.95 - 1.20 ohms Secondary ........................................................................................................................................... ....................................... 11,300 - 13,300 ohms Diamond Coil Primary ................................................................................................................................................ ............................................. 0.97 - 1.18 ohms Secondary ........................................................................................................................................... ...................................... 11,300 - 15,300 ohms Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Electrical Specifications > Page 3876 Ignition Coil: Mechanical Specifications DESCRIPTION .................................................................................................................................... .............................................................. TORQUE Ignition Coil Mounting if tapped bolts are used ........................................................................................................................................... 5 Nm (50 in lb) Ignition Coil Mounting if nuts/bolts are used ........................................................................................................................................... 11 Nm (100 in lb) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 3877 V6/V8 Coil Location Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 3878 Coil Connector Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 3879 Ignition Coil: Description and Operation DESCRIPTION Battery voltage is supplied to the ignition coil positive terminal from the Auto Shutdown (ASD) relay. The ignition coil is not oil filled. The windings are embedded in an epoxy compound. This provides heat and vibration resistance that allows the ignition coil to be mounted on the engine. OPERATION The Powertrain Control Module (PCM) opens and closes the ignition coil ground circuit for ignition coil operation. Base ignition timing is not adjustable on any engine. By controlling the coil ground circuit, the PCM is able to set the base timing and adjust the ignition timing advance. This is done to meet changing engine operating conditions. CIRCUIT OPERATION When the Powertrain Control Module (PCM) grounds the Automatic Shut Down (ASD) relay, the contacts CLOSE and connect circuits A16 and A142. Circuit A142 supplies battery voltage to the ignition coil. The PCM controls the ground path for the ignition coil on circuit K19. Circuit K19 connects to cavity A7 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Testing and Inspection > Helpful Information Ignition Coil: Testing and Inspection Helpful Information - Circuit A142 splices to supply voltage to the fuel injectors, ignition coil, and heated oxygen sensor. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Testing and Inspection > Helpful Information > Page 3882 Ignition Coil: Testing and Inspection Ignition Coil Test Fig. 13 Ignition Coil - Typical The ignition coil is designed to operate without an external ballast resistor. Ignition Coil Resistance Inspect the ignition coil for arcing. Test the coil according to coil tester manufacturer's instructions. Test the coil primary and secondary resistance. Replace any coil that does not meet specifications. Refer to the Ignition Coil Resistance chart. If the ignition coil is being replaced, the secondary spark plug cable must also be checked. Replace cable if it has been burned or damaged. Arcing at the tower will carbonize the cable boot, which if it is connected to a new ignition coil, will cause the coil to fail. If the secondary coil cable shows any signs of damage, it should be replaced with a new cable and new terminal. Carbon tracking on the old cable can cause arcing and the failure of a new ignition coil. For more information, see Powertrain Management/Testing and Inspection. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Testing and Inspection > Page 3883 Ignition Coil: Service and Repair 1. Disconnect primary wiring from ignition coil. 2. Disconnect ignition coil secondary spark plug cable from ignition coil. 3. Remove ignition coil from mounting bracket. 4. Reverse procedure to install. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations Camshaft Position Sensor: Component Locations Camshaft Position Sensor The Camshaft Position (CMP) Sensor is mounted in the distributor housing. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 3889 Distributor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3890 CPS Connector Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3891 Camshaft Position Sensor: Description and Operation LOCATION The camshaft position sensor is located in the distributor on all engines. DESCRIPTION The sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft. The pulse ring rotates 180 degrees through the sync signal generator. Its signal is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. OPERATION When the leading edge of the pulse ring (shutter) enters the sync signal generator, the following occurs: The interruption of magnetic field causes the voltage to switch high resulting in a sync signal of approximately 5 volts. When the trailing edge of the pulse ring (shutter) leaves the sync signal generator, the change of the magnetic field causes the sync signal voltage to switch low to 0 volts. CIRCUIT OPERATION The camshaft position sensor is located internal to the distributor on all engine applications. The Powertrain Control Module (PCM) supplies 5 Volts to the camshaft position sensor on circuit K6. Circuit K6 connects to cavity A17 of the PCM. The PCM receives the camshaft position sensor signal on circuit K44. Circuit K44 connects to cavity A18 of the PCM. The PCM provides a ground for the camshaft position sensor (circuit K44) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3892 Camshaft Position Sensor: Testing and Inspection Circuit K6 splices to supply 5 Volts to the crankshaft position sensor, manifold absolute pressure sensor, and throttle position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Crankshaft position sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3893 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor NOTE: Distributor removal is not necessary to remove camshaft position sensor. REMOVAL 1. Remove air cleaner assembly 2. Disconnect negative cable from battery 3. Remove distributor cap from distributor (two screws). 4. Disconnect camshaft position sensor wiring harness from main engine wiring harness. 5. Remove distributor rotor from distributor shaft. 6. Lift the camshaft position sensor assembly from the distributor housing. INSTALLATION 1. Install camshaft position sensor to distributor. Align sensor into notch on distributor housing. 2. Connect wiring harness. 3. Install rotor 4. Install distributor cap. Tighten mounting screws. 5. Install air cleaner assembly. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications DESCRIPTION .................................................................................................................................... .............................................................. TORQUE Crankshaft Position Sensor ................................................................................................................. .......................................................... 8 Nm (70 in lb) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3897 Crankshaft Position Sensor: Locations Crankshaft Position Sensor The sensor is located on the top of cylinder block near the rear of right cylinder head. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3898 CKP Connector Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3899 Crankshaft Position Sensor: Description and Operation Fig. 4 Sensor Operation DESCRIPTION The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. The flywheel/drive plate has groups of notches at its outer edge. there are three sets of double notches and three sets of single notches. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. OPERATION Engine speed and crankshaft position are provided through the 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. CIRCUIT OPERATION The Powertrain Control Module (PCM) supplies 5 Volts to the crankshaft position sensor on circuit K6. Circuit K6 connects to cavity A17 of the PCM. The PCM receives the crankshaft position sensor signal on circuit K24. Circuit K24 connects to cavity A8 of the PCM. The PCM provides a ground for the crankshaft position sensor (circuit K24) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector. NOTE: The engine will not operate if the PCM does not receive a crankshaft position sensor input. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3900 Crankshaft Position Sensor: Testing and Inspection Circuit K6 splices to supply 5 Volts to the camshaft position sensor, manifold absolute pressure sensor, and throttle position sensor. Circuit K4 splices to supply ground for the signals from the following: - Heated oxygen sensors - Camshaft position sensor - Intake air temperature sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Vehicle speed sensor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3901 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor NOTE: The sensor is bolted to the top of the cylinder block near the rear of right cylinder head. The sensor is accessed by removing the right front fender liner. REMOVAL 1. Remove right front tire and right front wheelhouse liner. 2. Disconnect crankshaft position sensor pigtail harness from main wiring harness. 3. Remove two sensor (recessed hex head) mounting bolts. 4. Remove sensor from engine. INSTALLATION 1. Position crankshaft position sensor to engine. 2. Install mounting bolts and tighten to 8 Nm (70 in lb) torque. 3. Connect main harness electrical connector to sensor. 4. Install right front tire and right front wheelhouse liner. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Description and Operation Ignition Switch: Description and Operation IGNITION SWITCH AND KEY LOCK CYLINDER The ignition switch is located on the steering column. The Key-In-Switch is located in the ignition switch module. For electrical diagnosis of the Key-In-Switch, refer to Chime/Buzzer Warning Systems. For removal/installation of either the key lock cylinder or ignition switch, refer to Ignition Switch and Key Cylinder Removal/Installation. On vehicles equipped with an automatic transmission, a cable connects an interlock device within the steering column assembly to the transmission floor shift lever. This interlock device is used to lock the transmission shifter in the PARK position when the key is in the LOCKED or ACCESSORY position. The interlock device is not serviceable. If repair is necessary, the steering column assembly must be replaced. Refer to procedures. The shifter interlock cable can be adjusted or replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Description and Operation > Page 3905 Ignition Switch: Service and Repair Fig 46 Shroud Removal/Installation - Typical IGNITION SWITCH AND KEY CYLINDER The ignition key must be in the key cylinder for cylinder removal. KEY CYLINDER REMOVAL 1. Disconnect negative cable from battery. 2. If equipped with tilt column, remove tilt lever by turning it counterclockwise. 3. Remove upper and lower covers (shrouds) from steering column. 4. If equipped with automatic transmission, place shifter in PARK position. Fig 47 Retaining Pin 5. A retaining pin is located at side of key cylinder assembly. a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder from ignition switch. IGNITION SWITCH REMOVAL 1. Remove key lock cylinder. Refer to previous steps. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Description and Operation > Page 3906 Fig 48 Switch Mounting Screws 2. Remove 3 ignition switch mounting screws. Use tamper proof torx bit (Snap-On SDMTR10 or equivalent) to remove screws. 3. Gently pull switch away from column. Release connector locks on 7-terminal wiring connector at ignition switch and remove connector. 4. Release connector lock on 4-terminal halo lamp wiring connector and remove connector. IGNITION SWITCH AND KEY CYLINDER INSTALLATION If installing ignition key lock cylinder only, proceed to following steps 2, 3 and 4. Also refer to following steps 12 through 18. If installing both switch and key cylinder, refer to steps 1 through 18. Fig 50 Flag In RUN Position Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Description and Operation > Page 3907 Fig 51 Key Cylinder - Rear View 1. Rotate flag on rear of ignition switch until in RUN position. This step must be done to allow tang on key cylinder to fit into slots within ignition switch. Fig 52 Installing Key Cylinder Into Switch 2. With key into ignition key cylinder, rotate key clockwise until retaining pin can be depressed. 3. Install key cylinder into ignition switch by aligning retaining pin into retaining pin slot. Push key cylinder into switch until retaining pin engages. After pin engages, rotate key to OFF or LOCK position. 4. Check for proper retention of key cylinder by attempting to pull cylinder from switch. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Description and Operation > Page 3908 Fig 53 Ignition Switch View From Column Fig 54 Park Lock Linkage - Automatic Transmission - Typical 5. Automatic Transmission Only: Before attaching ignition switch to steering column, the transmission shifter must be in PARK position. The park lock dowel pin on rear of ignition switch must also be properly indexed into the park lock linkag before installing switch. 6. The flag at rear of ignition switch must be properly indexed into steering column before installing switch. This flag is used to operate the steering wheel lock lever in steering column. This lever allows steering wheel position to be locked when key switch is in LOCK position. 7. Place ignition switch in LOCK position. The switch is in the LOCK position when column lock flag is parallel to ignition switch terminals. 8. Automatic Transmission Only: Apply a light coating of grease to park lock dowel pin and park lock slider linkage. Before installing switch, push the park lock slider linkage forward until it bottoms. Do a final positioning by pulling it rearward about one-quarter inch. 9. Apply a light coating of grease to both column lock flag and shaft at end of flag. 10. Place ignition switch into openings on steering column. a. Automatic Transmission Only: Be sure park lock dowel pin on rear of ignition switch enters slot in park lock slider linkage. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Description and Operation > Page 3909 Fig 55 Steering Wheel Lock Lever b. Be sure flag on rear of switch is positioned above steering wheel lock lever. c. Align dowel pins on rear of switch into holes on side of steering column. d. Install 3 ignition switch mounting screws. Tighten screws to 3 Nm +/- 5 Nm (26 in lb +/- 4 in lb) torque. 11. Connect electrical connectors to ignition switch and halo lamp. Make sure that switch locking tabs are fully seated in wiring connectors. 12. Install steering column covers (shrouds). Tighten screws to 2 Nm (17 in lb) torque. 13. Install tilt column lever (if equipped). 14. Connect negative cable to battery. 15. Check for proper operation of halo light. 16. Automatic Transmission Only: Shifter should lock in PARK position when key is in LOCK position (if equipped with shift lock device). Shifter should unlock when key rotated to ON position. 17. Check for proper operation of ignition switch in ACCESSORY, LOCK, OFF, ON, RUN, and START positions. 18. Steering wheel should lock when key is in LOCK position. Rotate steering wheel to verify Steering wheel should unlock when key is rotated to ON position. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications Spark Plug: Specifications Electrode Gap ...................................................................................................................................... ..................................................... 1.01 mm (0.040 in) Torque ............................................................ ............................................................................................................................................. 41 Nm (30 ft. lb.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3913 Spark Plug: Application and ID Plug Type ............................................................................................................................................ .................................................................... RC12LC4 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3914 Spark Plug: Description and Operation DESCRIPTION All engines use resistor type spark plugs. 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 recommended intervals. Spark plugs that have low milage may be cleaned and reused if not otherwise defective, carbon or oil fouled. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator Spark Plug: Testing and Inspection Broken, Cracked or Chipped 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 Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 3917 Spark Plug: Testing and Inspection Brown to Gray/Tan Color - Normal Operating Condition Normal Operation And Carbon Fouling The few deposits present on the spark plug will probably be light tan or slightly gray in color. This is evident with most grades of commercial gasoline. There will not be evidence of electrode burning. Gap growth will not average more than approximately 0.025 mm (.001 in) per 1600 km (1000 miles) of operation. Spark plugs that have normal wear can usually be cleaned, have the electrodes filed, have the gap set and then be installed. Some fuel refiners in several areas of the United States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT causes the entire tip of the spark plug to be coated with a rust colored deposit. This rust color can be misdiagnosed as being caused by coolant in the combustion chamber. Spark plug performance is not affected by MMT deposits. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 3918 Spark Plug: Testing and Inspection Dry, Fluffy Black Deposits - Cold or Carbon Fouling Normal Operation And Carbon Fouling Cold fouling is sometimes referred to as carbon fouling. The deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or defective spark plug cables. Cold (carbon) fouling of the entire set of spark plugs may be caused by a clogged air filter or repeated short operating times (short trips). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 3919 Spark Plug: Testing and Inspection 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 Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 3920 Spark Plug: Testing and Inspection Broken, Cracked or Chipped 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. Brown to Gray/Tan Color - Normal Operating Condition Normal Operation And Carbon Fouling The few deposits present on the spark plug will probably be light tan or slightly gray in color. This is evident with most grades of commercial gasoline. There will not be evidence of electrode burning. Gap growth will not average more than approximately 0.025 mm (.001 in) per 1600 km (1000 miles) of operation. Spark plugs that have normal wear can usually be cleaned, have the electrodes filed, have the gap set and then be installed. Some fuel refiners in several areas of the United States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT causes the entire tip of the spark plug to be coated with a rust colored deposit. This rust color can be misdiagnosed as being caused by coolant in the combustion chamber. Spark plug performance is not affected by MMT deposits. Dry, Fluffy Black Deposits - Cold or Carbon Fouling Normal Operation And Carbon Fouling Cold fouling is sometimes referred to as carbon fouling. The deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a set may be caused by sticking valves or defective spark plug cables. Cold (carbon) fouling of the entire set of spark plugs may be caused by a clogged air filter or repeated short operating times (short trips). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 3921 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. 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. Overheating Spark Plug Overheating Overheating is indicated by a white or gray center electrode insulator that also appears blistered. The increase in electrode gap will be considerably in excess of 0.001 inch per 1000 miles of operation. This suggests that a plug with a cooler heat range rating should be used. Over advanced ignition Premature Electrode Wear - Preignition Damage Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 3922 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.) 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. 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 Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Page 3923 Spark Plug: Service and Repair Fig. 31 Heat Shields Spark plug cable heat shields are pressed into the cylinder head to surround each cable boot and spark plug. If removal of the heat shield(s) is necessary, remove the spark plug cable and compress the sides of shield for removal. Each shield is slotted to allow for compression and removal. To install the shields, align shield to machined opening in cylinder head and tap into place with a block of wood. Fig. 11 Cable Removal PLUG REMOVAL 1. Always remove spark plug or ignition coil cables by grasping at the cable boot. Turn the cable boot 1/2 turn and pull straight back in a steady motion. Never pull directly on the cable. Internal damage to cable will result. 2. Prior to removing the spark plug, spray compressed air around the spark plug hole and the area around the spark plug. This will help prevent foreign material from entering the combustion chamber. 3. Remove the spark plug using a quality socket with a rubber or foam insert. 4. Inspect the spark plug condition. PLUG CLEANING The plugs may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file the center electrode flat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator and will cause plug misfire. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Page 3924 Fig. 44 Setting Spark Plug Gap - Typical PLUG GAP ADJUSTMENT Check the spark plug gap with a gap gauge tool. If the gap is not correct, adjust it by bending the ground electrode. Never attempt to adjust the gap by bending the center electrode. SPARK PLUG GAP 1.01 mm (0.040 in). PLUG INSTALLATION Special care should be taken when installing spark plugs into the cylinder head spark plug wells. Be sure the plugs do not drop into the plug wells as electrodes can be damaged. Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap or a cracked porcelain insulator. When replacing the spark plug and ignition coil cables, route the cables correctly and secure them in the appropriate retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise. It could cause cross ignition of the spark plugs or short circuit the cables to ground. 1. Start the spark plug into the cylinder head by hand to avoid cross threading. 2. Tighten spark plugs to 35-41 Nm (26-30 ft lb) torque. 3. Install spark plug cables over spark plugs. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold Pressure Regulating Solenoid: Customer Interest A/T - Buzz/Whining in Reverse When Cold NUMBER: 21-08-99 GROUP: Transmission DATE: April 30, 1999 SUBJECT: "Buzz", "Whining", Or "Moaning" Like Noise From A Cold Transmission When Reverse Is Selected. OVERVIEW: This bulletin involves replacing the transmission regulator valve. MODELS: 1996 - 1999 (AB) Ram Van 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (TJ) Wrangler 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1999 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A RE OR RH AUTOMATIC TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may exhibit an intermittent noise from the transmission when reverse gear is selected. This noise has been described as a "buzz", whining", or "moaning" like noise. The noise is most noticeable when transmission fluid temperature is below 38 C. (100 F.). The condition is caused by a resonance of the transmission regulator valve system. Other items may cause regulator valve resonance, including air ingestion into the valve body or out of specification parts. These two items may be the result a possible cracked pump housing, a torn pump gasket, an under filled transmission, a restricted fluid filter or cooler flow, or an out of specification valve and/or valve body. You should remember these additional items / components when you perform your diagnosis. Vehicles built prior to August 1, 1995 may experience this condition if either a transmission valve body or an entire automatic transmission was replaced with components manufactured after August 1, 1995. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostics Procedure Manual, verify all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. For 1996 and 1997 model year product, review Technical Service Bulletin 21-11-97 Rev A to determine if it applies to this vehicle before attempting to complete the analysis or repairs described in this bulletin. In most instances, the sump temperature of vehicles exhibiting transmission regulator valve resonance in reverse has been less than 38 C. (100 F). If possible, allow the suspect vehicle to remain parked in a cool place overnight. Then perform the following steps: 1. Set the vehicle parking brake. 2. Start the engine (make certain windows are closed, to eliminate outside noise). 3. With brakes applied, place the transmission selector lever in reverse. 4. Listen for any buzz/moaning/whining like noises as the transmission sump temperature rises to normal operating temperature (180 - 210 degrees F). 5. If a buzz/moaning/whining like noise is present, perform the Repair Procedure. PARTS REQUIRED: 1 04130169 Valve, Steel Transmission Regulator Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold > Page 3936 1 02464324 Gasket, Transmission Pan AR 05010124AA Fluid, ATF Plus 3, Type 7176E EQUIPMENT REQUIRED: 1 C-3763 Gauge Tool, Throttle Pressure Adjustment REPAIR PROCEDURE: 1. Following the procedures in the applicable service manual, remove the valve body from the transmission (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - REMOVAL AND INSTALLATION). 2. Remove the screws holding the adjusting screw bracket and replace the regulator valve with p/n 04130169 (Figure 1). Install the adjusting screw bracket 3. Verify and adjust, if necessary, both the line pressure and the throttle pressure settings by following the procedures in the service manual (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section ADJUSTMENTS - VALVE BODY). 4. Following the procedures in the appropriate Service Manual, re-install the valve body with the new regulator valve into the transmission. 5. After filling the transmission with the proper automatic transmission fluid, and verifying correct fill level, check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - ADJUSTMENTS - TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-90 1.2 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold Pressure Regulating Solenoid: All Technical Service Bulletins A/T - Buzz/Whining in Reverse When Cold NUMBER: 21-08-99 GROUP: Transmission DATE: April 30, 1999 SUBJECT: "Buzz", "Whining", Or "Moaning" Like Noise From A Cold Transmission When Reverse Is Selected. OVERVIEW: This bulletin involves replacing the transmission regulator valve. MODELS: 1996 - 1999 (AB) Ram Van 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (TJ) Wrangler 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1999 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A RE OR RH AUTOMATIC TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may exhibit an intermittent noise from the transmission when reverse gear is selected. This noise has been described as a "buzz", whining", or "moaning" like noise. The noise is most noticeable when transmission fluid temperature is below 38 C. (100 F.). The condition is caused by a resonance of the transmission regulator valve system. Other items may cause regulator valve resonance, including air ingestion into the valve body or out of specification parts. These two items may be the result a possible cracked pump housing, a torn pump gasket, an under filled transmission, a restricted fluid filter or cooler flow, or an out of specification valve and/or valve body. You should remember these additional items / components when you perform your diagnosis. Vehicles built prior to August 1, 1995 may experience this condition if either a transmission valve body or an entire automatic transmission was replaced with components manufactured after August 1, 1995. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostics Procedure Manual, verify all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. For 1996 and 1997 model year product, review Technical Service Bulletin 21-11-97 Rev A to determine if it applies to this vehicle before attempting to complete the analysis or repairs described in this bulletin. In most instances, the sump temperature of vehicles exhibiting transmission regulator valve resonance in reverse has been less than 38 C. (100 F). If possible, allow the suspect vehicle to remain parked in a cool place overnight. Then perform the following steps: 1. Set the vehicle parking brake. 2. Start the engine (make certain windows are closed, to eliminate outside noise). 3. With brakes applied, place the transmission selector lever in reverse. 4. Listen for any buzz/moaning/whining like noises as the transmission sump temperature rises to normal operating temperature (180 - 210 degrees F). 5. If a buzz/moaning/whining like noise is present, perform the Repair Procedure. PARTS REQUIRED: 1 04130169 Valve, Steel Transmission Regulator Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold > Page 3942 1 02464324 Gasket, Transmission Pan AR 05010124AA Fluid, ATF Plus 3, Type 7176E EQUIPMENT REQUIRED: 1 C-3763 Gauge Tool, Throttle Pressure Adjustment REPAIR PROCEDURE: 1. Following the procedures in the applicable service manual, remove the valve body from the transmission (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - REMOVAL AND INSTALLATION). 2. Remove the screws holding the adjusting screw bracket and replace the regulator valve with p/n 04130169 (Figure 1). Install the adjusting screw bracket 3. Verify and adjust, if necessary, both the line pressure and the throttle pressure settings by following the procedures in the service manual (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section ADJUSTMENTS - VALVE BODY). 4. Following the procedures in the appropriate Service Manual, re-install the valve body with the new regulator valve into the transmission. 5. After filling the transmission with the proper automatic transmission fluid, and verifying correct fill level, check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - ADJUSTMENTS - TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-90 1.2 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Regulating Solenoid: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: All Technical Service Bulletins TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Regulating Solenoid: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3948 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Regulating Solenoid: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3949 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Regulating Solenoid: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3955 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Regulating Solenoid: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3956 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations O/D (3-4) Solenoid, TCC Solenoid, Governor Pressure Sensor, Governor Pressure Solenoid Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 3960 Shift Solenoid: Description and Operation The shift valves are moved by a combination of throttle and governor pressure. The governor pressure is generated by electrical components. The conditions under which a shift to fourth will not occur are: - Overdrive switch is Off - Transmission fluid temperature is below 10 °C (50 °F) or above 121 °C (250 °F) - Shift to third not yet completed - Vehicle speed too low for 3-4 shift to occur - Battery temperature below -5 °F Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations O/D (3-4) Solenoid, TCC Solenoid, Governor Pressure Sensor, Governor Pressure Solenoid Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation Overdrive Indicator Lamp: Description and Operation SYSTEM OPERATION The overdrive-off indicator lamp gives the driver an indication that the automatic transmission overdrive has been locked out. The lamp is controlled by the Powertrain Control Module (PCM) on a hard-wired circuit to instrument cluster. The PCM uses an input from the momentary overdrive lockout switch on the end of the automatic transmission gearshift selector lever to decide whether to turn the lamp on or off. The PCM then controls the lamp ground based upon the overdrive lockout switch input and its internal programming. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Page 3969 Overdrive Indicator Lamp: Testing and Inspection The diagnosis found here addresses an inoperative overdrive-off indicator lamp condition. If the overdrive-off indicator lamp comes on and stays on with the engine running, refer to the proper Diagnostic Procedures for diagnosis of the Powertrain Control Module (PCM) in Powertrain Management /Computer and Control Systems and the transmission control system circuits in Transmission and Drivetrain. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check the fuse in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Turn the ignition switch to the On position. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the ignition switch as required. 3. Disconnect and isolate the battery negative cable. Unplug the gray PCM wire harness connector. Install a jumper wire between the overdrive lamp driver circuit cavity of the gray PCM wire harness connector and a good ground. Connect the battery negative cable. Turn the ignition switch to the On position. The overdrive-off indicator lamp should light. Remove the jumper wire and the lamp should turn off. If OK, refer to the proper Diagnostic Procedures for diagnosis of the Powertrain Control Module (PCM) in Powertrain Management/Computer and Control Systems and the transmission control system circuits in Transmission and Drivetrain. If not OK, go to Step 4. 4. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Remove the instrument cluster bezel and the cluster as described. Check for continuity between the overdrive lamp driver circuit cavity of the gray PCM wire harness connector and a good ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the short circuit as required. 5. Check for continuity between the overdrive lamp driver circuit cavities of the gray PCM wire harness connector and the cluster wire harness connector. There should be continuity If OK, replace the faulty bulb. If not OK, repair the open circuit as required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Description and Operation Shift Indicator: Description and Operation SYSTEM OPERATION Vehicles equipped with a manual transmission have an upshift indicator lamp. The upshift indicator lamp gives an indication when the driver should shift to the next highest gear for the best fuel economy The lamp is turned on by the instrument cluster circuitry for about three seconds when the ignition switch is turned to the On position as a bulb test. After the bulb test, the lamp is controlled by the instrument cluster circuitry based upon a message received from the Powertrain Control Module (PCM) on the Chrysler Collision Detection (CCD) data bus. The PCM uses inputs from many sensors and its internal programming to decide whether the engine speed and load conditions are proper for a transmission upshift. The PCM then sends the proper message to the instrument cluster on the CCD data bus to turn the lamp on or off. The PCM will send a lamp-off message three to five seconds after a lamp-on message, if an upshift is not performed. The lamp will then remain off until the vehicle stops accelerating and is brought back into the range of lamp operation, or until the transmission is shifted into another gear. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Description and Operation > Page 3973 Shift Indicator: Testing and Inspection NOTE: For complete testing, refer to Powertrain Management/Computers and Control Systems/Body Control Module/Testing and Inspection. See: Computers and Control Systems/Central Timer Module ( CTM ) High Option/Testing and Inspection The diagnosis found here addresses an inoperative upshift indicator lamp condition. If lamp accuracy is suspect, diagnosis should be performed with a DRB scan tool. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. If the upshift indicator lamp fails to light during the bulb test (about three seconds after the ignition switch is turned to the On position), replace the upshift indicator lamp bulb with a known good unit. If the indicator lamp still fails to operate, diagnosis of the Powertrain Control Module (PCM) and the Chrysler Collision Detection (CCD) data bus should be performed with a DRB scan tool. For diagnosis of the upshift indicator lamp and the instrument cluster circuitry, see Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Instrument Cluster. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four-Wheel Drive (4WD) Indicator Lamp <--> [Four Wheel Drive Indicator Lamp] > Component Information > Description and Operation Four-Wheel Drive (4WD) Indicator Lamp: Description and Operation SYSTEM OPERATION On vehicles equipped with the optional four-wheel drive system, a four-wheel drive indicator lamp is located in the transfer case shift bezel on the floor pan transmission tunnel. This lamp lights any time the transfer case is engaged in a four-wheel drive operating mode. When the ignition switch is in the On position, battery voltage is supplied to one side of the indicator lamp bulb. A normally-open, plunger-type, four-wheel drive switch in the transfer case is hard-wired in series between the other side of the indicator lamp bulb and ground. When the transfer case is shifted into the 4L or 4H positions, the plunger of the four-wheel drive switch is moved, closing the switch and providing a path to ground. This causes the four-wheel drive indicator lamp bulb to light. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four-Wheel Drive (4WD) Indicator Lamp <--> [Four Wheel Drive Indicator Lamp] > Component Information > Description and Operation > Page 3978 Four-Wheel Drive (4WD) Indicator Lamp: Testing and Inspection NOTE: For complete testing, refer to Powertrain Management/Computers and Control Systems/Body Control Module/Testing and Inspection. See: Computers and Control Systems/Central Timer Module ( CTM ) High Option/Testing and Inspection The diagnosis found here addresses an inoperative four-wheel drive indicator lamp condition. If the problem being diagnosed is related to lamp accuracy, be certain to confirm that the problem is with the lamp or switch and not with a damaged or inoperative transfer case or transfer case linkage. If no transfer case problem is found, the following procedure will help locate a short or open in the indicator lamp circuit. 1. Check the fuse in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component and replace the faulty fuse. 2. Turn the ignition switch to the On position. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the ignition switch as required. 3. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Unplug the transfer case switch wire harness connector. Check for continuity between the ground circuit cavity of the transfer case switch wire harness connector and a good ground. There should be continuity. if OK, go to Step 4. If not OK, repair the open circuit to ground as required. 4. Connect the battery negative cable. Turn the ignition switch to the On position. Install a jumper wire between the 4WD sense circuit cavity of the transfer case switch wire harness connector and a good ground. The four-wheel drive indicator lamp should light. If OK, replace the faulty transfer case switch. If not OK, go to Step 5. 5. Turn the ignition switch to the Off position. Remove the transfer case shifter bezel, and unplug the four-wheel drive indicator lamp wire harness connector. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output circuit cavity of the four-wheel drive indicator lamp wire harness connector. If OK, go to Step 6. If not OK, repair the open circuit to the junction block as required. 6. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. With the transfer case switch wire harness connector still unplugged, check for continuity between the 4WD sense circuit cavity of the four-wheel drive indicator lamp wire harness connector and a good ground. There should be no continuity If OK, go to Step 7. If not OK, repair the short circuit as required. 7. Check for continuity between the 4WD sense circuit cavities of the four-wheel drive indicator lamp wire harness connector and the transfer case switch wire harness connector. There should be continuity If OK, replace the faulty bulb. If not OK, repair the open circuit as required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: Customer Interest TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3989 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3990 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: All Technical Service Bulletins TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3996 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 3997 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 3998 Control Module: Description and Operation This vehicle does not have a Transmission Control Module. Transmission control is accomplished through the Engine Control Module or Powertrain Control Module. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Torque Converter Clutch Relay > Component Information > Locations Torque Converter Clutch Relay: Locations Power Distribution Center Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Torque Converter Clutch Relay > Component Information > Locations > Page 4002 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Power Distribution Center Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4006 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4007 Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4008 Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4009 Transmission Control System Relay: Description and Operation CIRCUIT OPERATION Four Speed Automatic Transmission The electronic transmission relay powers the overdrive solenoid, torque convertor clutch solenoid, and governor pressure solenoid. All three solenoids are molded together. Power for the coil side of the relay is supplied on circuit T4. This circuit is controlled by the Powertrain Control Module (PCM), and is the feed for the generator. Ground for the coil side of the relay is controlled by the PCM on circuit T3. This circuit connects to cavity E30 of the PCM connector. When the PCM grounds the relay, the relay contacts connect circuit A14 to circuit T8. Circuit T8 powers the solenoids. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4010 Transmission Control System Relay: Testing and Inspection - Check the 20 Amp fuse in cavity 3 of the PDC Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm Fluid Pressure Sensor/Switch: Customer Interest A/T - Engine Bucking/Surging at 5,300 Rpm NO: 18-19-98 GROUP: Driveability DATE: Apr. 10, 1998 SUBJECT: Vehicle Bucking During Wide Open Throttle Acceleration MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE JAN 16, 1998 MDH (0116XX) EQUIPPED WITH GASOLINE ENGINES AND A 42/44/46 OR 47RE TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may experience bucking during wide open throttle (WOT) acceleration. The bucking occurs at approximately 5300 RPM. This condition may be caused by reaching the high RPM fuel shut off rev limit before the transmission can shift into the next higher gear and is most likely to occur with high electrical loads (high beams on, heated back lite, heated seats, radio, HVAC blower on MAX etc.). During high current demands, the generator may emit electrical noise that can affect the transmission governor pressure sensor output. If this occurs, the transmission may not shift properly to the next higher gear under (WOT) acceleration conditions and therefore reach the fuel shut off rev limiter. This may be seen most often between the 2-3 shift but can also be experienced between the 1-2 shift. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. NOTE: ONLY PERFORM THE FOLLOWING PROCEDURE SAFELY ON A HIGHWAY OR ROAD OBEYING ALL POSTED SPEED LIMITS AND LAWS. Attempt to duplicate the condition by switching on all accessory loads and driving the vehicle with WOT accelerations through a shift sequence to see if the engine will reach the fuel shut off rev limiter before the 2-3 or 1-2 shift is made. If the bucking condition is experienced at approximately 5300 RPM before making the appropriate upshifts, switch off all electrical loads and repeat the procedure. Repeat the procedure with the electrical loads on and off a second time. If the bucking occurs with the electrical loads on and does not occur with the loads off, perform the Repair Procedure. PARTS REQUIRED: 1 56041403AA Sensor, Governor Pressure REPAIR PROCEDURE: This bulletin involves installing a newly designed governor pressure sensor. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm > Page 4021 1. Following the procedures in the applicable service manual, replace the governor pressure sensor with p/n 56041403AA (Figure 1). 2. Check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-96-06-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm Fluid Pressure Sensor/Switch: All Technical Service Bulletins A/T - Engine Bucking/Surging at 5,300 Rpm NO: 18-19-98 GROUP: Driveability DATE: Apr. 10, 1998 SUBJECT: Vehicle Bucking During Wide Open Throttle Acceleration MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE JAN 16, 1998 MDH (0116XX) EQUIPPED WITH GASOLINE ENGINES AND A 42/44/46 OR 47RE TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may experience bucking during wide open throttle (WOT) acceleration. The bucking occurs at approximately 5300 RPM. This condition may be caused by reaching the high RPM fuel shut off rev limit before the transmission can shift into the next higher gear and is most likely to occur with high electrical loads (high beams on, heated back lite, heated seats, radio, HVAC blower on MAX etc.). During high current demands, the generator may emit electrical noise that can affect the transmission governor pressure sensor output. If this occurs, the transmission may not shift properly to the next higher gear under (WOT) acceleration conditions and therefore reach the fuel shut off rev limiter. This may be seen most often between the 2-3 shift but can also be experienced between the 1-2 shift. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. NOTE: ONLY PERFORM THE FOLLOWING PROCEDURE SAFELY ON A HIGHWAY OR ROAD OBEYING ALL POSTED SPEED LIMITS AND LAWS. Attempt to duplicate the condition by switching on all accessory loads and driving the vehicle with WOT accelerations through a shift sequence to see if the engine will reach the fuel shut off rev limiter before the 2-3 or 1-2 shift is made. If the bucking condition is experienced at approximately 5300 RPM before making the appropriate upshifts, switch off all electrical loads and repeat the procedure. Repeat the procedure with the electrical loads on and off a second time. If the bucking occurs with the electrical loads on and does not occur with the loads off, perform the Repair Procedure. PARTS REQUIRED: 1 56041403AA Sensor, Governor Pressure REPAIR PROCEDURE: This bulletin involves installing a newly designed governor pressure sensor. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm > Page 4027 1. Following the procedures in the applicable service manual, replace the governor pressure sensor with p/n 56041403AA (Figure 1). 2. Check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-96-06-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > Page 4028 Fluid Pressure Sensor/Switch: Description and Operation NOTE: This input is used with 4-speed electronic transmissions only DESCRIPTION The transmission governor pressure sensor provides a signal proportional to the transmission governor pressure. OPERATION It provides feedback for control of the variable force solenoid, which regulates transmission governor pressure. CIRCUIT OPERATION The governor pressure sensor supplies the transmission pressure input to the Powertrain Control Module on circuit T25. Circuit T25 connects to cavity B29 of the PCM. Circuit K7 from cavity B31 of the PCM supplies 5 Volts to the sensor. The PCM provides ground for the governor pressure sensor on circuit K4. Circuit K4 connects to cavity A4 of the PCM. The governor pressure sensor is part of the transmission solenoid assembly. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Description and Operation > Switch Operation Overdrive Switch: Description and Operation Switch Operation The overdrive OFF (control) switch is located on the gearshift lever. The switch is a momentary contact device that signals the Powertrain Control Module (PCM) to toggle current status of the overdrive function. 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 Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Description and Operation > Switch Operation > Page 4033 Overdrive Switch: Description and Operation Overdrive Override Switch-PCM Input PURPOSE On vehicles equipped with an automatic transmission and overdrive, the powertrain control module (PCM) regulates the 3-4 overdrive up-shift and downshift through the overdrive solenoid. OPERATION This solenoid is located in the transmission. An overdrive/override push-button switch is located at the end of transmission shift lever. This solenoid is located in the transmission. An overdrive/override push-button switch is located at the end of the transmission shift lever. The overdrive/override push-button switch is normally open (overdrive allowed) when the lamp is not illuminated. It momentarily closes (overdrive not allowed) when the operator presses the switch and the lamp is illuminated. Overdrive will revert to ON (lamp off) each time the ignition switch in turned on. The transmission downshifts if the operator presses the override switch while in overdrive. CIRCUIT OPERATION Automatic transmission equipped vehicles may have an overdrive switch. The operator disables or enables overdrive when the switch is depressed. The overdrive switch consists of a switch connected to the Powertrain Control Module (PCM), an illumination lamp and an overdrive ON/OFF indicator lamp. If overdrive is currently enabled, it is disabled when the operator depresses the overdrive switch. Conversely, if the operator already disabled over-drive, it is enabled when the switch is depressed. Circuit T6 from the overdrive switch connects to cavity C13 of the PCM and provides the overdrive signal. The PCM turns the overdrive ON/OFF indicator lamp ON or OFF by providing a ground for the lamp on circuit T18. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4037 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. 4. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 5. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 6. Test continuity of new switch with 12V test lamp. 7. Connect switch wires and lower vehicle. 8. Top off transmission fluid level. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Sensor Mounting ................................................................................................................................. ..................................................... 27 Nm (20 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 4041 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 4042 Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Shaft Speed Sensor-PCM Input Transmission Speed Sensor: Description and Operation Output Shaft Speed Sensor-PCM Input This sensor generates a signal to the PCM relating to the speed of the transmission main drive shaft. NOTE: This input is used with 4-speed electronic transmissions only. CIRCUIT OPERATION Four Speed Automatic Transmission The output shaft speed sensor generates a signal indicating the speed of the transmission output shaft. Circuits T13 and T14 connect the sensor to the Powertrain Control Module (PCM). Circuit T13 connects to cavity B25 of the PCM. Circuit T14 connects to cavity B28. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Shaft Speed Sensor-PCM Input > Page 4045 Transmission Speed Sensor: Description and Operation Sensor Operation The speed sensor is located in the overdrive gear case. The sensor is positioned over the park gear and monitors transmission output shaft rotating speed. Speed sensor signals are triggered by the park gear lugs as they rotate past the sensor pickup face. Input signals from the sensor are sent to the transmission control module for processing. The vehicle speed sensor also serves as a backup for the transmission speed sensor. Signals from this sensor are shared with the powertrain control module. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Page 4046 Transmission Speed Sensor: Service and Repair Removal Transmission Speed Sensor Removal Installation 1. Remove transmission speed sensor and O-ring seal from overdrive case. Installation 1. Install transmission speed sensor and O-ring seal in overdrive case. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations Governor Pressure Sensor, Transmission Temperature Sensor, Governor Pressure Solenoid, Governor The transmission temperature sensor is located in the transmission solenoid assembly in the valve body. The governor pressure sender and the transmission fluid temperature thermistor are separate sensors in the same component. This component is attached to the governor body in the solenoid assembly of the valve body. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission Temperature Sensor - Description and Operation Transmission Temperature Sensor/Switch: Description and Operation Transmission Temperature Sensor - Description and Operation Transmission fluid temperature readings are supplied to the transmission control module by the thermistor. The temperature readings are used to control engagement of the fourth gear overdrive clutch, the converter clutch, and governor pressure. Normal resistance value for the thermistor at room temperature is approximately 1000 ohms. The PCM prevents engagement of the converter clutch and overdrive clutch, when fluid temperature is below approximately 10 °C (50 °F). If fluid temperature exceeds 126 °C (260 °F), the PCM causes a 4-3 downshift and engage the converter clutch. Engagement is according to the third gear converter clutch engagement schedule. The overdrive OFF lamp in the instrument panel illuminates when the shift back to third occurs. The transmission will not allow fourth gear operation until fluid temperature decreases to approximately 110 °C (230 °F). The thermistor is part of the governor pressure sensor assembly and is immersed in transmission fluid at all times. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission Temperature Sensor - Description and Operation > Page 4052 Transmission Temperature Sensor/Switch: Description and Operation Transmission Temperature Sensor - PCM Input NOTE: This input is used in the shift operation for 4-speed electronic transmissions only. The temperature data is used for: torque converter clutch operation, overdrive shift, low temperature shift compensation, wide open throttle shift strategy and governor pressure transducer calibration. CIRCUIT OPERATION The transmission temperature sensor is located in the transmission solenoid assembly. The sensor is a variable resistor, as transmission temperature changes the resistance in the sensor changes. Circuit T34 connects from the Powertrain Control Module (PCM) to the sensor. Ground for the sensor is supplied on circuit K4. This circuit is the ground circuit for many of the components used in the fuel/ignition system. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 25-003-01 > Feb > 01 > PCM - MIL ON/Erroneous DTC P1398 (or $BA) PROM - Programmable Read Only Memory: Customer Interest PCM - MIL ON/Erroneous DTC P1398 (or $BA) NUMBER: 25-003-01 GROUP: Emissions DATE: Feb. 23, 2001 SUBJECT: Erroneous DTC P1398 (or $BA) - No Crank Sensor Learn OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration level 96Cal18 or 97Cal18). MODELS: 1996 - 1997 (AB) Ram Van 1996 - 1997 (AN) Dakota 1996 - 1997 (BR/BE)Ram Truck 1997 (TJ) Wrangler 1996 - 1997 (XJ) Cherokee 1996 - 1997 (ZJ) Grand Cherokee NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A GASOLINE ENGINE. SYMPTOM/CONDITION: A customer may experience a MIL (Check Engine Lamp) illumination due to an erroneous DTC P1398 - No Crank Sensor Learn. This DTC may also be displayed as a $BA - Adaptive Numerator at Limit. This condition may be caused by a momentary drop in the supply voltage to the powertrain control module. This condition may occur when a normal, or higher, electrical load is applied to the battery. A momentary drop in the supply voltage to the PCM may be caused by a marginal battery or poor electrical connections from the battery to the PCM. The condition may be further aggravated by cold ambient temperatures or when the vehicle has been left unused for an extended period of time. DIAGNOSIS: 1. Verify the calibration level of the PCM software. If the PCM software is at 96Cal18 or 97Cal18, or higher, then this TSB does not apply. Further diagnosis is required. 2. If PCM software is earlier (lower or less) than either 96Cal18 or 97Cal18, then perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 MUST BE OPERATING AT CIS CD 2077 OR HIGHER. REPAIR PROCEDURE: Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 25-003-01 > Feb > 01 > PCM - MIL ON/Erroneous DTC P1398 (or $BA) > Page 4061 1. Reprogram the PCM using the MDS2 (Mopar Diagnostic System) and the DRBIII(R) (Scan Tool). NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (BCM, MIC, SKIM, ETC.) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS BETWEEN MODULES. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM LAST, AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASE. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 2. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the Powertrain Control Module and cover the label with the clear plastic overlay. 3. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Fig. 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-08-00 > Jun > 00 > MIL ON, Erroneous DTC P0107 Set Technical Service Bulletin # 18-08-00 Date: 000623 MIL ON, Erroneous DTC P0107 Set NUMBER: 18-08-00 GROUP: Vehicle Performance DATE: June 23, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-03-99, DATED FEB. 19, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination Due To DTC P0107 - Map Sensor Voltage Too Low OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18 and 98Cal12). **MODELS:** **1996** - 1998 (AB) Ram Van **1996** - 1998 (AN) Dakota **1996** - 1998 (BR/BE) Ram Truck 1998 (DN) Durango **1997** - 1998 (TJ) Wrangler **1996** - 1998 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH GASOLINE ENGINE. SYMPTOM/CONDITION: Erroneous MIL illumination with DTC P0107 - MAP SENSOR VOLTAGE TOO LOW. This may occur during downhill decelerations at altitude or when performing off-road maneuvers when the engine is operating over 1500 rpm. The MIL illuminates due to the monitor running during incorrect parameters. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH700017001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-08-00 > Jun > 00 > MIL ON, Erroneous DTC P0107 Set > Page 4066 Labor Operation No: 08-19-42-93 0.5 Hrs. FAILURE CODE: FM - Flash Module Repair Procedure 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4 Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the ORB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and ORB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1) Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-08-00 > Jun > 00 > MIL ON, Erroneous DTC P0107 Set > Page 4067 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information Technical Service Bulletin # 25-02-98 Date: 981023 I/M Testing - OBDII CARB Readiness Monitor Information NO: 25-02-98 GROUP: Emissions DATE: Oct. 23, 1998 SUBJECT: I/M (Inspection Maintenance) Testing - OBD II "CARB" Readiness Monitor Information MODELS: 1996 - 1999 (AB) Ram Van/Wagon 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (FJ) Avenger/Sebring/Talon 1996 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1996 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1995 - 1999 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper Roadster/Coupe 1997 - 1999 (TJ) Wrangler 1999 (WJ) Grand Cherokee 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO NATURALLY ASPIRATED (NON-TURBO) GASOLINE ENGINES. DISCUSSION: Some states that require I/M inspections are beginning to include OBD II "CARB" Readiness as a prerequisite to an I/M test. OBD Readiness tells an I/M station if the OBD II systems have run their self test. Owners, in those states that use OBD Readiness, may be denied an I/M test if one or more of the Readiness monitors read "NO" or in other words the OBD II monitors have not run their tests. It is important to understand that the MIL will not be illuminated because OBD Readiness reads "NO". MIL illumination happens when an actual malfunction or failure of a monitored emissions system occurs. It is possible to have MIL illumination for a detected failure while at the same time having a "NO" for an OBO Readiness monitor. NOTE: MIL ILLUMINATION INDICATES ADDITIONAL PROBLEMS WITH THE VEHICLE. FURTHER DIAGNOSIS AND REPAIR WILL BE REQUIRED BEFORE PROCEEDING FURTHER WITH THIS BULLETIN. OBD Readiness that reads "NO" can be caused by the following: PCM reprogramming, PCM replacement, fault code erasure, battery disconnects and/or replacement. If any of the above items occur before an I/M test, a good chance exists that one or more of the monitors will read "NO" for OBD Readiness. Some customers may be directed back to their dealers for assistance when an I/M test station has not allowed an I/M test due to Readiness status. The following procedures will help technicians efficiently run the Readiness tests so an owner can have their I/M test completed. EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III(R)) 1 CH7000/7001 J1962Cable 1 CH7OlO J1962 MMC Cable POLICY: Reimbursable within the provisions of the warranty. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 4072 TIME ALLOWANCE: Labor Operation No: 25-01-01-91 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure This bulletin involves operating the vehicle under specific parameters to run or complete the OBD monitors. The number of monitors applicable to a vehicle will vary by type of vehicle and emissions application. In addition, the parameters to run each monitor will vary. Preliminary Checks 1. Perform a MIL bulb check by switching the ignition key "ON" (engine off). The MIL will illuminate as a bulb check. If the MIL does not illuminate, repair the bulb or bulb circuit. 2. Connect a DRB III(R) to the vehicle. Select DRB III(R) standalone, current model year diagnostics, engine, DTC's and related functions, read DTC's. 3. Verity that no emission related DTC's are present and that the MIL is not illuminated with the engine running. NOTE: EMISSION RELATED DTC'S AND MIL ILLUMINATION MAY PREVENT OTHER OBD MONITORS FROM RUNNING. DTC'S THAT ILLUMINATE THE MIL MUST BE REPAIRED BEFORE ATTEMPTING TO RUN THE MONITORS. OBD "CARB" Readiness Check 1. With the DRB III(R) select engine, OBD II monitors, CARB Readiness Status. 2. Read the monitor status. "YES" tells you that monitor has run and is ready for an I/M test, "NO" tells you that the monitor must be run. If all monitors listed read "YES", the vehicle can be returned to the customer for completion of their I/M test. Only monitors that read "NO" must be run to read "YES". NOTE: THE MONITORS LISTED IN THE OBD "CARB" READINESS SCREEN ARE THE ONLY ONES APPLICABLE FOR THE VEHICLE BEING WORKED ON. The vehicle must be operated in various conditions (speed, temperature, etc.) for the monitors to run. Each monitor includes a pre-test and monitor test that can be viewed on the DRB III(R). The pre-test/monitor test screen lists all the preliminary parameters that must be met along with the running parameters for that specific monitor to run. An example of one screen is shown in Figure 1. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 4073 NOTE: 1997 AND PREVIOUS MODEL VEHICLES WILL HAVE A DIFFERENT LOOKING SCREEN. PRESS THE F1 KEY TO OBTAIN MONITOR RUN CONDITIONS. THE WAY IN WHICH THE MONITORS RUN WILL BE SIMILAR. The following explains how to interpret each section of the screen: PRE-TEST REQUIREMENTS The pre-test requirements include all the operating parameters that must be met before the actual test can run. The vehicle must be operated until each item within the pre-test section are fulfilled. LOW VALUE/HIGH VALUE/BAR GRAPH The low value/high value provides the minimum and maximum operating conditions for each item (ie ECT Range must be between 170° and 260° F in Figure 1). The bar graph will begin to fill when the lowest value required for each item is met. This provides a visual indication that the parameters are being met. The vehicle should be driven until most of each pre-test bar graph is filled. MONITOR REQUIREMENTS Once all pre-test requirements are met, the vehicle must be brought within the parameters listed in the monitor requirements section for the monitors to begin running. As the monitor begins to run, the DRB III(R) will begin to beep. This is an audible indication that the test is in progress. If vehicle operation falls outside any of the parameters, the beeping will stop. If this occurs, the technician must determine if the pre-test requirements or the monitor requirements have fallen outside the window for the test and the vehicle must be driven accordingly for the test to restart. When the monitor completes its test, the DRB III(R) will beep 3 consecutive times. NOTE: THE PURGE FLOW PRE-TEST SCREEN WILL LOOK DIFFERENT THAN THE REST OF THE PRE-TEST/MONITOR SCREENS. PRESS THE F1 KEY ON THE DRB III(R) TO SEE A SIMILAR SCREEN FOR THIS MONITOR. MONITOR RUN PROCESS The following will provide the most efficient order along with tips to help run through the monitor tests quickly. The monitors listed include all possible monitors for either Front Wheel Drive or Rear Wheel Drive vehicles. The vehicle being worked on may have fewer monitors than the maximum available. Only those listed on the DRB III(R) are applicable for the vehicle being worked on. The only monitors that will require attention are those that read "NO" under the OBD "CARB" Readiness Status screen. Front Wheel Drive 1. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight soak either indoors or out depending on conditions). The ambient (outside) temperature must be between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining requirements. 2. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the pre-test screen. If the vehicle is equipped with a manual transaxle, use fourth gear to help meet the requirements. 3. EGR Monitor - It is necessary to maintain TPS, MAP, and RPM ranges listed in the pre-test screen for this test to complete. 4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the pre-test screen. Automatic transaxle vehicles must be left in drive during the stop period. 5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the monitor will attempt to run on every other throttle closure. Automatic transaxle vehicles must be left in drive for the test to run. If all parameters are met and the test still will not run, place your foot on the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF cells to update. 6. O2 Sensor Heater Monitor - The open throttle time for the O2 Heater pre-test must be exceeded. This monitor will run after the ignition key is switched "Off". After the DRB III(R) switches to No Response (approximately 3 minutes) turn the ignition key "On" and check the O2 Sensor Heater monitor status. It should have switched to "YES". All other monitors should be completed before running this test. Rear Wheel Drive 1. O2 Sensor Heater Monitor - This test will require a cold start (possibly an overnight soak either indoors or outdoors depending on conditions). The ambient (outside) temperature must be between 18° and 38° C (0° and 100° F with the engine coolant temperature within 6° C (10° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 4074 requirements. 2. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight soak either indoors or outdoors depending on conditions). The ambient (outside) temperature must be between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining requirements. 3. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the pre-test screen. If the vehicle is equipped with a manual transmission, use 4th gear to help meet the requirements. 4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the pre-test screen. Automatic transmission vehicles must be left in drive during the stop period. 5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the monitor will attempt to run on every other throttle closure. Automatic transmission vehicles must be left in drive for the test to run. If all parameters are met and the test will still not run, place your foot on the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF cells to update. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-24-98 > Jul > 98 > PCM - Light Spark Knock Condition Technical Service Bulletin # 18-24-98 Date: 980731 PCM - Light Spark Knock Condition NO: 18-24-98 GROUP: Vehicle Performance DATE: Jul. 31, 1998 SUBJECT: Light Spark Knock Timing Retard Feature MODELS: 1996 - 1997 (AB) Ram Van 1996 - 1997 (AN) Dakota 1996 - 1997 (BR) Ram Truck 1996 - 1997 (XJ) Cherokee 1996 - 1997 (ZJ) GrandCherokee 1996 - 1997 (ZG) Grand Cherokee (International Markets) NOTE: THIS INFORMATION APPLIES TO VEHICLES EOUIPPED WITH A 2.5L, 4.OL, 3.9L, 5.2L AND 5.9L LIGHT DUTY GASOLINE ENGINES. SYMPTOM/CONDITION: Some vehicles may exhibit light spark knock with a warm engine under load. DISCUSSION: Determine when the customer exhibits this condition and verify it by driving the vehicle in similar conditions. If the vehicle exhibits light spark knock with a warm engine under load perform the flash update procedure. Once the flash procedure is completed, spark advance/retard may be adjusted. NOTE: THE DRB III(R) MUST BE OPERATING AT RELEASE 25.5 OR HIGHER. Select DRB III(R) stand alone, current model year diagnostics, engine, and miscellaneous. When in miscellaneous, spark advance will be available. Use the arrow keys to retard timing in 20 increments to a maximum of A°. When the DRB III(R) screen reads 0 the vehicle will be set at maximum advance and when at -4 it will be set at maximum retard. NOTE: THE IGNITION KEY MUST BE CYCLED FOR THE CHANGES TO TAKE EFFECT. After performing the spark advance/retard feature, drive the vehicle to verify that the light spark knock is gone. This feature will not compensate for heavy spark knock conditions. If heavy knock is experienced, funher diagnosis and testing will be required. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. EQUIPMENT/PARTS REQUIRED: 1 CH6OOO ScanTool (DRBIII(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7OOO/7001 J1962 Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III(R) ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1165 OR HIGHER MUST BE INSTALLED. THE DRB III(R) MUST BE OPERATING AT RELEASE 25.5 OR HIGHER. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-24-98 > Jul > 98 > PCM - Light Spark Knock Condition > Page 4079 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-41-96 0.5 Hrs. FAILURE CODE: FM - Flash Module Repair Procedure This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. 1. Connect the MDS (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and power them up. 3. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III(R) MAIN MENU Screen. 4. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 5. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III(R) on the MDS, then press NEXT MENU. 7. Follow the steps presented on the MDS and DRB III(R) which will allow the DRB III(R) to obtain the current part number of the PCM. 8. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the POM has already been updated, then another condition exists that will require further diagnosis and repair. 9. The MDS and DRB III(R) will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 10. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-24-98 > Jul > 98 > PCM - Light Spark Knock Condition > Page 4080 11. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-10-98 > Feb > 98 > OBD II - Improper MIL Illumination Technical Service Bulletin # 18-10-98 Date: 980227 OBD II - Improper MIL Illumination NO: 18-10-98 GROUP: Vehicle Performance DATE: Feb. 27, 1998 SUBJECT: OBD II Misfire Indicator THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-26-97 REV. A, DATED SEP. 5, 1997 THAT SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1997 TECHNICAL SERVICE BULLETIN MANUAL (P/N 81-699-98004). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF 1997 AN MODELS. MODELS: **1997**-1998 (AN) Dakota 1998 (BR/BE) Ram Truck NOTE: THIS BULLETIN APPLIES TO 1998 MODELS BUILT BEFORE AND INCLUDING THE FOLLOWING DATES: 11TH POSITION OF VIN G (SALTILLO), J (ST LOUIS), M (LAGO) AUG. 20, 1997 (MDH 0820XX) - S (DODGE CITY) AUG. 19, 1997 (MDH 0819XX) AND **ALL 1997 AN MODELS**. This information applies to all gasoline equipped models except heavy duty emission 5.9L federal and heavy duty emission 8.0L federal packages. The VECI label can be inspected to see if the 5.9L or 8.0L applies to this action. The VECI code sequence for these heavy duty emission models will be WCRXH08.0BA1 for 8.0L and WCRXH05.9BA1 for 5.9L. The highlighted H designates heavy duty. The location of the label for 5.9L is on the air cleaner and 8.0L on the air pump bracket. No diesel vehicles apply to this action. DISCUSSION: **The above model trucks with gasoline engines will not illuminate the MIL properly when misfire is detected. The software within the powertrain control module has been revised to correct an OBD II system monitor that is non-compliant based on misfire requirements set forth by the Federal Government and C.A.R.B.. ** **NOTE: ALL APPLICABLE VEHICLES BROUGHT IN FOR ANY MAINTENANCE MUST HAVE THIS REFLASH PROCEDURE PERFORMED.** EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1152 OR HIGHER MUST BE INSTALLED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-49-98 0.5 Hrs. FAILURE CODE: FM - Flash Module Repair Procedure This procedure involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration change). 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-10-98 > Feb > 98 > OBD II - Improper MIL Illumination > Page 4085 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 181297 > Mar > 97 > PCM - Erroneous MIL ON/Driveability Improvements PROM - Programmable Read Only Memory: Customer Interest PCM - Erroneous MIL ON/Driveability Improvements NO: 18-12-97 GROUP: Vehicle Performance DATE: Mar. 14, 1997 SUBJECT: Erroneous MIL Illumination/Driveability Improvements MODELS: 1997 (AB) Ram Van/Wagon 1997 (AN) Dakota 1997 (BR) Ram Truck 1997 (TJ) Wrangler 1997 (XJ) Cherokee 1997 (ZJ) Grand Cherokee SYMPTOM/CONDITION: NOTE: THIS FLASH UPDATE DOES NOT APPLY TO WRANGLER MODELS BUILT PRIOR TO JULY 15, 1996 (MDH 01-15-XX) 8 DIGIT PCM PART NUMBER. APPLICABLE MODELS CAN BE IDENTIFIED WITH A 10 DIGIT PCM PART NUMBER. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's or those listed above are present and any of the above symptoms have been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 181297 > Mar > 97 > PCM - Erroneous MIL ON/Driveability Improvements > Page 4090 REPLACEMENT PCM SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL. EQUIPMENT REQUIRED: All Symptoms (Flash Programming) 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification NOTE: THE MDS AND DRB III ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1127 OR HIGHER MUST BE INSTALLED. REPAIR PROCEDURE: This repair involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes) for all conditions listed. 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020. Attach the label to the PCM and cover the label with the clear plastic overlay. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 181297 > Mar > 97 > PCM - Erroneous MIL ON/Driveability Improvements > Page 4091 10. Type the necessary information on the Authorized Modification Label p/n 04275086. Attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-47-97 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 182696 > Sep > 96 > PCM - Erroneous MIL, and/or Driveability Concerns PROM - Programmable Read Only Memory: Customer Interest PCM - Erroneous MIL, and/or Driveability Concerns NO: 18-26-96 GROUP: Vehicle Performance DATE: Sep. 27, 1996 SUBJECT: Erroneous MIL Illumination and/or Driveability Concerns MODELS: 1997 (AB) Ram Van/wagon 1997 (AN) Dakota 1997 (BR) Ram Truck 1997 (ZJ) Grand Cherokee 1997 (TJ) Wrangler NOTE: THIS BULLETIN DOES NOT APPLY TO 1997 WRANGLERS BUILT BEFORE JULY 15, 1996 (MDH 0715XX). 1997 WRANGLERS BUILT AFTER THIS DATE CAN BE IDENTIFIED BY HAVING A TEN DIGIT PART NUMBER ON THE POWERTRAIN CONTROL MODULE (PCM) WHERE AS VEHICLES BUILT PRIOR TO THIS DATE HAVE AN EIGHT DIGIT PART NUMBER ON THE PCM. SYMPTOM/CONDITION: Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 182696 > Sep > 96 > PCM - Erroneous MIL, and/or Driveability Concerns > Page 4096 These illustrations list PCM updates for erroneous MIL (Check Engine Lamp) illumination and/or driveability concerns. Please perform updates to the PCM for any vehicle listed above that you encounter. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) and appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order. Any DTCs not identified in this TSB and/or DTCs identified in this TSB that are not listed in the SYMPTOM/CONDITION as erroneous should be repaired as necessary. If any of the above conditions or DTCs exist, perform the Repair Procedure. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000 J1962 Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification REPAIR PROCEDURE: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration change). NOTE: MDS AND DRB III ARE REQUIRED TO PERFORM THE FOLLOWING REPAIR. MDS MUST BE OPERATING WITH RELEASE 20 OR HIGHER AND TIL 1117 OR HIGHER INSTALLED. 1. Connect the MDS to the DRB III and connect the DRB III to the vehicle 16-way Data Link Connector (DLC) and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS WITH MDS AND DRB III on the MDS then press NEXT Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 182696 > Sep > 96 > PCM - Erroneous MIL, and/or Driveability Concerns > Page 4097 MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then a system problem actually exists and should be corrected. 8. The MDS and DRB III will prompt the operator for any action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update" label, P/N 4669020. Attach the label to the PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Reprogram Powertrain Control Module 08-19-46-90 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery Technical Service Bulletin # 18-037-05 Date: 051020 Engine Controls - Flash Programming Failure Recovery NUMBER: 18-037-05 GROUP: Vehicle Performance DATE: October 20, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-020-02, DATED JUNE 24, 2002 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Flash Programming Failure Recovery Using DRBIII(R) OVERVIEW: This Bulletin provides guidelines, to minimize flash reprogramming problems, and information on recovery procedures for failed flash attempts. MODELS: 1992 - 1994 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2003 (AB) Ramvan/Wagon 1992 - 1994 (AJ) Lebaron Coupe/Convertible 1995 - 2004 (AN) Dakota 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 2002 (BRIBE) Ram Pickup 2004 - 2006 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2005 (DR/DH/D1) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1996 - 2000 (CS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2006 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2005 (KJ) Liberty/Cherokee (International Markets) 1993 - 2003 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 (PG) PT Cruiser (International Markets) 1997 - 2002 (PR) Prowler 2001 - 2005 (PT) PT Cruiser 2001 - 2006 (RG) Chrysler Voyager (International Markets) 2001 - 2006 (RS) Town & Country/Caravan/Voyager Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4103 1995 - 2002 (SR) Viper 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) 1999 - 2004 (WJ) Grand Cherokee 1997 - 2001 (XJ) Cherokee 1993 - 1995 (YJ) Wrangler 2003 - 2006 (ZB) Viper 1995 - 1998 (ZG) Grand Cherokee (International Markets) 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: NOTE: Many of the reasons a flash reprogramming procedure may not complete are documented in this service bulletin, but if you are constantly having issues performing the flash reprogramming procedure using a specific DRBIII(R), it is suggested you send the DRBIII(R) in question to SPX/Miller Special Tools for service. Occasionally a flash update procedure may not complete properly and/or the diagnostic equipment may lock up or become disconnected during the procedure. Flash Reprogramming is a "CRITICAL PROCESS"; an error may result in a no-start/failed control module. Most modules, encountering an interruption or failure while reprogramming, are recoverable; a recoverable module is not covered under the provisions of the warranty. This service bulletin covers items that may cause this condition, a process to restart the flash procedure, and miscellaneous information that will help prevent needless replacement of control modules. GENERAL: Flash Reprogramming is only authorized by a specific SERVICE BULLETIN, or RECALL. Review the entire Service Bulletin/Recall prior to performing a flash reprogramming update. Often other parts may need to be serviced, replaced, or tested, prior to flash reprogramming, and ARE REQUIRED as part of completing the Service Bulletin/Recall. When flashing a Powertrain Control Module (PCM) or Transmission Control Module (TCM) there are other legal requirements with labeling issues that are included in those service bulletins. Other non-emission related modules, such as instrument clusters and Body Control Modules (BCMs) do not require labels. FLASH REPROGRAMMING SEQUENCE OF EVENTS The process of flash reprogramming is similar to flashing the BIOS on a Personal Computer. Interruptions, voltage problems, and a variety of other outside interactions can potentially interfere with the process. This document seeks to provide information to minimize problems associated with vehicle control module flash reprogramming. The description that follows is for most PCMs and some TCMs. Other modules use different initiation procedures. The process starts by selecting an update from the TechCONNECT Client or ISIS and then "loading" that update into the DRBIII(R). Once the flash reprogramming update is loaded into the DRBIII(R), and before the flash reprogramming begins, the DRBIII(R) verifies that the update loaded from the TechCONNECT Client or ISIS is the proper update for the module. This is done using part number supersedence. This verification occurs only if an update is required, available (on the TechCONNECT Client or ISIS) and has been selected for programming. ^ The module is then placed into "Boot Strap" programming mode by the DRBIII(R). This module mode gives the DRBIII(R) permission and the ability to proceed with the flash reprogramming session. ^ Next, the current part number, which resides in the module's flash memory, is stored in a "Safe Memory" location within the module. This memory location is not affected by flash memory erasure and reprogramming, which are to follow. ^ Once the part number is safely stored, the flash memory in the control module is erased. From this point forward any interruption in the flash process, Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4104 will result in a Non-Responsive module (NR). A NR module is a module that is either partially erased or partially programmed. ^ After erasure, the actual reprogramming procedure starts, and the update software is programmed into the flash memory within the module. ^ When reprogramming is completed, the flash memory is verified through an internal process in the DRBIII(R) using a "Check Sum". This value is compared against another value that represents what should be in memory and when matched, verifies successful reprogramming. ^ Next, a DRBIII(R) prompt is displayed instructing that the ignition switch be turned OFF. The module exits the "Boot Strap" mode when the switch is turned off. ^ After a slight pause, the DRBIII(R) will prompt for the ignition switch to be turned ON. The DRBIII(R) then reads the new part number in flash memory (along with a new computer program the new part number is placed into the module's memory). If the new part number matches the expected part number, the flash reprogramming session has completed successfully. SOFTWARE VERSIONS MUST BE CURRENT Before attempting a flash reprogramming session using the TechCONNECT Client, make sure you have the most current DRBIII(R) software installed. To verify whether your DRBIII(R) software is current, check the upper right-hand corner of the TechCONNECT Client screen for DRBIII(R) Available Version, DRBIII(R) Current Version. Often, because of multiple DRBIII(R)s in the shop, not all will get updated on a timely manner. The installed DRBIII(R) software version can generally be found at the bottom center of most screens. Alternately the version can be checked by pressing 6, 2, 5 from the DRBIII(R) Main Menu and comparing it to what is available from a current TechCONNECT Client as described above. If the TechCONNECT Client is current and the DRBIII(R) is not, it may be due to the fact that the TechCONNECT Client does not force DRBIII(R) updates for "minor" revisions. Changes and new support are added to the Vehicle Flash application on "minor" revisions on a regular basis. This is why your TechCONNECT Client and DRBIII(R) must have the LATEST software revisions installed. DO NOT PASS on the option for updating to a "minor" revision! Major updates require the DRBIII(R) to be updated prior to allowing any flash programming. DRBIII(R) CABLES A NEW DRBIII(R) cable was released as an Essential Service Tool! CH7000A - 8 ft. Cable, DRBIII(R) to OBDII (J1962) DLC Connector. CH7000A is the required cable for ALL flash reprogramming. The older CH7000 cable can be used for diagnostics ONLY. One (1) cable was shipped to all dealerships. Easily identified, the correct cable has a RED connector, which plugs into the DRBIII(R). The cable modification enhances the DRBIII(R) communication capabilities when dealing with the flash requirements of certain controllers/ECUs affected in part by the recent changes in DLC connector configurations. The new cable is required for ALL flash reprogramming sessions, and can be used wherever the previous CH700017001 cables were used. While not recommended for flash reprogramming usage, if you require a longer cable, there is also a 12-foot cable released under pin CH7001A The production of the previous CH700017001 cables has ceased. All orders placed will be superseded to part number CH7000A/CH7001A. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4105 NOTE: Consider all cables wear items. Always inspect for worn, damaged cables, connectors that are damaged or do not lock securely, and all mating connections including checking for corrosion on the pins. REPLACE ALL suspect cables. Do not use worn or damaged cables when flash reprogramming. Failure to use the new cable or to use a damaged cable often results in failed flash reprogramming sessions. The 2 door Sebring, Stratus, and Avenger coupes (supplied by MMC) generally use the CH7O1O cable (Pre-OBDII MMC vehicles will use the CH7005 cable). TechCONNECT CABLE (GPIB) Replace any suspect GPIB cable. The GPIB cable provides the connection between TechCONNECT Client and the DRBIII(R). This cable is used by the TechCONNECT Client for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash session, you may have to reload the update file that you selected on the TechCONNECT Client. TROUBLESHOOTING CONNECTIVITY OF THE DRBIII(R) UNIT TO THE TechCONNECT APPLICATION. 1. Turn-on the power to the DRBIII(R) unit. 2. Select option 2 "Connect to TechCONNECT" and press Enter. 3. Attach the male mini D-shell amphenol GPIB connector of the new DRBIII(R) cable (part number CH7035B) to the DRBIII(R) unit. 4. Insure that the larger female D-shell amphenol GPIB connector of the new DRBIII(R) cable is properly attached to the male D-shell amphenol GPIB connector on the GPIB-USB-B protocol converter, (part number CHGPIB-B). 5. Attach the USB cable from the GPIB-USB-B protocol converter to one of the USB ports on the rear panel of the client CPU. 6. When the cable is attached to the USB port of the CPU for the first time, Windows 2000 will detect the device and install software for it. Please wait for 25-30 seconds to complete the installation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4106 ISIS NULL MODEM CABLE Replace any suspect null modem cables. International (ISIS), a PC-based CD program similar to TechCONNECT Client uses a null modem cable for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash download session, you will have to reload the update file or files. GENERAL NOTES FOR CABLES AND VEHICLE CONNECTIONS Consider ALL cables to be wear items. Many successful dealers have dedicated cables devoted to "Flash ONLY". Always have spare CH7000A, CH7010 and CH2002 GPIB or null modem cables available. Inspect vehicle diagnostic connectors for potential problems that might cause communication interruptions. There are now clip repair kits available through teamPSE to replace the retaining clips for two of these cables. To protect the DRBIII(R) from internal damage, the clips are designed to fail at above 25 lbs. of axial force. Kits are described in the table. It is a good practice to discard cables that have damage to the pins, cuts, corrosion, or general damage beyond the retaining clips. ST22 SEBRING STRATUS 2 DOOR COUPES (2001-2005) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4107 These vehicles use MMC based modules. The CH8432 Supplemental Reprogramming Tool (SRT) was shipped as a 2001 Essential Tool. The flash reprogramming update files will be downloaded from TechCONNECT Client to the SRT for flash reprogramming sessions on these vehicles. Users should closely follow the instructions that come with the tool. If the tool has not been initialized, there is a known condition where it may take up to 5 or more attempts for it to fully initialize and become functional. NOTE: Once it has successfully flashed, it is initialized and no further action is required. PREPARING TO FLASH It is highly recommended that a sign, or other process, be used that notifies other users that a FLASH SESSION IS IN-PROGRESS and must NOT be interrupted. Interrupting some flash reprogramming sessions at critical junctures can render a module inoperative. Another user may not realize that a flash session is in-progress and may disturb or disconnect the DRBIII(R) or do something on the vehicle that could interrupt the flash process. Before starting the flash session, read, record and erase all DTCs found on the vehicle. Also "Cold Boot" the DRBIII(R) and download the flash since this will erase the flash file from the DRBIII(R) memory. (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Be sure to arrange the TechCONNECT and DRBIII(R) so that no cables are stretched across an area where someone might trip over or kick a cable. When setting up your DRBIII(R), insure that it rests on a surface where it will not fall or be bumped during reprogramming e.g.: DRBIII's have been known to be swept off vehicle windshields by accident when a user bumps the wiper switch). Check User settings on the DRBIII(R). From the DRBIII(R) Main menu, press 6,1 and check to make sure item 1. Echo on PC is set to OFF. On occasion, when Echo on PC is set to ON, flash reprogramming errors may occur. VEHICLE BATTERY VOLTAGE The flash programming procedure puts a load on the electrical system that may last from five to twenty minutes depending on the particular flash reprogramming update. Connect a battery charger to the vehicle. Set the charger to as close to 14 volts as possible. If the charger has a timer, set it for 30 minutes BEFORE starting a flash reprogramming session. This will help to prevent unwanted resets by either the DRBIII(R) and/or the vehicle module that are caused by voltage fluctuations. Alternately, as a bare minimum, use a "Battery Jump Box" when a battery charger is unavailable to ensure adequate and stable system voltages on the module being flash reprogrammed. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Connected/Disconnected Flash Mode Using TechCONNECT CONNECTED MODE FLASHING USING TechCONNECT NOTE: Capable but not recommended. In this mode, the DRBIII(R) remains connected to the TechCONNECT Client and the vehicle throughout the flash session. The DRBIII(R) is connected to the TechCONNECT Client using the GPIB (CH7035) cable and to the vehicle using the vehicle I/O cable (the CH7000A for most vehicles). This mode is useful when the TechCONNECT Client is next to the vehicle being flashed. Another advantage of this mode is that you are able to determine all available flash updates for the vehicle you are connected to by clicking on the "Read Part Number(s) From Vehicle" button. Again, it is important that other users do not attempt to reboot or move the TechCONNECT Client while a flash update is in-progress. The reprogramming procedure of this mode is initiated by selecting the controller option and clicking "Download/Update" button on the TechCONNECT client. DISCONNECTED FLASH MODE NOTE: Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4108 This is the preferred method. This mode allows a user to flash a vehicle without being connected to the TechCONNECT Client. This is a popular mode for flashing in a remote area of the service garage or in a back lot. Before you attempt to use this mode, you must configure the DRBIII(R) for the desired update(s). To do this, you must connect the DRBIII(R) to the TechCONNECT Client using the GPIB cable and the CH7025 cable. It is not necessary to be connected to a vehicle. The GPIB (CH7035) cable will be used to communicate with the TechCONNECT Client (for update file downloading) while the CH7025 cable is used to provide power to the DRBIII(R). After making the above connections, you are able to select one or more updates that you want to perform. These selections are made by highlighting the desired updates and then clicking on the "Download/Update" button by selecting the DRBIII(R) option on the TechCONNECT client. Obviously, the DRBIII(R) does not have unlimited memory. If the file size of the selected updates exceeds 948 KB, the "DRB Space Used" indicator (at the bottom-center of the TechCONNECT Client screen) will change color from GREEN to RED. At this point you must de-select entries until the indicator changes color to GREEN again. When the updates have finished downloading, you may disconnect from the TechCONNECT Client and take the DRBIII(R) to wherever the vehicle is located. The updates will remain in DRBIII(R) memory for 8 hours while the DRBIII(R) is without power. If the DRBIII(R) is powered up for several minutes before the 8 hour time period has expired, the update files will remain on the DRBIII(R) for another 8 hours without power. To start the actual flash process, after connecting to the vehicle in Disconnected Mode, you must press "7 - Vehicle Flash" from the Main Menu on the DRBIII(R). Step by step instruction will follow on the DRBIII(R) display. As with Connected Flash Mode, take the necessary precautions to insure that others are aware of the flash session and that nothing disturbs the vehicle, DRBIII(R), or cabling while performing the flash. Remember to use a battery charger set to 14 volts or a "battery jump box". Pay Attention While Performing Flash Reprogram Procedures PAY ATTENTION WHILE PERFORMING FLASH REPROGRAMMING PROCEDURES Before downloading the flash files, double check to see if the files that you have selected are the appropriate ones for that vehicle. Don't forget about the "Read Part Numbers From Vehicle" option on TechCONNECT Client, this can be of great assistance when trying to flash a module. If the files selected don't download on the first attempt, try again. The technician should NOT leave the vehicle when flash reprogramming a module. Again, check to make sure that all cable connections are secure and that the DRBIII(R) rests on a stable surface. If you are using a battery charger, insure that the settings and charging times are correct and that the battery post clamps are securely fastened. Read, record, and erase all DTCs found on the vehicle. Read and record the module type and part number from the module that is to be flash reprogrammed. Some control modules are not "abort-recovery" capable. When this is true, the scan tool will indicate so by displaying a WARNING message prior to the start of reprogramming. For these modules it is especially important that all precautions and procedures, outlined here, are carefully followed. Pay special attention to DRBIII(R) screen directions relating to key cycles. Missing a "Key ON" or "Key OFF" can cause the module to have to be reflashed again. Due to the variety of module types and vehicle options, you can't always anticipate key prompts, so be alert and ready to respond to DRBIII(R) instructions. Some screens will also instruct that certain modules, connectors or fuses be disconnected or pulled prior to the start of reprogramming and re-installed immediately after completion. Be careful not to anticipate the steps or order of operations for reprogramming any vehicle modules. Because of the many possible changes that occur with each new release of scan tool software, always allow the TSB/Recall and scan tool instructions to be your guide while performing flash reprogramming. Flash reprogramming sessions usually range from 5 to 20 minutes. If the flash session has not completed within 25 minutes after starting a flash reprogramming update, an error has most likely occurred (Record the message that appears on the screen when a failure occurs). If this is the case, or if you know that the flash process was interrupted, cycle the ignition key (OFF to the locked position, then back ON). Reset the DRBIII(R) (power down for 4 seconds and then power up) before attempting to restart the flash process. If the module still won't respond, turn the ignition key off, disconnect the module from the vehicle for 2 minutes, reconnect the module, turn the ignition key to run and try to restart the flash process again. Regardless of what mode that you are in (Connected Flash or Disconnected Flash), if you have tried twice (2 times) unsuccessfully to do a flash recovery and ALL DRBIII(R) instructions were followed, perform the following: ^ Cold boot the DRBIII(R). This resets memory and removes all update files from the DRBIII(R). (Push MORE and YES buttons at the same time, then press F4). ^ Reload the flash update file from the TechCONNECT Client. ^ If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4109 ^ Proceed to reflash the module. On vehicles that have multiple flash updates available, always complete and verify each flash update before attempting the next one. After all flash reprogramming is completed, read and erase all DTCs in all modules on the vehicle. A variety of DTCs may be set, which are usually related to a loss of communication with the module(s) being reprogrammed. Verify the update by reading the new part number using the DRBIII(R). A good double check is to read the part number using DRBIII(R) stand alone. At times, other modules, wired in parallel, to the DLC connector have prevented flash reprogramming sessions to be successful. After the failed attempt, review the appropriate wiring diagram for the vehicle you are flash reprogramming and, with the key "OFF"; disconnect the other modules and retry the flash. Complete the flash, turn the key "OFF" and reconnect any modules that were disconnected. Refer to the "Programmable Modules" section later in this document for more information. Error Messages ERROR MESSAGES Block Echo/Compare Errors Block Echo and Block Compare errors are often caused by voltage fluctuations, faulty I/O cables (CH7OOOA, CH7005, CH7010) or faulty communication connections at the diagnostic connector. Inspect for these conditions and review the sections on Vehicle Battery Voltage and Cable recommendations. Checksum Errors Checksum Errors are generally caused by corrupt flash update files, which can be caused by DRBIII(R) memory problems. If the DRBIII(R) has been without power for more than 8 hours, the update files and system memory could be in a corrupted state. "Cold Boot" the DRBIII(R). (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Reload the flash update file(s) from the TechCONNECT CLIENT. If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Then re-attempt the flash reprogramming process. Enhanced and Original Abort Recovery ENHANCED ABORT RECOVERY Interruptions in the flash process are one of the main reasons for failed flash sessions and non-responsive (NR) modules. Interrupting the flash process after the erase phase has started will leave the control module in a non-functional state. Generally, but not always, NR modules may be recovered successfully. Briefly, abort recovery is the process used to get a NR module back to a fully functional state with the latest software update. The technician should be familiar with the other sections in this document and follow all DRBIII(R) user prompts carefully. There are two methods for abort-recovery. The newer method is called "Enhanced Abort Recovery". This is the preferred method since the original method takes several minutes longer and requires the correct selection of module type from a list of possible PCM's or TCM's. Starting with Release 60.1, a new useful feature was added to the flash reprogramming application for Engine and Transmission control modules. The DRBIII(R) "writes" the YME and Controller Type information to a "Safe Memory" location. This method allows for rapid recovery of the module part number and minimizes errors that could otherwise be made by selecting the wrong controller type. It also assumes that the user will attempt abort recovery for a failed flash attempt before moving to another vehicle with the same DRBIII(R). If you need to move to another vehicle for flash reprogramming you must erase the saved recovery information in order to successfully perform flash reprogramming. Be careful to match the YME information displayed on the enhanced abort recovery screen with the vehicle and module that you are attempting to recover. If you use the recovery file on a different vehicle and module you could damage the module. The recovery information will be displayed on your DRBIII(R), at the start of a flash session, only if you previously encountered a problem that prevented a flash session from completing normally. If your prior flash session was successful, the DRBIII(R) automatically erases the recovery file so that the flash application will not show any recovery information at the start of your next flash session. Enhanced abort recovery features: ^ Reduces the amount of time for the Module ID process. ^ Lowers the risk of possible user mistakes by presenting the user the Year, Model, Engine, and Controller Type. ^ Currently only applicable to Engine and Transmission flash reprogramming. ^ The enhanced abort recovery file will only be erased upon a successful flash or manually by the user. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4110 ^ Cold booting (simultaneously pushing MORE & YES, then F4) the DRBIII(R) will not erase the enhanced abort recovery file, but cold booting the DRBIII(R) will still erase the flash file so it can be reloaded. ^ The user has a choice, at the start of a flash session, whether or not to use the enhanced abort recovery feature. If the user chooses to erase the recovery file, then the DRBIII(R) will use the original method of abort recovery. ^ Cycling the ignition key, when prompted by the DRBIII(R), is still necessary to put the controller into bootstrap (reprogramming) mode. ORIGINAL ABORT RECOVERY If the choice is made to use the original method of abort recovery, a NR module is not always able to provide the DRBIII with ID information. In this case the technician must enter this when prompted by the DRBIII(R). Be patient when performing this process. If the module does not respond to standard diagnostic requests, the DRBIII(R) may take several minutes before it determines that the engine module is in a NR state. At this point, the DRBIII(R) displays the prompt "Could not determine engine controller type. Please select from list" along with a list of possible controller types (if the DRBIII(R) is attempting to identify a TCM, the prompt will say "trans" instead of "engine" and list the possible trans controller types). Because of module variations, it is important to correctly identify the PCM/TCM type so that the correct flash procedure is used. Failure to do this will cause further problems and may damage the module. Tables are provided below to help identify the proper module type to select. These tables correctly identify the modules that were on the vehicles when they were built. However, some vehicles will have module types which were superseded to a new type when a replacement part was installed (ie: EATX4 modules replaced with an EATX4A). Correctly identify these modules using DRBIII(R) Standalone prior to attempting flash reprogramming. NOTE: When instructed to turn the key to the LOCKED position, be sure that the key is not just turned to the OFF position. The key must be rotated to the point at which it can be removed from the ignition switch. On most vehicles the switch is on the steering column and at this position the steering column is LOCKED. When instructed to turn the key to the RUN position, be careful not to turn the key past this position which may engage the starter motor. This creates electrical noise which interferes with the flash process. General Steps for Abort Recovery 1. Review all Tips and Techniques before continuing. Pay special attention to the section on Preparing to Flash a controller and to the Programmable Modules section. 2. Cycle the vehicle's ignition key to the LOCKED position and back to the RUN position. 3. Reset the DRBIII(R) by disconnecting the vehicle cable from the DRBIII(R) for 4 seconds and then reconnecting the cable. 4. Depending on where the flash session was aborted, the DRBIII(R) may require that the technician identify the control module type that was being flash reprogrammed. Use the PCM/TCM configuration table below as a guide. This step is not necessary if using the enhanced abort recovery method. 5. After selecting the proper control module type or choosing enhanced abort recovery, follow the prompts that are displayed on the DRBIII(R). NOTE: If an error message is displayed at this point, an incorrect module type was most likely selected. If this occurs, start the process over. 6. If the recovery process is unsuccessful, perform the following: a. Review the TSB/Recall notice (authorizing the flash update) and all Tips and Techniques in this document. b. Reboot/Restart the TechCONNECT Client. c. "Cold Boot" the DRBIII(R). (Press the MORE and YES buttons on the DRBIII(R) at the same time, then press F4). d. Start this process over from item # 1. If using Disconnected Mode, the flash update will have to be reloaded from the TechCONNECT Client or ISIS DVD. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4111 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4112 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4113 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4114 Programmable Modules The following pages list the various modules that have flash reprogramming capability. It does not mean that a flash is currently available. What will be described are the module types and variations, followed by items to note, and finally, abort recovery specifics if applicable. Powertrain Modules - Engine and Transmission ENGINE - POWERTRAIN CONTROL MODULE (PCM) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4115 There are a variety of Engine (PCM) modules that are flash reprogrammable. Suggestions that are somewhat unique to each type will have comments. Prior to reprogramming a PCM, retrieve the module information and module type using your DRBII I®. PCM information is used by many modules. Be sure to check DIG's before and after performing all flash reprogramming event. The DTC's associated with flash reprogramming generally relate to "lack of communication" with the other modules during the reprogramming session. SBEC Types: SBEC, SBEC 2, SBEC 3, SBEC 3+, SBEC 3A, SBEC 3A+, and SBEC 3B NOTE: During recovery, if the DRBIII® is not seeing the key off, you may need to remove power (B+) to PCM by removing fuse(s) or disconnecting the PCM. When DRBIII® states to turn key ON, reconnect fuse or harness connection. Abort Recovery Specifics: ^ Follow instructions on the DRBIII® for the module type. See table above. ^ Some SBEC 3A, SBEC 3A+ AND SBEC 3B may be in a state where they can not correctly identify a key cycle. In this case a Modified Key Cycle routine is required. This state is present when the following message is displayed on the DRBIII(R): "Can not read Part Number. Did not see Key On or PCM/TCM Controller may not be flashable". When this occurs restart the flash session and when prompted to turn the ignition key to the LOCKED position, pull the fuse(s) that supply battery power to the module instead. When prompted to turn the key to the RUN position, replace the battery supply fuse(s) instead. JTEC Types: ^ JTEC, JTEC+ NOTE: Viper ALL - Roll down windows especially Coupes before attempting a flash. NOTE: 1999 WJ JTEC with Speed Proportional Steering module. Disconnect before and reconnect after the PCM flash reprogramming session. Also see Transmission. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NGC Types: ^ NGC 1, NGC 2, and NGC 3 NOTE: There are derivatives of NGC 3 that will be significant when reprogramming and or testing. NGC modules use one of the longest time spans for flash reprogramming (approximately 15 minutes). The NGCI and NGC3 controllers incorporate both an engine as well as a transmission controller in a common package. The NGC2 controller incorporates the engine controller and an Electronic Throttle Control (ETC) module in place of the TCM. All NGC controllers can be visually identified by noting its four (4) wiring connectors. On manual transmission applications and the NGC2, only 3 connectors may be populated with pins. NOTE: On certain vehicles, the ABS CAB module connector MUST be disconnected prior to performing this Repair Procedure. The CAB module and the PCM are connected at the same diagnostic connector pin (Pin # 9). Turn ignition switch to the OFF position, disconnect the CAB module connector, and reprogram the PCM per the Repair Procedure. When reprogramming is complete turn the ignition switch to the OFF position, connect the CAB module connector, and then check for DTC's. If the PCM becomes "locked" during reprogramming because the ABS CAB module connector was not disconnected, then the PCM may be recovered by following the procedure in this NOTE. Abort Recovery Specifics: Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4116 ^ Follow DRBIII(R) prompts carefully. ^ Power down the DRBIII(R) then cycle ignition before powering up the DRBIII(R) to attempt the flash. CUMMINS Types: ^ CM551 and CM84x series NOTE: Cummins flash reprogrammable PCMs are used on 1998.5 and newer Dodge Trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Model Year 2000 and earlier vehicles have one Engine Control Fuse to pull when prompted by the DRBIII(R). Model Year 2001 and later have two Engine Control Fuses (one 20 Amp and one 30 Amp) to pull when prompted by the DRBIII(R). The fuse(s) are located in the PDC and need to be pulled/removed, when prompted, for at least 10 seconds. SIEMENS Types: ^ SIM-70 NOTE: The SIM-70 is currently used on BUX PL and PG vehicles with a 1.6L ONLY. Abort Recovery Specifics: Follow DRBIII(R) prompts carefully. BOSCH Types: ^ EDC15V, EDC15-C5, and EDC16 NOTE: While there have been other Bosch modules, the EDC15V is not flash reprogrammable. Transmission controllers are usually flashed on the vehicle (since 1996). Technicians may set the pinion factor on "NEW" modules either before or after flash reprogramming. Suggestions follow. After flash reprogramming and before returning the vehicle to the customer, always perform a "QuickLearn" to the TCM. EATX Types: ^ EATX, EATX 2, EATX 3, EATX 3A, EATX 3B, EATX 4, and EATX 4A NOTE: Table shows which TCM was installed "as-built". Often TCMs are superseded by parts and or a service bulletin. Abort Recovery Specifics: ^ 1999 - 2000 WJ and 2000 AN/DN using 4.7L engines the service replacement EATX4A part numbers 56041814AD and 56028227AH currently display a P/N read failed error after the flash is completed during PIN verification. This DOES NOT mean the flash failed. Check for the part number using DRBIII(R) in standalone mode. This exists only for the service replacement modules listed above. Flash reprogramming for OE modules flash and read the part number correctly. Follow DRBIII(R) prompts carefully. NGC Types: Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4117 ^ NGC1, NGC2, NGC3 NOTE: The NGC I1and NGC 3 have the EATX/XCORE and Engine modules combined. NGC 2 does not. Vehicles with automatic transmissions using NGC2 will use an EATX4A. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ 2002 DR, 2002.5 DN, 2003 AN/DN and later with NGC have shown that in some instances the CAB controller may need to be disconnected when attempting to flash the NGC controller. (This should only be performed if an error occurs at the very beginning of the TCM flash portion.) SIEMENS Types: ^ EG552 NOTE: EGS52 is used with the A580 automatic transmission WG Grand Cherokees with a 2.7L diesel engine (BUX), ZH Crossfire and VA Sprinter. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. JTEC Types: ^ JTEC,JTEC+ NOTE: Except for the 45RFE, 545RFE, and AW4 automatic transmissions, the JTEC controller also provides transmission control functions on Dodge trucks and Jeep vehicles. Additionally, they are used on some Cummins equipped Dodge trucks with manual and automatic transmissions. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PRE 1996 EATX TRANSMISSION CONTROL MODULES Prior to 1996 there was not a vehicle SCI communication wire going to the FWD EATX controller only to the PCM. Those vehicle TCMs only communicate to the DRBIII(R) using CCD communications. For these FWD vehicles, use the CH5500 kit and CH7025 DIN cable when connecting those modules to the DRBIII(R) vehicle connector. For 1992-1993 vehicles, the TCM modules were upgraded to MY1995 software. Because of this you will need to use the Yellow SuperCard2, CH8361,to set pinion factor or when using a "new" (superseded) TCM from parts as only the SuperCard2 properly sets the pinion factor on these updated modules. Additionally, when flashing or installing P/Ns 4796121, 4796122, 4796123, or 4796124. The wire from cavity 49 must be removed from the TCM connector, refer to service bulletin 18-24-95. Types: ^ TCCM NOTE: These modules are found on AN, DN, and DR trucks. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4118 NON-POWERTRAIN CONTROL MODULES BODY CONTROL MODULE (BCM) Types: ^ BCM NOTE: Body control modules are found on passenger vehicles. NOTE: The following vehicle BCMs support flash reprogramming: CS, JR, KJ, LH, RS, WJ, and ZB. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ BUX ONLY for 2001 JR - Compass/Mini Trip (BCM) Flash - Use special international release software version 52.25 ^ 2001 LH - there is NO abort recovery available for the BCM. CENTRAL TIMER MODULE (CTM) Types: ^ CTM NOTE: CTMs are found on: AB, AN, DN, BR, and BE trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ELECTRONIC VEHICLE INFORMATION CENTER (EVIC) Types: ^ EVIC NOTE: 02-03 LH & WJ, and 03-04 KJ Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. FRONT CONTROL MODULE (FCM) Types: ^ FCM NOTE: Front control modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. INTEGRATED POWER MODULE (IPM) Types: Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4119 ^ 1PM NOTE: Integrated power modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. POWER LIFT GATE (PLG) Types: ^ PLC NOTE: Power liftgate modules are found on CS and RS. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER SLIDING DOOR MODULE (PSDM) Types: ^ PSDM NOTE: Passenger power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. DRIVER SLIDING DOOR MODULE (DSDM) Types: ^ DSDM NOTE: Driver power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NOTE: When flashing a vehicle that is equipped with both Passenger and Driver Power Sliding Doors, you must Reboot the DRBIII(R) and cycle the ignition key before flashing the next door module. DRIVER DOOR MODULE (DDM) Types: ^ DDM NOTE: Driver Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER DOOR MODULE (PDM) Types: ^ PDM NOTE: Passenger Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLUSTERS/MECHANICAL INSTRUMENT CLUSTER (MIC) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4120 Types: ^ MICs, eMICs NOTE: MICs that have flash reprogramming are on the following vehicles: DR, JR, KJ, PL, PT, WJ, ZB Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. In certain cases, you will be asked to cycle the ignition key and pull a specific fuse. ^ The DRBIII(R) may power down during the procedure with some modules. This is NORMAL and is explained in the user prompts displayed during abort-recovery. Take the time to read and understand the instructions before proceeding. ALARM REMOTE KEYLESS ENTRY MODULE (ARKEM) Types: ^ ARKEM NOTE: Arkem modules are found on PL and PT vehicles. There are up to and after modules. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLIMATE CONTROL (ATC, HVAC) Types: ^ HVAC, ATC, MTC NOTE: Generally, reprogramming for these modules is done using the standalone application rather than the Vehicle Flash application. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. ADJUSTABLE PEDAL MODULE (APM) Types: ^ APM NOTE: Found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. RAIN SENSOR MODULE (RSM) Types: ^ RSM NOTE:RSM modules are found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4121 INTRUSION TRANSCEIVER MODULE (ITM) Types: ^ ITM ^ Updates for this module, to version 7.05 have involved a coordinated BCM flash update. See the TSB for important instructions. NOTE: ITM modules are found on WJ (BUX) and KJ (BUX) vehicles. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. SUPPLEMENTAL RESTRAINT SYSTEMS (SRS) - AIRBAGS, ETC. Types: ^ SRS, ORC NOTE: While used on most vehicles, only CS, JR, LH, PT, RS, and WJ vehicles have the potential to support flash updates. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 25-003-01 > Feb > 01 > PCM - MIL ON/Erroneous DTC P1398 (or $BA) PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - MIL ON/Erroneous DTC P1398 (or $BA) NUMBER: 25-003-01 GROUP: Emissions DATE: Feb. 23, 2001 SUBJECT: Erroneous DTC P1398 (or $BA) - No Crank Sensor Learn OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration level 96Cal18 or 97Cal18). MODELS: 1996 - 1997 (AB) Ram Van 1996 - 1997 (AN) Dakota 1996 - 1997 (BR/BE)Ram Truck 1997 (TJ) Wrangler 1996 - 1997 (XJ) Cherokee 1996 - 1997 (ZJ) Grand Cherokee NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A GASOLINE ENGINE. SYMPTOM/CONDITION: A customer may experience a MIL (Check Engine Lamp) illumination due to an erroneous DTC P1398 - No Crank Sensor Learn. This DTC may also be displayed as a $BA - Adaptive Numerator at Limit. This condition may be caused by a momentary drop in the supply voltage to the powertrain control module. This condition may occur when a normal, or higher, electrical load is applied to the battery. A momentary drop in the supply voltage to the PCM may be caused by a marginal battery or poor electrical connections from the battery to the PCM. The condition may be further aggravated by cold ambient temperatures or when the vehicle has been left unused for an extended period of time. DIAGNOSIS: 1. Verify the calibration level of the PCM software. If the PCM software is at 96Cal18 or 97Cal18, or higher, then this TSB does not apply. Further diagnosis is required. 2. If PCM software is earlier (lower or less) than either 96Cal18 or 97Cal18, then perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: NOTE: THE MDS2 MUST BE OPERATING AT CIS CD 2077 OR HIGHER. REPAIR PROCEDURE: Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 25-003-01 > Feb > 01 > PCM - MIL ON/Erroneous DTC P1398 (or $BA) > Page 4126 1. Reprogram the PCM using the MDS2 (Mopar Diagnostic System) and the DRBIII(R) (Scan Tool). NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (BCM, MIC, SKIM, ETC.) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS BETWEEN MODULES. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM LAST, AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASE. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 2. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the Powertrain Control Module and cover the label with the clear plastic overlay. 3. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Fig. 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-08-00 > Jun > 00 > MIL ON, Erroneous DTC P0107 Set Technical Service Bulletin # 18-08-00 Date: 000623 MIL ON, Erroneous DTC P0107 Set NUMBER: 18-08-00 GROUP: Vehicle Performance DATE: June 23, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-03-99, DATED FEB. 19, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination Due To DTC P0107 - Map Sensor Voltage Too Low OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18 and 98Cal12). **MODELS:** **1996** - 1998 (AB) Ram Van **1996** - 1998 (AN) Dakota **1996** - 1998 (BR/BE) Ram Truck 1998 (DN) Durango **1997** - 1998 (TJ) Wrangler **1996** - 1998 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH GASOLINE ENGINE. SYMPTOM/CONDITION: Erroneous MIL illumination with DTC P0107 - MAP SENSOR VOLTAGE TOO LOW. This may occur during downhill decelerations at altitude or when performing off-road maneuvers when the engine is operating over 1500 rpm. The MIL illuminates due to the monitor running during incorrect parameters. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH700017001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-08-00 > Jun > 00 > MIL ON, Erroneous DTC P0107 Set > Page 4131 Labor Operation No: 08-19-42-93 0.5 Hrs. FAILURE CODE: FM - Flash Module Repair Procedure 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4 Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the ORB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and ORB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1) Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-08-00 > Jun > 00 > MIL ON, Erroneous DTC P0107 Set > Page 4132 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information Technical Service Bulletin # 25-02-98 Date: 981023 I/M Testing - OBDII CARB Readiness Monitor Information NO: 25-02-98 GROUP: Emissions DATE: Oct. 23, 1998 SUBJECT: I/M (Inspection Maintenance) Testing - OBD II "CARB" Readiness Monitor Information MODELS: 1996 - 1999 (AB) Ram Van/Wagon 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (FJ) Avenger/Sebring/Talon 1996 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1996 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1995 - 1999 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper Roadster/Coupe 1997 - 1999 (TJ) Wrangler 1999 (WJ) Grand Cherokee 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO NATURALLY ASPIRATED (NON-TURBO) GASOLINE ENGINES. DISCUSSION: Some states that require I/M inspections are beginning to include OBD II "CARB" Readiness as a prerequisite to an I/M test. OBD Readiness tells an I/M station if the OBD II systems have run their self test. Owners, in those states that use OBD Readiness, may be denied an I/M test if one or more of the Readiness monitors read "NO" or in other words the OBD II monitors have not run their tests. It is important to understand that the MIL will not be illuminated because OBD Readiness reads "NO". MIL illumination happens when an actual malfunction or failure of a monitored emissions system occurs. It is possible to have MIL illumination for a detected failure while at the same time having a "NO" for an OBO Readiness monitor. NOTE: MIL ILLUMINATION INDICATES ADDITIONAL PROBLEMS WITH THE VEHICLE. FURTHER DIAGNOSIS AND REPAIR WILL BE REQUIRED BEFORE PROCEEDING FURTHER WITH THIS BULLETIN. OBD Readiness that reads "NO" can be caused by the following: PCM reprogramming, PCM replacement, fault code erasure, battery disconnects and/or replacement. If any of the above items occur before an I/M test, a good chance exists that one or more of the monitors will read "NO" for OBD Readiness. Some customers may be directed back to their dealers for assistance when an I/M test station has not allowed an I/M test due to Readiness status. The following procedures will help technicians efficiently run the Readiness tests so an owner can have their I/M test completed. EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III(R)) 1 CH7000/7001 J1962Cable 1 CH7OlO J1962 MMC Cable POLICY: Reimbursable within the provisions of the warranty. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 4137 TIME ALLOWANCE: Labor Operation No: 25-01-01-91 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure This bulletin involves operating the vehicle under specific parameters to run or complete the OBD monitors. The number of monitors applicable to a vehicle will vary by type of vehicle and emissions application. In addition, the parameters to run each monitor will vary. Preliminary Checks 1. Perform a MIL bulb check by switching the ignition key "ON" (engine off). The MIL will illuminate as a bulb check. If the MIL does not illuminate, repair the bulb or bulb circuit. 2. Connect a DRB III(R) to the vehicle. Select DRB III(R) standalone, current model year diagnostics, engine, DTC's and related functions, read DTC's. 3. Verity that no emission related DTC's are present and that the MIL is not illuminated with the engine running. NOTE: EMISSION RELATED DTC'S AND MIL ILLUMINATION MAY PREVENT OTHER OBD MONITORS FROM RUNNING. DTC'S THAT ILLUMINATE THE MIL MUST BE REPAIRED BEFORE ATTEMPTING TO RUN THE MONITORS. OBD "CARB" Readiness Check 1. With the DRB III(R) select engine, OBD II monitors, CARB Readiness Status. 2. Read the monitor status. "YES" tells you that monitor has run and is ready for an I/M test, "NO" tells you that the monitor must be run. If all monitors listed read "YES", the vehicle can be returned to the customer for completion of their I/M test. Only monitors that read "NO" must be run to read "YES". NOTE: THE MONITORS LISTED IN THE OBD "CARB" READINESS SCREEN ARE THE ONLY ONES APPLICABLE FOR THE VEHICLE BEING WORKED ON. The vehicle must be operated in various conditions (speed, temperature, etc.) for the monitors to run. Each monitor includes a pre-test and monitor test that can be viewed on the DRB III(R). The pre-test/monitor test screen lists all the preliminary parameters that must be met along with the running parameters for that specific monitor to run. An example of one screen is shown in Figure 1. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 4138 NOTE: 1997 AND PREVIOUS MODEL VEHICLES WILL HAVE A DIFFERENT LOOKING SCREEN. PRESS THE F1 KEY TO OBTAIN MONITOR RUN CONDITIONS. THE WAY IN WHICH THE MONITORS RUN WILL BE SIMILAR. The following explains how to interpret each section of the screen: PRE-TEST REQUIREMENTS The pre-test requirements include all the operating parameters that must be met before the actual test can run. The vehicle must be operated until each item within the pre-test section are fulfilled. LOW VALUE/HIGH VALUE/BAR GRAPH The low value/high value provides the minimum and maximum operating conditions for each item (ie ECT Range must be between 170° and 260° F in Figure 1). The bar graph will begin to fill when the lowest value required for each item is met. This provides a visual indication that the parameters are being met. The vehicle should be driven until most of each pre-test bar graph is filled. MONITOR REQUIREMENTS Once all pre-test requirements are met, the vehicle must be brought within the parameters listed in the monitor requirements section for the monitors to begin running. As the monitor begins to run, the DRB III(R) will begin to beep. This is an audible indication that the test is in progress. If vehicle operation falls outside any of the parameters, the beeping will stop. If this occurs, the technician must determine if the pre-test requirements or the monitor requirements have fallen outside the window for the test and the vehicle must be driven accordingly for the test to restart. When the monitor completes its test, the DRB III(R) will beep 3 consecutive times. NOTE: THE PURGE FLOW PRE-TEST SCREEN WILL LOOK DIFFERENT THAN THE REST OF THE PRE-TEST/MONITOR SCREENS. PRESS THE F1 KEY ON THE DRB III(R) TO SEE A SIMILAR SCREEN FOR THIS MONITOR. MONITOR RUN PROCESS The following will provide the most efficient order along with tips to help run through the monitor tests quickly. The monitors listed include all possible monitors for either Front Wheel Drive or Rear Wheel Drive vehicles. The vehicle being worked on may have fewer monitors than the maximum available. Only those listed on the DRB III(R) are applicable for the vehicle being worked on. The only monitors that will require attention are those that read "NO" under the OBD "CARB" Readiness Status screen. Front Wheel Drive 1. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight soak either indoors or out depending on conditions). The ambient (outside) temperature must be between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining requirements. 2. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the pre-test screen. If the vehicle is equipped with a manual transaxle, use fourth gear to help meet the requirements. 3. EGR Monitor - It is necessary to maintain TPS, MAP, and RPM ranges listed in the pre-test screen for this test to complete. 4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the pre-test screen. Automatic transaxle vehicles must be left in drive during the stop period. 5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the monitor will attempt to run on every other throttle closure. Automatic transaxle vehicles must be left in drive for the test to run. If all parameters are met and the test still will not run, place your foot on the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF cells to update. 6. O2 Sensor Heater Monitor - The open throttle time for the O2 Heater pre-test must be exceeded. This monitor will run after the ignition key is switched "Off". After the DRB III(R) switches to No Response (approximately 3 minutes) turn the ignition key "On" and check the O2 Sensor Heater monitor status. It should have switched to "YES". All other monitors should be completed before running this test. Rear Wheel Drive 1. O2 Sensor Heater Monitor - This test will require a cold start (possibly an overnight soak either indoors or outdoors depending on conditions). The ambient (outside) temperature must be between 18° and 38° C (0° and 100° F with the engine coolant temperature within 6° C (10° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 4139 requirements. 2. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight soak either indoors or outdoors depending on conditions). The ambient (outside) temperature must be between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining requirements. 3. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the pre-test screen. If the vehicle is equipped with a manual transmission, use 4th gear to help meet the requirements. 4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the pre-test screen. Automatic transmission vehicles must be left in drive during the stop period. 5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the monitor will attempt to run on every other throttle closure. Automatic transmission vehicles must be left in drive for the test to run. If all parameters are met and the test will still not run, place your foot on the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF cells to update. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-24-98 > Jul > 98 > PCM - Light Spark Knock Condition Technical Service Bulletin # 18-24-98 Date: 980731 PCM - Light Spark Knock Condition NO: 18-24-98 GROUP: Vehicle Performance DATE: Jul. 31, 1998 SUBJECT: Light Spark Knock Timing Retard Feature MODELS: 1996 - 1997 (AB) Ram Van 1996 - 1997 (AN) Dakota 1996 - 1997 (BR) Ram Truck 1996 - 1997 (XJ) Cherokee 1996 - 1997 (ZJ) GrandCherokee 1996 - 1997 (ZG) Grand Cherokee (International Markets) NOTE: THIS INFORMATION APPLIES TO VEHICLES EOUIPPED WITH A 2.5L, 4.OL, 3.9L, 5.2L AND 5.9L LIGHT DUTY GASOLINE ENGINES. SYMPTOM/CONDITION: Some vehicles may exhibit light spark knock with a warm engine under load. DISCUSSION: Determine when the customer exhibits this condition and verify it by driving the vehicle in similar conditions. If the vehicle exhibits light spark knock with a warm engine under load perform the flash update procedure. Once the flash procedure is completed, spark advance/retard may be adjusted. NOTE: THE DRB III(R) MUST BE OPERATING AT RELEASE 25.5 OR HIGHER. Select DRB III(R) stand alone, current model year diagnostics, engine, and miscellaneous. When in miscellaneous, spark advance will be available. Use the arrow keys to retard timing in 20 increments to a maximum of A°. When the DRB III(R) screen reads 0 the vehicle will be set at maximum advance and when at -4 it will be set at maximum retard. NOTE: THE IGNITION KEY MUST BE CYCLED FOR THE CHANGES TO TAKE EFFECT. After performing the spark advance/retard feature, drive the vehicle to verify that the light spark knock is gone. This feature will not compensate for heavy spark knock conditions. If heavy knock is experienced, funher diagnosis and testing will be required. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. EQUIPMENT/PARTS REQUIRED: 1 CH6OOO ScanTool (DRBIII(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7OOO/7001 J1962 Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III(R) ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1165 OR HIGHER MUST BE INSTALLED. THE DRB III(R) MUST BE OPERATING AT RELEASE 25.5 OR HIGHER. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-24-98 > Jul > 98 > PCM - Light Spark Knock Condition > Page 4144 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-41-96 0.5 Hrs. FAILURE CODE: FM - Flash Module Repair Procedure This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. 1. Connect the MDS (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and power them up. 3. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III(R) MAIN MENU Screen. 4. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 5. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III(R) on the MDS, then press NEXT MENU. 7. Follow the steps presented on the MDS and DRB III(R) which will allow the DRB III(R) to obtain the current part number of the PCM. 8. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the POM has already been updated, then another condition exists that will require further diagnosis and repair. 9. The MDS and DRB III(R) will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 10. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-24-98 > Jul > 98 > PCM - Light Spark Knock Condition > Page 4145 11. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-10-98 > Feb > 98 > OBD II - Improper MIL Illumination Technical Service Bulletin # 18-10-98 Date: 980227 OBD II - Improper MIL Illumination NO: 18-10-98 GROUP: Vehicle Performance DATE: Feb. 27, 1998 SUBJECT: OBD II Misfire Indicator THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-26-97 REV. A, DATED SEP. 5, 1997 THAT SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1997 TECHNICAL SERVICE BULLETIN MANUAL (P/N 81-699-98004). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF 1997 AN MODELS. MODELS: **1997**-1998 (AN) Dakota 1998 (BR/BE) Ram Truck NOTE: THIS BULLETIN APPLIES TO 1998 MODELS BUILT BEFORE AND INCLUDING THE FOLLOWING DATES: 11TH POSITION OF VIN G (SALTILLO), J (ST LOUIS), M (LAGO) AUG. 20, 1997 (MDH 0820XX) - S (DODGE CITY) AUG. 19, 1997 (MDH 0819XX) AND **ALL 1997 AN MODELS**. This information applies to all gasoline equipped models except heavy duty emission 5.9L federal and heavy duty emission 8.0L federal packages. The VECI label can be inspected to see if the 5.9L or 8.0L applies to this action. The VECI code sequence for these heavy duty emission models will be WCRXH08.0BA1 for 8.0L and WCRXH05.9BA1 for 5.9L. The highlighted H designates heavy duty. The location of the label for 5.9L is on the air cleaner and 8.0L on the air pump bracket. No diesel vehicles apply to this action. DISCUSSION: **The above model trucks with gasoline engines will not illuminate the MIL properly when misfire is detected. The software within the powertrain control module has been revised to correct an OBD II system monitor that is non-compliant based on misfire requirements set forth by the Federal Government and C.A.R.B.. ** **NOTE: ALL APPLICABLE VEHICLES BROUGHT IN FOR ANY MAINTENANCE MUST HAVE THIS REFLASH PROCEDURE PERFORMED.** EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1152 OR HIGHER MUST BE INSTALLED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-49-98 0.5 Hrs. FAILURE CODE: FM - Flash Module Repair Procedure This procedure involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration change). 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-10-98 > Feb > 98 > OBD II - Improper MIL Illumination > Page 4150 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 181297 > Mar > 97 > PCM - Erroneous MIL ON/Driveability Improvements PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - Erroneous MIL ON/Driveability Improvements NO: 18-12-97 GROUP: Vehicle Performance DATE: Mar. 14, 1997 SUBJECT: Erroneous MIL Illumination/Driveability Improvements MODELS: 1997 (AB) Ram Van/Wagon 1997 (AN) Dakota 1997 (BR) Ram Truck 1997 (TJ) Wrangler 1997 (XJ) Cherokee 1997 (ZJ) Grand Cherokee SYMPTOM/CONDITION: NOTE: THIS FLASH UPDATE DOES NOT APPLY TO WRANGLER MODELS BUILT PRIOR TO JULY 15, 1996 (MDH 01-15-XX) 8 DIGIT PCM PART NUMBER. APPLICABLE MODELS CAN BE IDENTIFIED WITH A 10 DIGIT PCM PART NUMBER. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's or those listed above are present and any of the above symptoms have been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 181297 > Mar > 97 > PCM - Erroneous MIL ON/Driveability Improvements > Page 4155 REPLACEMENT PCM SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL. EQUIPMENT REQUIRED: All Symptoms (Flash Programming) 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification NOTE: THE MDS AND DRB III ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1127 OR HIGHER MUST BE INSTALLED. REPAIR PROCEDURE: This repair involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes) for all conditions listed. 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020. Attach the label to the PCM and cover the label with the clear plastic overlay. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 181297 > Mar > 97 > PCM - Erroneous MIL ON/Driveability Improvements > Page 4156 10. Type the necessary information on the Authorized Modification Label p/n 04275086. Attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-47-97 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 182696 > Sep > 96 > PCM - Erroneous MIL, and/or Driveability Concerns PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - Erroneous MIL, and/or Driveability Concerns NO: 18-26-96 GROUP: Vehicle Performance DATE: Sep. 27, 1996 SUBJECT: Erroneous MIL Illumination and/or Driveability Concerns MODELS: 1997 (AB) Ram Van/wagon 1997 (AN) Dakota 1997 (BR) Ram Truck 1997 (ZJ) Grand Cherokee 1997 (TJ) Wrangler NOTE: THIS BULLETIN DOES NOT APPLY TO 1997 WRANGLERS BUILT BEFORE JULY 15, 1996 (MDH 0715XX). 1997 WRANGLERS BUILT AFTER THIS DATE CAN BE IDENTIFIED BY HAVING A TEN DIGIT PART NUMBER ON THE POWERTRAIN CONTROL MODULE (PCM) WHERE AS VEHICLES BUILT PRIOR TO THIS DATE HAVE AN EIGHT DIGIT PART NUMBER ON THE PCM. SYMPTOM/CONDITION: Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 182696 > Sep > 96 > PCM - Erroneous MIL, and/or Driveability Concerns > Page 4161 These illustrations list PCM updates for erroneous MIL (Check Engine Lamp) illumination and/or driveability concerns. Please perform updates to the PCM for any vehicle listed above that you encounter. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) and appropriate Diagnostic Procedure Manual, verify that all engine systems are functioning correctly. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order. Any DTCs not identified in this TSB and/or DTCs identified in this TSB that are not listed in the SYMPTOM/CONDITION as erroneous should be repaired as necessary. If any of the above conditions or DTCs exist, perform the Repair Procedure. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000 J1962 Cable 1 4669020 Label - Authorized Software Update 1 4275086 Label - Authorized Modification REPAIR PROCEDURE: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration change). NOTE: MDS AND DRB III ARE REQUIRED TO PERFORM THE FOLLOWING REPAIR. MDS MUST BE OPERATING WITH RELEASE 20 OR HIGHER AND TIL 1117 OR HIGHER INSTALLED. 1. Connect the MDS to the DRB III and connect the DRB III to the vehicle 16-way Data Link Connector (DLC) and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS WITH MDS AND DRB III on the MDS then press NEXT Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 182696 > Sep > 96 > PCM - Erroneous MIL, and/or Driveability Concerns > Page 4162 MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then a system problem actually exists and should be corrected. 8. The MDS and DRB III will prompt the operator for any action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update" label, P/N 4669020. Attach the label to the PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Reprogram Powertrain Control Module 08-19-46-90 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery Technical Service Bulletin # 18-037-05 Date: 051020 Engine Controls - Flash Programming Failure Recovery NUMBER: 18-037-05 GROUP: Vehicle Performance DATE: October 20, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-020-02, DATED JUNE 24, 2002 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Flash Programming Failure Recovery Using DRBIII(R) OVERVIEW: This Bulletin provides guidelines, to minimize flash reprogramming problems, and information on recovery procedures for failed flash attempts. MODELS: 1992 - 1994 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2003 (AB) Ramvan/Wagon 1992 - 1994 (AJ) Lebaron Coupe/Convertible 1995 - 2004 (AN) Dakota 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 2002 (BRIBE) Ram Pickup 2004 - 2006 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2005 (DR/DH/D1) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1996 - 2000 (CS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2006 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2005 (KJ) Liberty/Cherokee (International Markets) 1993 - 2003 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 (PG) PT Cruiser (International Markets) 1997 - 2002 (PR) Prowler 2001 - 2005 (PT) PT Cruiser 2001 - 2006 (RG) Chrysler Voyager (International Markets) 2001 - 2006 (RS) Town & Country/Caravan/Voyager Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4168 1995 - 2002 (SR) Viper 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) 1999 - 2004 (WJ) Grand Cherokee 1997 - 2001 (XJ) Cherokee 1993 - 1995 (YJ) Wrangler 2003 - 2006 (ZB) Viper 1995 - 1998 (ZG) Grand Cherokee (International Markets) 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: NOTE: Many of the reasons a flash reprogramming procedure may not complete are documented in this service bulletin, but if you are constantly having issues performing the flash reprogramming procedure using a specific DRBIII(R), it is suggested you send the DRBIII(R) in question to SPX/Miller Special Tools for service. Occasionally a flash update procedure may not complete properly and/or the diagnostic equipment may lock up or become disconnected during the procedure. Flash Reprogramming is a "CRITICAL PROCESS"; an error may result in a no-start/failed control module. Most modules, encountering an interruption or failure while reprogramming, are recoverable; a recoverable module is not covered under the provisions of the warranty. This service bulletin covers items that may cause this condition, a process to restart the flash procedure, and miscellaneous information that will help prevent needless replacement of control modules. GENERAL: Flash Reprogramming is only authorized by a specific SERVICE BULLETIN, or RECALL. Review the entire Service Bulletin/Recall prior to performing a flash reprogramming update. Often other parts may need to be serviced, replaced, or tested, prior to flash reprogramming, and ARE REQUIRED as part of completing the Service Bulletin/Recall. When flashing a Powertrain Control Module (PCM) or Transmission Control Module (TCM) there are other legal requirements with labeling issues that are included in those service bulletins. Other non-emission related modules, such as instrument clusters and Body Control Modules (BCMs) do not require labels. FLASH REPROGRAMMING SEQUENCE OF EVENTS The process of flash reprogramming is similar to flashing the BIOS on a Personal Computer. Interruptions, voltage problems, and a variety of other outside interactions can potentially interfere with the process. This document seeks to provide information to minimize problems associated with vehicle control module flash reprogramming. The description that follows is for most PCMs and some TCMs. Other modules use different initiation procedures. The process starts by selecting an update from the TechCONNECT Client or ISIS and then "loading" that update into the DRBIII(R). Once the flash reprogramming update is loaded into the DRBIII(R), and before the flash reprogramming begins, the DRBIII(R) verifies that the update loaded from the TechCONNECT Client or ISIS is the proper update for the module. This is done using part number supersedence. This verification occurs only if an update is required, available (on the TechCONNECT Client or ISIS) and has been selected for programming. ^ The module is then placed into "Boot Strap" programming mode by the DRBIII(R). This module mode gives the DRBIII(R) permission and the ability to proceed with the flash reprogramming session. ^ Next, the current part number, which resides in the module's flash memory, is stored in a "Safe Memory" location within the module. This memory location is not affected by flash memory erasure and reprogramming, which are to follow. ^ Once the part number is safely stored, the flash memory in the control module is erased. From this point forward any interruption in the flash process, Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4169 will result in a Non-Responsive module (NR). A NR module is a module that is either partially erased or partially programmed. ^ After erasure, the actual reprogramming procedure starts, and the update software is programmed into the flash memory within the module. ^ When reprogramming is completed, the flash memory is verified through an internal process in the DRBIII(R) using a "Check Sum". This value is compared against another value that represents what should be in memory and when matched, verifies successful reprogramming. ^ Next, a DRBIII(R) prompt is displayed instructing that the ignition switch be turned OFF. The module exits the "Boot Strap" mode when the switch is turned off. ^ After a slight pause, the DRBIII(R) will prompt for the ignition switch to be turned ON. The DRBIII(R) then reads the new part number in flash memory (along with a new computer program the new part number is placed into the module's memory). If the new part number matches the expected part number, the flash reprogramming session has completed successfully. SOFTWARE VERSIONS MUST BE CURRENT Before attempting a flash reprogramming session using the TechCONNECT Client, make sure you have the most current DRBIII(R) software installed. To verify whether your DRBIII(R) software is current, check the upper right-hand corner of the TechCONNECT Client screen for DRBIII(R) Available Version, DRBIII(R) Current Version. Often, because of multiple DRBIII(R)s in the shop, not all will get updated on a timely manner. The installed DRBIII(R) software version can generally be found at the bottom center of most screens. Alternately the version can be checked by pressing 6, 2, 5 from the DRBIII(R) Main Menu and comparing it to what is available from a current TechCONNECT Client as described above. If the TechCONNECT Client is current and the DRBIII(R) is not, it may be due to the fact that the TechCONNECT Client does not force DRBIII(R) updates for "minor" revisions. Changes and new support are added to the Vehicle Flash application on "minor" revisions on a regular basis. This is why your TechCONNECT Client and DRBIII(R) must have the LATEST software revisions installed. DO NOT PASS on the option for updating to a "minor" revision! Major updates require the DRBIII(R) to be updated prior to allowing any flash programming. DRBIII(R) CABLES A NEW DRBIII(R) cable was released as an Essential Service Tool! CH7000A - 8 ft. Cable, DRBIII(R) to OBDII (J1962) DLC Connector. CH7000A is the required cable for ALL flash reprogramming. The older CH7000 cable can be used for diagnostics ONLY. One (1) cable was shipped to all dealerships. Easily identified, the correct cable has a RED connector, which plugs into the DRBIII(R). The cable modification enhances the DRBIII(R) communication capabilities when dealing with the flash requirements of certain controllers/ECUs affected in part by the recent changes in DLC connector configurations. The new cable is required for ALL flash reprogramming sessions, and can be used wherever the previous CH700017001 cables were used. While not recommended for flash reprogramming usage, if you require a longer cable, there is also a 12-foot cable released under pin CH7001A The production of the previous CH700017001 cables has ceased. All orders placed will be superseded to part number CH7000A/CH7001A. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4170 NOTE: Consider all cables wear items. Always inspect for worn, damaged cables, connectors that are damaged or do not lock securely, and all mating connections including checking for corrosion on the pins. REPLACE ALL suspect cables. Do not use worn or damaged cables when flash reprogramming. Failure to use the new cable or to use a damaged cable often results in failed flash reprogramming sessions. The 2 door Sebring, Stratus, and Avenger coupes (supplied by MMC) generally use the CH7O1O cable (Pre-OBDII MMC vehicles will use the CH7005 cable). TechCONNECT CABLE (GPIB) Replace any suspect GPIB cable. The GPIB cable provides the connection between TechCONNECT Client and the DRBIII(R). This cable is used by the TechCONNECT Client for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash session, you may have to reload the update file that you selected on the TechCONNECT Client. TROUBLESHOOTING CONNECTIVITY OF THE DRBIII(R) UNIT TO THE TechCONNECT APPLICATION. 1. Turn-on the power to the DRBIII(R) unit. 2. Select option 2 "Connect to TechCONNECT" and press Enter. 3. Attach the male mini D-shell amphenol GPIB connector of the new DRBIII(R) cable (part number CH7035B) to the DRBIII(R) unit. 4. Insure that the larger female D-shell amphenol GPIB connector of the new DRBIII(R) cable is properly attached to the male D-shell amphenol GPIB connector on the GPIB-USB-B protocol converter, (part number CHGPIB-B). 5. Attach the USB cable from the GPIB-USB-B protocol converter to one of the USB ports on the rear panel of the client CPU. 6. When the cable is attached to the USB port of the CPU for the first time, Windows 2000 will detect the device and install software for it. Please wait for 25-30 seconds to complete the installation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4171 ISIS NULL MODEM CABLE Replace any suspect null modem cables. International (ISIS), a PC-based CD program similar to TechCONNECT Client uses a null modem cable for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash download session, you will have to reload the update file or files. GENERAL NOTES FOR CABLES AND VEHICLE CONNECTIONS Consider ALL cables to be wear items. Many successful dealers have dedicated cables devoted to "Flash ONLY". Always have spare CH7000A, CH7010 and CH2002 GPIB or null modem cables available. Inspect vehicle diagnostic connectors for potential problems that might cause communication interruptions. There are now clip repair kits available through teamPSE to replace the retaining clips for two of these cables. To protect the DRBIII(R) from internal damage, the clips are designed to fail at above 25 lbs. of axial force. Kits are described in the table. It is a good practice to discard cables that have damage to the pins, cuts, corrosion, or general damage beyond the retaining clips. ST22 SEBRING STRATUS 2 DOOR COUPES (2001-2005) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4172 These vehicles use MMC based modules. The CH8432 Supplemental Reprogramming Tool (SRT) was shipped as a 2001 Essential Tool. The flash reprogramming update files will be downloaded from TechCONNECT Client to the SRT for flash reprogramming sessions on these vehicles. Users should closely follow the instructions that come with the tool. If the tool has not been initialized, there is a known condition where it may take up to 5 or more attempts for it to fully initialize and become functional. NOTE: Once it has successfully flashed, it is initialized and no further action is required. PREPARING TO FLASH It is highly recommended that a sign, or other process, be used that notifies other users that a FLASH SESSION IS IN-PROGRESS and must NOT be interrupted. Interrupting some flash reprogramming sessions at critical junctures can render a module inoperative. Another user may not realize that a flash session is in-progress and may disturb or disconnect the DRBIII(R) or do something on the vehicle that could interrupt the flash process. Before starting the flash session, read, record and erase all DTCs found on the vehicle. Also "Cold Boot" the DRBIII(R) and download the flash since this will erase the flash file from the DRBIII(R) memory. (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Be sure to arrange the TechCONNECT and DRBIII(R) so that no cables are stretched across an area where someone might trip over or kick a cable. When setting up your DRBIII(R), insure that it rests on a surface where it will not fall or be bumped during reprogramming e.g.: DRBIII's have been known to be swept off vehicle windshields by accident when a user bumps the wiper switch). Check User settings on the DRBIII(R). From the DRBIII(R) Main menu, press 6,1 and check to make sure item 1. Echo on PC is set to OFF. On occasion, when Echo on PC is set to ON, flash reprogramming errors may occur. VEHICLE BATTERY VOLTAGE The flash programming procedure puts a load on the electrical system that may last from five to twenty minutes depending on the particular flash reprogramming update. Connect a battery charger to the vehicle. Set the charger to as close to 14 volts as possible. If the charger has a timer, set it for 30 minutes BEFORE starting a flash reprogramming session. This will help to prevent unwanted resets by either the DRBIII(R) and/or the vehicle module that are caused by voltage fluctuations. Alternately, as a bare minimum, use a "Battery Jump Box" when a battery charger is unavailable to ensure adequate and stable system voltages on the module being flash reprogrammed. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Connected/Disconnected Flash Mode Using TechCONNECT CONNECTED MODE FLASHING USING TechCONNECT NOTE: Capable but not recommended. In this mode, the DRBIII(R) remains connected to the TechCONNECT Client and the vehicle throughout the flash session. The DRBIII(R) is connected to the TechCONNECT Client using the GPIB (CH7035) cable and to the vehicle using the vehicle I/O cable (the CH7000A for most vehicles). This mode is useful when the TechCONNECT Client is next to the vehicle being flashed. Another advantage of this mode is that you are able to determine all available flash updates for the vehicle you are connected to by clicking on the "Read Part Number(s) From Vehicle" button. Again, it is important that other users do not attempt to reboot or move the TechCONNECT Client while a flash update is in-progress. The reprogramming procedure of this mode is initiated by selecting the controller option and clicking "Download/Update" button on the TechCONNECT client. DISCONNECTED FLASH MODE NOTE: Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4173 This is the preferred method. This mode allows a user to flash a vehicle without being connected to the TechCONNECT Client. This is a popular mode for flashing in a remote area of the service garage or in a back lot. Before you attempt to use this mode, you must configure the DRBIII(R) for the desired update(s). To do this, you must connect the DRBIII(R) to the TechCONNECT Client using the GPIB cable and the CH7025 cable. It is not necessary to be connected to a vehicle. The GPIB (CH7035) cable will be used to communicate with the TechCONNECT Client (for update file downloading) while the CH7025 cable is used to provide power to the DRBIII(R). After making the above connections, you are able to select one or more updates that you want to perform. These selections are made by highlighting the desired updates and then clicking on the "Download/Update" button by selecting the DRBIII(R) option on the TechCONNECT client. Obviously, the DRBIII(R) does not have unlimited memory. If the file size of the selected updates exceeds 948 KB, the "DRB Space Used" indicator (at the bottom-center of the TechCONNECT Client screen) will change color from GREEN to RED. At this point you must de-select entries until the indicator changes color to GREEN again. When the updates have finished downloading, you may disconnect from the TechCONNECT Client and take the DRBIII(R) to wherever the vehicle is located. The updates will remain in DRBIII(R) memory for 8 hours while the DRBIII(R) is without power. If the DRBIII(R) is powered up for several minutes before the 8 hour time period has expired, the update files will remain on the DRBIII(R) for another 8 hours without power. To start the actual flash process, after connecting to the vehicle in Disconnected Mode, you must press "7 - Vehicle Flash" from the Main Menu on the DRBIII(R). Step by step instruction will follow on the DRBIII(R) display. As with Connected Flash Mode, take the necessary precautions to insure that others are aware of the flash session and that nothing disturbs the vehicle, DRBIII(R), or cabling while performing the flash. Remember to use a battery charger set to 14 volts or a "battery jump box". Pay Attention While Performing Flash Reprogram Procedures PAY ATTENTION WHILE PERFORMING FLASH REPROGRAMMING PROCEDURES Before downloading the flash files, double check to see if the files that you have selected are the appropriate ones for that vehicle. Don't forget about the "Read Part Numbers From Vehicle" option on TechCONNECT Client, this can be of great assistance when trying to flash a module. If the files selected don't download on the first attempt, try again. The technician should NOT leave the vehicle when flash reprogramming a module. Again, check to make sure that all cable connections are secure and that the DRBIII(R) rests on a stable surface. If you are using a battery charger, insure that the settings and charging times are correct and that the battery post clamps are securely fastened. Read, record, and erase all DTCs found on the vehicle. Read and record the module type and part number from the module that is to be flash reprogrammed. Some control modules are not "abort-recovery" capable. When this is true, the scan tool will indicate so by displaying a WARNING message prior to the start of reprogramming. For these modules it is especially important that all precautions and procedures, outlined here, are carefully followed. Pay special attention to DRBIII(R) screen directions relating to key cycles. Missing a "Key ON" or "Key OFF" can cause the module to have to be reflashed again. Due to the variety of module types and vehicle options, you can't always anticipate key prompts, so be alert and ready to respond to DRBIII(R) instructions. Some screens will also instruct that certain modules, connectors or fuses be disconnected or pulled prior to the start of reprogramming and re-installed immediately after completion. Be careful not to anticipate the steps or order of operations for reprogramming any vehicle modules. Because of the many possible changes that occur with each new release of scan tool software, always allow the TSB/Recall and scan tool instructions to be your guide while performing flash reprogramming. Flash reprogramming sessions usually range from 5 to 20 minutes. If the flash session has not completed within 25 minutes after starting a flash reprogramming update, an error has most likely occurred (Record the message that appears on the screen when a failure occurs). If this is the case, or if you know that the flash process was interrupted, cycle the ignition key (OFF to the locked position, then back ON). Reset the DRBIII(R) (power down for 4 seconds and then power up) before attempting to restart the flash process. If the module still won't respond, turn the ignition key off, disconnect the module from the vehicle for 2 minutes, reconnect the module, turn the ignition key to run and try to restart the flash process again. Regardless of what mode that you are in (Connected Flash or Disconnected Flash), if you have tried twice (2 times) unsuccessfully to do a flash recovery and ALL DRBIII(R) instructions were followed, perform the following: ^ Cold boot the DRBIII(R). This resets memory and removes all update files from the DRBIII(R). (Push MORE and YES buttons at the same time, then press F4). ^ Reload the flash update file from the TechCONNECT Client. ^ If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4174 ^ Proceed to reflash the module. On vehicles that have multiple flash updates available, always complete and verify each flash update before attempting the next one. After all flash reprogramming is completed, read and erase all DTCs in all modules on the vehicle. A variety of DTCs may be set, which are usually related to a loss of communication with the module(s) being reprogrammed. Verify the update by reading the new part number using the DRBIII(R). A good double check is to read the part number using DRBIII(R) stand alone. At times, other modules, wired in parallel, to the DLC connector have prevented flash reprogramming sessions to be successful. After the failed attempt, review the appropriate wiring diagram for the vehicle you are flash reprogramming and, with the key "OFF"; disconnect the other modules and retry the flash. Complete the flash, turn the key "OFF" and reconnect any modules that were disconnected. Refer to the "Programmable Modules" section later in this document for more information. Error Messages ERROR MESSAGES Block Echo/Compare Errors Block Echo and Block Compare errors are often caused by voltage fluctuations, faulty I/O cables (CH7OOOA, CH7005, CH7010) or faulty communication connections at the diagnostic connector. Inspect for these conditions and review the sections on Vehicle Battery Voltage and Cable recommendations. Checksum Errors Checksum Errors are generally caused by corrupt flash update files, which can be caused by DRBIII(R) memory problems. If the DRBIII(R) has been without power for more than 8 hours, the update files and system memory could be in a corrupted state. "Cold Boot" the DRBIII(R). (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Reload the flash update file(s) from the TechCONNECT CLIENT. If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Then re-attempt the flash reprogramming process. Enhanced and Original Abort Recovery ENHANCED ABORT RECOVERY Interruptions in the flash process are one of the main reasons for failed flash sessions and non-responsive (NR) modules. Interrupting the flash process after the erase phase has started will leave the control module in a non-functional state. Generally, but not always, NR modules may be recovered successfully. Briefly, abort recovery is the process used to get a NR module back to a fully functional state with the latest software update. The technician should be familiar with the other sections in this document and follow all DRBIII(R) user prompts carefully. There are two methods for abort-recovery. The newer method is called "Enhanced Abort Recovery". This is the preferred method since the original method takes several minutes longer and requires the correct selection of module type from a list of possible PCM's or TCM's. Starting with Release 60.1, a new useful feature was added to the flash reprogramming application for Engine and Transmission control modules. The DRBIII(R) "writes" the YME and Controller Type information to a "Safe Memory" location. This method allows for rapid recovery of the module part number and minimizes errors that could otherwise be made by selecting the wrong controller type. It also assumes that the user will attempt abort recovery for a failed flash attempt before moving to another vehicle with the same DRBIII(R). If you need to move to another vehicle for flash reprogramming you must erase the saved recovery information in order to successfully perform flash reprogramming. Be careful to match the YME information displayed on the enhanced abort recovery screen with the vehicle and module that you are attempting to recover. If you use the recovery file on a different vehicle and module you could damage the module. The recovery information will be displayed on your DRBIII(R), at the start of a flash session, only if you previously encountered a problem that prevented a flash session from completing normally. If your prior flash session was successful, the DRBIII(R) automatically erases the recovery file so that the flash application will not show any recovery information at the start of your next flash session. Enhanced abort recovery features: ^ Reduces the amount of time for the Module ID process. ^ Lowers the risk of possible user mistakes by presenting the user the Year, Model, Engine, and Controller Type. ^ Currently only applicable to Engine and Transmission flash reprogramming. ^ The enhanced abort recovery file will only be erased upon a successful flash or manually by the user. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4175 ^ Cold booting (simultaneously pushing MORE & YES, then F4) the DRBIII(R) will not erase the enhanced abort recovery file, but cold booting the DRBIII(R) will still erase the flash file so it can be reloaded. ^ The user has a choice, at the start of a flash session, whether or not to use the enhanced abort recovery feature. If the user chooses to erase the recovery file, then the DRBIII(R) will use the original method of abort recovery. ^ Cycling the ignition key, when prompted by the DRBIII(R), is still necessary to put the controller into bootstrap (reprogramming) mode. ORIGINAL ABORT RECOVERY If the choice is made to use the original method of abort recovery, a NR module is not always able to provide the DRBIII with ID information. In this case the technician must enter this when prompted by the DRBIII(R). Be patient when performing this process. If the module does not respond to standard diagnostic requests, the DRBIII(R) may take several minutes before it determines that the engine module is in a NR state. At this point, the DRBIII(R) displays the prompt "Could not determine engine controller type. Please select from list" along with a list of possible controller types (if the DRBIII(R) is attempting to identify a TCM, the prompt will say "trans" instead of "engine" and list the possible trans controller types). Because of module variations, it is important to correctly identify the PCM/TCM type so that the correct flash procedure is used. Failure to do this will cause further problems and may damage the module. Tables are provided below to help identify the proper module type to select. These tables correctly identify the modules that were on the vehicles when they were built. However, some vehicles will have module types which were superseded to a new type when a replacement part was installed (ie: EATX4 modules replaced with an EATX4A). Correctly identify these modules using DRBIII(R) Standalone prior to attempting flash reprogramming. NOTE: When instructed to turn the key to the LOCKED position, be sure that the key is not just turned to the OFF position. The key must be rotated to the point at which it can be removed from the ignition switch. On most vehicles the switch is on the steering column and at this position the steering column is LOCKED. When instructed to turn the key to the RUN position, be careful not to turn the key past this position which may engage the starter motor. This creates electrical noise which interferes with the flash process. General Steps for Abort Recovery 1. Review all Tips and Techniques before continuing. Pay special attention to the section on Preparing to Flash a controller and to the Programmable Modules section. 2. Cycle the vehicle's ignition key to the LOCKED position and back to the RUN position. 3. Reset the DRBIII(R) by disconnecting the vehicle cable from the DRBIII(R) for 4 seconds and then reconnecting the cable. 4. Depending on where the flash session was aborted, the DRBIII(R) may require that the technician identify the control module type that was being flash reprogrammed. Use the PCM/TCM configuration table below as a guide. This step is not necessary if using the enhanced abort recovery method. 5. After selecting the proper control module type or choosing enhanced abort recovery, follow the prompts that are displayed on the DRBIII(R). NOTE: If an error message is displayed at this point, an incorrect module type was most likely selected. If this occurs, start the process over. 6. If the recovery process is unsuccessful, perform the following: a. Review the TSB/Recall notice (authorizing the flash update) and all Tips and Techniques in this document. b. Reboot/Restart the TechCONNECT Client. c. "Cold Boot" the DRBIII(R). (Press the MORE and YES buttons on the DRBIII(R) at the same time, then press F4). d. Start this process over from item # 1. If using Disconnected Mode, the flash update will have to be reloaded from the TechCONNECT Client or ISIS DVD. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4176 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4177 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4178 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4179 Programmable Modules The following pages list the various modules that have flash reprogramming capability. It does not mean that a flash is currently available. What will be described are the module types and variations, followed by items to note, and finally, abort recovery specifics if applicable. Powertrain Modules - Engine and Transmission ENGINE - POWERTRAIN CONTROL MODULE (PCM) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4180 There are a variety of Engine (PCM) modules that are flash reprogrammable. Suggestions that are somewhat unique to each type will have comments. Prior to reprogramming a PCM, retrieve the module information and module type using your DRBII I®. PCM information is used by many modules. Be sure to check DIG's before and after performing all flash reprogramming event. The DTC's associated with flash reprogramming generally relate to "lack of communication" with the other modules during the reprogramming session. SBEC Types: SBEC, SBEC 2, SBEC 3, SBEC 3+, SBEC 3A, SBEC 3A+, and SBEC 3B NOTE: During recovery, if the DRBIII® is not seeing the key off, you may need to remove power (B+) to PCM by removing fuse(s) or disconnecting the PCM. When DRBIII® states to turn key ON, reconnect fuse or harness connection. Abort Recovery Specifics: ^ Follow instructions on the DRBIII® for the module type. See table above. ^ Some SBEC 3A, SBEC 3A+ AND SBEC 3B may be in a state where they can not correctly identify a key cycle. In this case a Modified Key Cycle routine is required. This state is present when the following message is displayed on the DRBIII(R): "Can not read Part Number. Did not see Key On or PCM/TCM Controller may not be flashable". When this occurs restart the flash session and when prompted to turn the ignition key to the LOCKED position, pull the fuse(s) that supply battery power to the module instead. When prompted to turn the key to the RUN position, replace the battery supply fuse(s) instead. JTEC Types: ^ JTEC, JTEC+ NOTE: Viper ALL - Roll down windows especially Coupes before attempting a flash. NOTE: 1999 WJ JTEC with Speed Proportional Steering module. Disconnect before and reconnect after the PCM flash reprogramming session. Also see Transmission. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NGC Types: ^ NGC 1, NGC 2, and NGC 3 NOTE: There are derivatives of NGC 3 that will be significant when reprogramming and or testing. NGC modules use one of the longest time spans for flash reprogramming (approximately 15 minutes). The NGCI and NGC3 controllers incorporate both an engine as well as a transmission controller in a common package. The NGC2 controller incorporates the engine controller and an Electronic Throttle Control (ETC) module in place of the TCM. All NGC controllers can be visually identified by noting its four (4) wiring connectors. On manual transmission applications and the NGC2, only 3 connectors may be populated with pins. NOTE: On certain vehicles, the ABS CAB module connector MUST be disconnected prior to performing this Repair Procedure. The CAB module and the PCM are connected at the same diagnostic connector pin (Pin # 9). Turn ignition switch to the OFF position, disconnect the CAB module connector, and reprogram the PCM per the Repair Procedure. When reprogramming is complete turn the ignition switch to the OFF position, connect the CAB module connector, and then check for DTC's. If the PCM becomes "locked" during reprogramming because the ABS CAB module connector was not disconnected, then the PCM may be recovered by following the procedure in this NOTE. Abort Recovery Specifics: Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4181 ^ Follow DRBIII(R) prompts carefully. ^ Power down the DRBIII(R) then cycle ignition before powering up the DRBIII(R) to attempt the flash. CUMMINS Types: ^ CM551 and CM84x series NOTE: Cummins flash reprogrammable PCMs are used on 1998.5 and newer Dodge Trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Model Year 2000 and earlier vehicles have one Engine Control Fuse to pull when prompted by the DRBIII(R). Model Year 2001 and later have two Engine Control Fuses (one 20 Amp and one 30 Amp) to pull when prompted by the DRBIII(R). The fuse(s) are located in the PDC and need to be pulled/removed, when prompted, for at least 10 seconds. SIEMENS Types: ^ SIM-70 NOTE: The SIM-70 is currently used on BUX PL and PG vehicles with a 1.6L ONLY. Abort Recovery Specifics: Follow DRBIII(R) prompts carefully. BOSCH Types: ^ EDC15V, EDC15-C5, and EDC16 NOTE: While there have been other Bosch modules, the EDC15V is not flash reprogrammable. Transmission controllers are usually flashed on the vehicle (since 1996). Technicians may set the pinion factor on "NEW" modules either before or after flash reprogramming. Suggestions follow. After flash reprogramming and before returning the vehicle to the customer, always perform a "QuickLearn" to the TCM. EATX Types: ^ EATX, EATX 2, EATX 3, EATX 3A, EATX 3B, EATX 4, and EATX 4A NOTE: Table shows which TCM was installed "as-built". Often TCMs are superseded by parts and or a service bulletin. Abort Recovery Specifics: ^ 1999 - 2000 WJ and 2000 AN/DN using 4.7L engines the service replacement EATX4A part numbers 56041814AD and 56028227AH currently display a P/N read failed error after the flash is completed during PIN verification. This DOES NOT mean the flash failed. Check for the part number using DRBIII(R) in standalone mode. This exists only for the service replacement modules listed above. Flash reprogramming for OE modules flash and read the part number correctly. Follow DRBIII(R) prompts carefully. NGC Types: Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4182 ^ NGC1, NGC2, NGC3 NOTE: The NGC I1and NGC 3 have the EATX/XCORE and Engine modules combined. NGC 2 does not. Vehicles with automatic transmissions using NGC2 will use an EATX4A. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ 2002 DR, 2002.5 DN, 2003 AN/DN and later with NGC have shown that in some instances the CAB controller may need to be disconnected when attempting to flash the NGC controller. (This should only be performed if an error occurs at the very beginning of the TCM flash portion.) SIEMENS Types: ^ EG552 NOTE: EGS52 is used with the A580 automatic transmission WG Grand Cherokees with a 2.7L diesel engine (BUX), ZH Crossfire and VA Sprinter. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. JTEC Types: ^ JTEC,JTEC+ NOTE: Except for the 45RFE, 545RFE, and AW4 automatic transmissions, the JTEC controller also provides transmission control functions on Dodge trucks and Jeep vehicles. Additionally, they are used on some Cummins equipped Dodge trucks with manual and automatic transmissions. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PRE 1996 EATX TRANSMISSION CONTROL MODULES Prior to 1996 there was not a vehicle SCI communication wire going to the FWD EATX controller only to the PCM. Those vehicle TCMs only communicate to the DRBIII(R) using CCD communications. For these FWD vehicles, use the CH5500 kit and CH7025 DIN cable when connecting those modules to the DRBIII(R) vehicle connector. For 1992-1993 vehicles, the TCM modules were upgraded to MY1995 software. Because of this you will need to use the Yellow SuperCard2, CH8361,to set pinion factor or when using a "new" (superseded) TCM from parts as only the SuperCard2 properly sets the pinion factor on these updated modules. Additionally, when flashing or installing P/Ns 4796121, 4796122, 4796123, or 4796124. The wire from cavity 49 must be removed from the TCM connector, refer to service bulletin 18-24-95. Types: ^ TCCM NOTE: These modules are found on AN, DN, and DR trucks. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4183 NON-POWERTRAIN CONTROL MODULES BODY CONTROL MODULE (BCM) Types: ^ BCM NOTE: Body control modules are found on passenger vehicles. NOTE: The following vehicle BCMs support flash reprogramming: CS, JR, KJ, LH, RS, WJ, and ZB. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ BUX ONLY for 2001 JR - Compass/Mini Trip (BCM) Flash - Use special international release software version 52.25 ^ 2001 LH - there is NO abort recovery available for the BCM. CENTRAL TIMER MODULE (CTM) Types: ^ CTM NOTE: CTMs are found on: AB, AN, DN, BR, and BE trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ELECTRONIC VEHICLE INFORMATION CENTER (EVIC) Types: ^ EVIC NOTE: 02-03 LH & WJ, and 03-04 KJ Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. FRONT CONTROL MODULE (FCM) Types: ^ FCM NOTE: Front control modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. INTEGRATED POWER MODULE (IPM) Types: Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4184 ^ 1PM NOTE: Integrated power modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. POWER LIFT GATE (PLG) Types: ^ PLC NOTE: Power liftgate modules are found on CS and RS. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER SLIDING DOOR MODULE (PSDM) Types: ^ PSDM NOTE: Passenger power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. DRIVER SLIDING DOOR MODULE (DSDM) Types: ^ DSDM NOTE: Driver power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NOTE: When flashing a vehicle that is equipped with both Passenger and Driver Power Sliding Doors, you must Reboot the DRBIII(R) and cycle the ignition key before flashing the next door module. DRIVER DOOR MODULE (DDM) Types: ^ DDM NOTE: Driver Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER DOOR MODULE (PDM) Types: ^ PDM NOTE: Passenger Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLUSTERS/MECHANICAL INSTRUMENT CLUSTER (MIC) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4185 Types: ^ MICs, eMICs NOTE: MICs that have flash reprogramming are on the following vehicles: DR, JR, KJ, PL, PT, WJ, ZB Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. In certain cases, you will be asked to cycle the ignition key and pull a specific fuse. ^ The DRBIII(R) may power down during the procedure with some modules. This is NORMAL and is explained in the user prompts displayed during abort-recovery. Take the time to read and understand the instructions before proceeding. ALARM REMOTE KEYLESS ENTRY MODULE (ARKEM) Types: ^ ARKEM NOTE: Arkem modules are found on PL and PT vehicles. There are up to and after modules. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLIMATE CONTROL (ATC, HVAC) Types: ^ HVAC, ATC, MTC NOTE: Generally, reprogramming for these modules is done using the standalone application rather than the Vehicle Flash application. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. ADJUSTABLE PEDAL MODULE (APM) Types: ^ APM NOTE: Found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. RAIN SENSOR MODULE (RSM) Types: ^ RSM NOTE:RSM modules are found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4186 INTRUSION TRANSCEIVER MODULE (ITM) Types: ^ ITM ^ Updates for this module, to version 7.05 have involved a coordinated BCM flash update. See the TSB for important instructions. NOTE: ITM modules are found on WJ (BUX) and KJ (BUX) vehicles. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. SUPPLEMENTAL RESTRAINT SYSTEMS (SRS) - AIRBAGS, ETC. Types: ^ SRS, ORC NOTE: While used on most vehicles, only CS, JR, LH, PT, RS, and WJ vehicles have the potential to support flash updates. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold Pressure Regulating Solenoid: Customer Interest A/T - Buzz/Whining in Reverse When Cold NUMBER: 21-08-99 GROUP: Transmission DATE: April 30, 1999 SUBJECT: "Buzz", "Whining", Or "Moaning" Like Noise From A Cold Transmission When Reverse Is Selected. OVERVIEW: This bulletin involves replacing the transmission regulator valve. MODELS: 1996 - 1999 (AB) Ram Van 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (TJ) Wrangler 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1999 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A RE OR RH AUTOMATIC TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may exhibit an intermittent noise from the transmission when reverse gear is selected. This noise has been described as a "buzz", whining", or "moaning" like noise. The noise is most noticeable when transmission fluid temperature is below 38 C. (100 F.). The condition is caused by a resonance of the transmission regulator valve system. Other items may cause regulator valve resonance, including air ingestion into the valve body or out of specification parts. These two items may be the result a possible cracked pump housing, a torn pump gasket, an under filled transmission, a restricted fluid filter or cooler flow, or an out of specification valve and/or valve body. You should remember these additional items / components when you perform your diagnosis. Vehicles built prior to August 1, 1995 may experience this condition if either a transmission valve body or an entire automatic transmission was replaced with components manufactured after August 1, 1995. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostics Procedure Manual, verify all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. For 1996 and 1997 model year product, review Technical Service Bulletin 21-11-97 Rev A to determine if it applies to this vehicle before attempting to complete the analysis or repairs described in this bulletin. In most instances, the sump temperature of vehicles exhibiting transmission regulator valve resonance in reverse has been less than 38 C. (100 F). If possible, allow the suspect vehicle to remain parked in a cool place overnight. Then perform the following steps: 1. Set the vehicle parking brake. 2. Start the engine (make certain windows are closed, to eliminate outside noise). 3. With brakes applied, place the transmission selector lever in reverse. 4. Listen for any buzz/moaning/whining like noises as the transmission sump temperature rises to normal operating temperature (180 - 210 degrees F). 5. If a buzz/moaning/whining like noise is present, perform the Repair Procedure. PARTS REQUIRED: 1 04130169 Valve, Steel Transmission Regulator Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold > Page 4198 1 02464324 Gasket, Transmission Pan AR 05010124AA Fluid, ATF Plus 3, Type 7176E EQUIPMENT REQUIRED: 1 C-3763 Gauge Tool, Throttle Pressure Adjustment REPAIR PROCEDURE: 1. Following the procedures in the applicable service manual, remove the valve body from the transmission (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - REMOVAL AND INSTALLATION). 2. Remove the screws holding the adjusting screw bracket and replace the regulator valve with p/n 04130169 (Figure 1). Install the adjusting screw bracket 3. Verify and adjust, if necessary, both the line pressure and the throttle pressure settings by following the procedures in the service manual (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section ADJUSTMENTS - VALVE BODY). 4. Following the procedures in the appropriate Service Manual, re-install the valve body with the new regulator valve into the transmission. 5. After filling the transmission with the proper automatic transmission fluid, and verifying correct fill level, check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - ADJUSTMENTS - TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-90 1.2 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold Pressure Regulating Solenoid: All Technical Service Bulletins A/T - Buzz/Whining in Reverse When Cold NUMBER: 21-08-99 GROUP: Transmission DATE: April 30, 1999 SUBJECT: "Buzz", "Whining", Or "Moaning" Like Noise From A Cold Transmission When Reverse Is Selected. OVERVIEW: This bulletin involves replacing the transmission regulator valve. MODELS: 1996 - 1999 (AB) Ram Van 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (TJ) Wrangler 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1999 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A RE OR RH AUTOMATIC TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may exhibit an intermittent noise from the transmission when reverse gear is selected. This noise has been described as a "buzz", whining", or "moaning" like noise. The noise is most noticeable when transmission fluid temperature is below 38 C. (100 F.). The condition is caused by a resonance of the transmission regulator valve system. Other items may cause regulator valve resonance, including air ingestion into the valve body or out of specification parts. These two items may be the result a possible cracked pump housing, a torn pump gasket, an under filled transmission, a restricted fluid filter or cooler flow, or an out of specification valve and/or valve body. You should remember these additional items / components when you perform your diagnosis. Vehicles built prior to August 1, 1995 may experience this condition if either a transmission valve body or an entire automatic transmission was replaced with components manufactured after August 1, 1995. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostics Procedure Manual, verify all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. For 1996 and 1997 model year product, review Technical Service Bulletin 21-11-97 Rev A to determine if it applies to this vehicle before attempting to complete the analysis or repairs described in this bulletin. In most instances, the sump temperature of vehicles exhibiting transmission regulator valve resonance in reverse has been less than 38 C. (100 F). If possible, allow the suspect vehicle to remain parked in a cool place overnight. Then perform the following steps: 1. Set the vehicle parking brake. 2. Start the engine (make certain windows are closed, to eliminate outside noise). 3. With brakes applied, place the transmission selector lever in reverse. 4. Listen for any buzz/moaning/whining like noises as the transmission sump temperature rises to normal operating temperature (180 - 210 degrees F). 5. If a buzz/moaning/whining like noise is present, perform the Repair Procedure. PARTS REQUIRED: 1 04130169 Valve, Steel Transmission Regulator Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold > Page 4204 1 02464324 Gasket, Transmission Pan AR 05010124AA Fluid, ATF Plus 3, Type 7176E EQUIPMENT REQUIRED: 1 C-3763 Gauge Tool, Throttle Pressure Adjustment REPAIR PROCEDURE: 1. Following the procedures in the applicable service manual, remove the valve body from the transmission (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - REMOVAL AND INSTALLATION). 2. Remove the screws holding the adjusting screw bracket and replace the regulator valve with p/n 04130169 (Figure 1). Install the adjusting screw bracket 3. Verify and adjust, if necessary, both the line pressure and the throttle pressure settings by following the procedures in the service manual (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section ADJUSTMENTS - VALVE BODY). 4. Following the procedures in the appropriate Service Manual, re-install the valve body with the new regulator valve into the transmission. 5. After filling the transmission with the proper automatic transmission fluid, and verifying correct fill level, check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - ADJUSTMENTS - TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-90 1.2 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations O/D (3-4) Solenoid, TCC Solenoid, Governor Pressure Sensor, Governor Pressure Solenoid Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 4208 Shift Solenoid: Description and Operation The shift valves are moved by a combination of throttle and governor pressure. The governor pressure is generated by electrical components. The conditions under which a shift to fourth will not occur are: - Overdrive switch is Off - Transmission fluid temperature is below 10 °C (50 °F) or above 121 °C (250 °F) - Shift to third not yet completed - Vehicle speed too low for 3-4 shift to occur - Battery temperature below -5 °F Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations O/D (3-4) Solenoid, TCC Solenoid, Governor Pressure Sensor, Governor Pressure Solenoid Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold Pressure Regulating Solenoid: Customer Interest A/T - Buzz/Whining in Reverse When Cold NUMBER: 21-08-99 GROUP: Transmission DATE: April 30, 1999 SUBJECT: "Buzz", "Whining", Or "Moaning" Like Noise From A Cold Transmission When Reverse Is Selected. OVERVIEW: This bulletin involves replacing the transmission regulator valve. MODELS: 1996 - 1999 (AB) Ram Van 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (TJ) Wrangler 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1999 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A RE OR RH AUTOMATIC TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may exhibit an intermittent noise from the transmission when reverse gear is selected. This noise has been described as a "buzz", whining", or "moaning" like noise. The noise is most noticeable when transmission fluid temperature is below 38 C. (100 F.). The condition is caused by a resonance of the transmission regulator valve system. Other items may cause regulator valve resonance, including air ingestion into the valve body or out of specification parts. These two items may be the result a possible cracked pump housing, a torn pump gasket, an under filled transmission, a restricted fluid filter or cooler flow, or an out of specification valve and/or valve body. You should remember these additional items / components when you perform your diagnosis. Vehicles built prior to August 1, 1995 may experience this condition if either a transmission valve body or an entire automatic transmission was replaced with components manufactured after August 1, 1995. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostics Procedure Manual, verify all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. For 1996 and 1997 model year product, review Technical Service Bulletin 21-11-97 Rev A to determine if it applies to this vehicle before attempting to complete the analysis or repairs described in this bulletin. In most instances, the sump temperature of vehicles exhibiting transmission regulator valve resonance in reverse has been less than 38 C. (100 F). If possible, allow the suspect vehicle to remain parked in a cool place overnight. Then perform the following steps: 1. Set the vehicle parking brake. 2. Start the engine (make certain windows are closed, to eliminate outside noise). 3. With brakes applied, place the transmission selector lever in reverse. 4. Listen for any buzz/moaning/whining like noises as the transmission sump temperature rises to normal operating temperature (180 - 210 degrees F). 5. If a buzz/moaning/whining like noise is present, perform the Repair Procedure. PARTS REQUIRED: 1 04130169 Valve, Steel Transmission Regulator Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold > Page 4222 1 02464324 Gasket, Transmission Pan AR 05010124AA Fluid, ATF Plus 3, Type 7176E EQUIPMENT REQUIRED: 1 C-3763 Gauge Tool, Throttle Pressure Adjustment REPAIR PROCEDURE: 1. Following the procedures in the applicable service manual, remove the valve body from the transmission (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - REMOVAL AND INSTALLATION). 2. Remove the screws holding the adjusting screw bracket and replace the regulator valve with p/n 04130169 (Figure 1). Install the adjusting screw bracket 3. Verify and adjust, if necessary, both the line pressure and the throttle pressure settings by following the procedures in the service manual (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section ADJUSTMENTS - VALVE BODY). 4. Following the procedures in the appropriate Service Manual, re-install the valve body with the new regulator valve into the transmission. 5. After filling the transmission with the proper automatic transmission fluid, and verifying correct fill level, check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section ADJUSTMENTS - TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-90 1.2 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold Pressure Regulating Solenoid: All Technical Service Bulletins A/T - Buzz/Whining in Reverse When Cold NUMBER: 21-08-99 GROUP: Transmission DATE: April 30, 1999 SUBJECT: "Buzz", "Whining", Or "Moaning" Like Noise From A Cold Transmission When Reverse Is Selected. OVERVIEW: This bulletin involves replacing the transmission regulator valve. MODELS: 1996 - 1999 (AB) Ram Van 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (TJ) Wrangler 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1999 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A RE OR RH AUTOMATIC TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may exhibit an intermittent noise from the transmission when reverse gear is selected. This noise has been described as a "buzz", whining", or "moaning" like noise. The noise is most noticeable when transmission fluid temperature is below 38 C. (100 F.). The condition is caused by a resonance of the transmission regulator valve system. Other items may cause regulator valve resonance, including air ingestion into the valve body or out of specification parts. These two items may be the result a possible cracked pump housing, a torn pump gasket, an under filled transmission, a restricted fluid filter or cooler flow, or an out of specification valve and/or valve body. You should remember these additional items / components when you perform your diagnosis. Vehicles built prior to August 1, 1995 may experience this condition if either a transmission valve body or an entire automatic transmission was replaced with components manufactured after August 1, 1995. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostics Procedure Manual, verify all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. For 1996 and 1997 model year product, review Technical Service Bulletin 21-11-97 Rev A to determine if it applies to this vehicle before attempting to complete the analysis or repairs described in this bulletin. In most instances, the sump temperature of vehicles exhibiting transmission regulator valve resonance in reverse has been less than 38 C. (100 F). If possible, allow the suspect vehicle to remain parked in a cool place overnight. Then perform the following steps: 1. Set the vehicle parking brake. 2. Start the engine (make certain windows are closed, to eliminate outside noise). 3. With brakes applied, place the transmission selector lever in reverse. 4. Listen for any buzz/moaning/whining like noises as the transmission sump temperature rises to normal operating temperature (180 - 210 degrees F). 5. If a buzz/moaning/whining like noise is present, perform the Repair Procedure. PARTS REQUIRED: 1 04130169 Valve, Steel Transmission Regulator Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold > Page 4228 1 02464324 Gasket, Transmission Pan AR 05010124AA Fluid, ATF Plus 3, Type 7176E EQUIPMENT REQUIRED: 1 C-3763 Gauge Tool, Throttle Pressure Adjustment REPAIR PROCEDURE: 1. Following the procedures in the applicable service manual, remove the valve body from the transmission (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - REMOVAL AND INSTALLATION). 2. Remove the screws holding the adjusting screw bracket and replace the regulator valve with p/n 04130169 (Figure 1). Install the adjusting screw bracket 3. Verify and adjust, if necessary, both the line pressure and the throttle pressure settings by following the procedures in the service manual (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section ADJUSTMENTS - VALVE BODY). 4. Following the procedures in the appropriate Service Manual, re-install the valve body with the new regulator valve into the transmission. 5. After filling the transmission with the proper automatic transmission fluid, and verifying correct fill level, check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - ADJUSTMENTS - TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-90 1.2 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations O/D (3-4) Solenoid, TCC Solenoid, Governor Pressure Sensor, Governor Pressure Solenoid Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Page 4232 Shift Solenoid: Description and Operation The shift valves are moved by a combination of throttle and governor pressure. The governor pressure is generated by electrical components. The conditions under which a shift to fourth will not occur are: - Overdrive switch is Off - Transmission fluid temperature is below 10 °C (50 °F) or above 121 °C (250 °F) - Shift to third not yet completed - Vehicle speed too low for 3-4 shift to occur - Battery temperature below -5 °F Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations O/D (3-4) Solenoid, TCC Solenoid, Governor Pressure Sensor, Governor Pressure Solenoid Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Adjustments Band: Adjustments FRONT BAND ADJUSTMENT The front (kickdown) band adjusting screw is located on the left side of the transmission case above the manual valve and throttle valve levers. 1. Raise vehicle. 2. Loosen band adjusting screw locknut. Then back locknut off 3-5 turns. BE sure adjusting screw turns freely in case. Apply lubricant to screw threads if necessary. 3. Tighten band adjusting screw to 8 Nm (72 inch lbs.) torque with Inch Pound Torque Wrench C-3380-A, a 3-inch extension and 5/16 socket. - Back off front band adjusting screw 3-5/8 turns. - Hold adjuster screw in position and tighten locknut to 41 Nm (30 ft. lbs.) torque. CAUTION: If Adapter C-3705 is needed to reach the adjusting screw, tighten the screw to only 5 Nm (47 - 50 inch lbs.) torque. 4. Lower vehicle. REAR BAND ADJUSTMENT The transmission oil pan must be removed for access to the rear band adjusting screw. 1. Raise vehicle. 2. Remove transmission oil pan and drain fluid. 3. Loosen band adjusting screw locknut 5-6 turns. Be sure adjusting screw turns freely in lever. 4. Tighten adjusting screw to 8 Nm (72 inch lbs.) torque. - Back off adjusting screw 4 turns. - Hold adjusting screw in place and tighten locknut to 34 Nm (25 ft. lbs.) torque. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Adjustments > Page 4239 5. Position new gasket on oil pan and install pan on transmission. Tighten pan bolts to 17 Nm (13 ft. lbs.) torque. 6. Lower vehicle and refill transmission with MOPAR atf plus 4, Type 9602 fluid. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Diagrams > Front Clutch Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Diagrams > Front Clutch > Page 4244 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Diagrams > Page 4245 Clutch: Application and ID Front Clutch ......................................................................................................................................... ....................................................................... 4 discs Rear Clutch .......................................................................................................................................... ........................................................................ 4 discs Overdrive Clutch .................................................................................................................................. ....................................................................... 3 discs Direct Clutch ........................................................................................................................................ ....................................................................... 6 discs Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Front Clutch Clutch: Service and Repair Front Clutch NOTE: The 42RE transmission uses four plates and discs for the front clutch. The front clutch retainer is not interchangeable between the 42/44RE transmissions. DISASSEMBLY 1. Remove waved snap ring and remove pressure plate, clutch plates and clutch discs. 2. Compress clutch piston spring with Compressor Tool C-3575-A, or equivalent. Be sure legs of tool are seated squarely on spring retainer before compressing spring. 3. Remove retainer snap ring and remove compressor tool. 4. Remove spring retainer and clutch spring. Note position of retainer on spring for assembly reference. 5. Remove clutch piston from clutch retainer. Remove piston by rotating it up and out of retainer. 6. Remove seals from clutch piston and clutch retainer hub. Discard both seals as they are not reusable. ASSEMBLY 1. Soak clutch discs in transmission fluid while assembling other clutch parts. 2. Install new seals on piston and in hub of retainer. Be sure lip of each seal faces interior of clutch retainer. 3. Lubricate lips of piston and retainer seals with liberal quantity of MOPAR Door Ease. Then lubricate retainer hub, bore and piston with light coat of transmission fluid. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Front Clutch > Page 4248 4. Install clutch piston in retainer. Use twisting motion to seat piston in bottom of retainer. CAUTION: Never push the clutch piston straight in. This will fold the seals over causing leakage and clutch slip. 5. Position spring in clutch piston. 6. Position spring retainer on top of piston spring. Make sure retainer is properly installed. Small raised tabs should be facing upward. Semicircular lugs on underside of retainer are for positioning retainer in spring. 7. Compress piston spring and retainer with Compressor Tool C-3575-A, or equivalent. Then install new snap ring to secure spring retainer and spring. 8. Install clutch plates and discs. Install steel plate then disc until all plates and discs are installed. The front clutch uses 4 clutch discs and plates. 9. Install pressure plate and waved snap ring. Front clutch clearance should be 1.70 to 3.40 mm (0.067 to 0.134 inch). If clearance is incorrect, clutch discs, plates, pressure plates and snap ring may have to be changed. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Front Clutch > Page 4249 Clutch: Service and Repair Rear Clutch DISASSEMBLY 1. Remove fiber thrust washer from forward side of clutch retainer. 2. Remove input shaft front/rear seal rings. 3. Remove selective clutch pack snap ring. 4. Remove top pressure plate, clutch discs, steel plates, bottom pressure plate and wave snap ring and wave spring. 5. Remove clutch piston with rotating motion. 6. Remove and discard piston seals. 7. Remove input shaft snap-ring. It may be necessary to press the input shaft in slightly to relieve tension on the snap-ring 8. Press input shaft out of retainer with shop press and suitable size press tool. Use a suitably sized press tool to support the retainer as close to the input shaft as possible. ASSEMBLY 1. Soak clutch discs in transmission fluid while assembling other clutch parts. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Front Clutch > Page 4250 2. Install new seal rings on clutch retainer hub and input shaft if necessary. - Be sure clutch hub seal ring is fully seated in groove and is not twisted. 3. Lubricate splined end of input shaft and clutch retainer with transmission fluid. Then press input shaft into retainer. Use a suitably sized press tool to support retainer as close to input shaft as possible. 4. Install input shaft snap-ring. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Front Clutch > Page 4251 5. Invert retainer and press input shaft in opposite direction until snap-ring is seated. 6. Install new seals on clutch piston. Be sure lip of each seal faces interior of clutch retainer. 7. Lubricate lip of piston seals with generous quantity of MOPAR Door Ease. Then lubricate retainer hub and bore with light coat of transmission fluid. 8. Install clutch piston in retainer. Use twisting motion to seat piston in bottom of retainer. A thin strip of plastic (about 0.020" thick), can be used to guide seals into place if necessary. CAUTION: Never push the clutch piston straight in. This will fold the seals over causing leakage and clutch slip. In addition, never use any type of metal tool to help ease the piston seals into place. Metal tools will cut, shave, or score the seals. 9. Install piston spring in retainer and on top of piston. Concave side of spring faces downward (toward piston). 10. Install wave spring in retainer. Be sure spring is completely seated in retainer groove. 11. Install bottom pressure plate. Ridged side of plate faces downward (toward piston) and flat side toward clutch pack. 12. Install first clutch disc in retainer on top of bottom pressure plate. Then install a clutch plate followed by a clutch disc until entire clutch pack is installed (4 discs and 3 plates are required). 13. Install top pressure plate. 14. Install selective snap ring. Be sure snap ring is fully seated in retainer groove. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Front Clutch > Page 4252 15. Using a suitable gauge bar and dial indicator, measure clutch pack clearance. a. Position gauge bar across the clutch drum with the dial indicator pointer on the pressure plate. b. Using two small screw drivers, lift the pressure plate and release it. c. Zero the dial indicator. d. Lift the pressure plate until it contacts the snap-ring and record the dial indicator reading. Clearance should be 0.64 - 1.14 mm (0.025 - 0.045 inch). If clearance is incorrect, steel Plates, discs, selective snap ring and pressure plates may have to be changed. The selective snap ring thicknesses are: 0.107 - 0.109 inch - 0.098 - 0.100 inch - 0.095 - 0.097 inch - 0.083 - 0.085 inch - 0.076 - 0.078 inch - 0.071 - 0.073 inch - 0.060 - 0.062 inch 16. Coat rear clutch thrust washer with petroleum jelly and install washer over input shaft and into clutch retainer. Use enough petroleum jelly to hold washer in place. 17. Set rear clutch aside for installation during Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: Customer Interest TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 4261 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 4262 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: All Technical Service Bulletins TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 4268 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 4269 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Page 4270 Control Module: Description and Operation This vehicle does not have a Transmission Control Module. Transmission control is accomplished through the Engine Control Module or Powertrain Control Module. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage Fluid - A/T: Technical Service Bulletins A/T - ATF + 4 Fluid Usage NUMBER: 21-014-07 GROUP: Transmission DATE: October 16, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-010-06, DATED APRIL 14, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES THE ADDITION OF THE ASIAN WARNER (AW4) TRANSMISSION AND ADDITIONAL MODELS AND YEARS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - **2008** (CS) Pacifica 1998-2003 (DN) Durango 2002 - **2008** (DR/DH/D1) Ram Truck 2007 - **2008** (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (GS) Chrysler Voyager (International Market) 2004 - **2008** (HB) Durango **2008 (HG) Aspen** 1995 - 2000 (JA) Cirrus/Stratus/Breeze Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 4275 2007 - **2008** (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - **2008** (JS) Avenger/Sebring/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible **2007 - 2008 (KA) Nitro** 2002 - 2007 (KJ) Liberty **2008 (KK) Liberty** **2008 (L2) 300C (China)** 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - **2008** (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - **2008** (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager **2008 (RT) Town & Country/Grand Caravan/Grand Voyager (U.S. & International Markets)** 1997-2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - **2008** (WK/WH) Grand Cherokee 2006 - **2008** (XK/XH) Commander 1989 - 1995 (YJ) Wrangler **1989 - 2001 (XJ) Cherokee** **1989 - 1993 (MJ) Comanche** 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: **AWA (Asian Warner) transmission are now included in this Service Bulletin. ATF+4(R) is recommended for AW-4 (Asian Warner) transmissions** NOTE: This Service Bulletin DOES NOT apply to Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 4276 Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE LISTED IN THE NOTE ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4(R) can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4® is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4® BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 4277 Fluid - A/T: Technical Service Bulletins A/T - ATF+4 Fluid Usage/Applications NUMBER: 21-010-06 GROUP: Transmission DATE: April 14, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-004-04, DATED MARCH 16, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - 2007 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2007 (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (CS) Chrysler Voyager (International Market) 2004 - 2007 (HB) Durango 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 4278 2007 (JS) Avenger/Sebring 1996 - 2000 (JX) Sebring Convertible 2002 - 2007 (KJ) Liberty 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - 2007 (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - 2007 (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - 2007 (WK/WH) Grand Cherokee 2006 - 2007 (XK/XH) Commander 1989 - 1995 (YJ) Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: This Service Bulletin DOES NOT apply to AW-4 transmissions, Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE NOTED ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4 can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4(R) is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 4279 BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid 42/44RE ............................................................................................................................................... ............................................. 9.0-10.4L (9.5-11.0 Qt) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 4282 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Type ............................................................................................................ ....................................................... MOPAR ATF +4 Type 9602 or Equivalent Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Level Check Fluid - A/T: Service and Repair Fluid Level Check NOTE: Transmission fluid level should be checked monthly under normal operation. If the vehicle is used for trailer towing or similar heavy load hauling, check fluid level and condition weekly. Fluid level is checked with the engine running at curb idle speed, the transmission in NEUTRAL and the transmission fluid at normal operating temperature. PROCEDURE 1. Transmission fluid must be at normal operating temperature for accurate fluid level check. Drive vehicle if necessary to bring fluid temperature up to normal hot operating temperature of 82°C (180°F). 2. Position vehicle on level surface. 3. Start and run engine at curb idle speed. 4. Apply parking brakes. 5. Shift transmission momentarily into all gear ranges. Then shift transmission back to Neutral. 6. Clean top of filler tube and dipstick to keep dirt from entering tube. 7. Remove dipstick and check fluid level as follows: a. Correct acceptable level is in crosshatch area. b. Correct maximum level is to MAX arrow mark. c. Incorrect level is at or below MIN line. d. If fluid is low, add only enough MOPAR ATF+4 to restore correct level. Do not overfill. CAUTION: Do not overfill the transmission. Overfilling may cause leakage out the pump vent which can be mistaken for a pump seal leak. Overfilling will also cause fluid aeration and foaming as the excess fluid is picked up and churned by the gear-train. This will significantly reduce fluid life. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Level Check > Page 4285 Fluid - A/T: Service and Repair Fluid and Filter Replacement NOTE: The service fluid fill after a filter change is approximately 3.8 liters (4.0 quarts). REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan. 3. Remove bolts holding front and sides of pan to transmission. 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 bolt 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 screws holding filter to valve body. 10. Separate filter from valve body and pour fluid in filter into drain pan. 11. Dispose of used bans fluid and filter properly. INSPECTION Inspect bottom of pan and magnet for excessive amounts of metal or fiber contamination. A light coating of clutch or band material on the bottom of the pan does not indicate a problem unless accompanied by slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts or debris. Check the adjustment of the front and rear bands, adjust if necessary. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Level Check > Page 4286 CLEANING 1. Using a suitable solvent, clean pan and magnet. 2. Using a suitable gasket scraper, clean gasket material from gasket surface of transmission case and the gasket flange around the pan. INSTALLATION 1. Place replacement filter in position on valve body. 2. Install screws to hold filter to valve body. Tighten screws to 4 Nm (35 inch lbs.) torque. 3. Place new gasket in position on pan and install pan on transmission. 4. Place pan in position on transmission. 5. Install screws to hold pan to transmission. Tighten bolts to 17 Nm (150 inch lbs.) torque. 6. Lower vehicle and fill transmission with MOPAR ATF+4, type 9602 fluid, or equivalent. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Specifications Fluid Filter - A/T: Specifications Mounting Screw ................................................................................................................................... ................................................... 4 Nm (35 inch lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Specifications > Page 4290 Fluid Filter - A/T: Service and Repair NOTE: The service fluid fill after a filter change is approximately 3.8 liters (4.0 quarts). REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan. 3. Remove bolts holding front and sides of pan to transmission. 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 bolt 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 screws holding filter to valve body. 10. Separate filter from valve body and pour fluid in filter into drain pan. 11. Dispose of used bans fluid and filter properly. INSPECTION Inspect bottom of pan and magnet for excessive amounts of metal or fiber contamination. A light coating of clutch or band material on the bottom of the pan does not indicate a problem unless accompanied by slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts or debris. Check the adjustment of the front and rear bands, adjust if necessary. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Specifications > Page 4291 CLEANING 1. Using a suitable solvent, clean pan and magnet. 2. Using a suitable gasket scraper, clean gasket material from gasket surface of transmission case and the gasket flange around the pan. INSTALLATION 1. Place replacement filter in position on valve body. 2. Install screws to hold filter to valve body. Tighten screws to 4 Nm (35 inch lbs.) torque. 3. Place new gasket in position on pan and install pan on transmission. 4. Place pan in position on transmission. 5. Install screws to hold pan to transmission. Tighten bolts to 17 Nm (150 inch lbs.) torque. 6. Lower vehicle and fill transmission with MOPAR ATF+4, type 9602 fluid, or equivalent. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T - Quick Connect Removal & Reconnect Procedure Technical Service Bulletin # 211596 Date: 961108 A/T - Quick Connect Removal & Reconnect Procedure NO: 21-15-96 GROUP: Transmissions DATE: Nov. 8, 1996 SUBJECT: Quick Connect Removal & Reconnect Procedure NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-02-95, DATED MAR. 31, 1995, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1995 BOUND COPY OF TECHNICAL SERVICE BULLETINS (PUBLICATION NO. 81-699-96084). THIS BULLETIN INCLUDES THE ADDITION OF THE 1996 AND 1997 MODEL YEARS. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1995 - **1997** (AB) Ram Van/Wagon 1995 - **1997** (AN) Dakota 1995 - **1997** (BR) Ram Truck 1995 - **1996** (XJ) Cherokee 1995 (YJ) Wrangler 1995 - **1997** (ZJ) Grand Cherokee NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH AN AUTOMATIC TRANSMISSION, WITH 3/8" COOLER LINE (ALL EXCEPT BR DIESEL & V-10) BUILT AFTER 1/20/95 (MDH 01-20-XX), AND WITH 1/2" COOLER LINE (BR DIESEL & V-10) BUILT AFTER 3/20/95 (MDH 03-20-95). DISCUSSION: Automatic transmission equipped vehicles now include quick connector fittings in the transmission cooler lines. If the transmission requires service, the connectors can be disconnected using either of the following two procedures. Proper reconnect procedures are also provided. **NOTE: SOME 1997 VEHICLES ARE NOT EQUIPPED WITH EXTERNAL RETAINER TABS. THESE VEHICLES MUST USE THE TOOL REMOVAL PROCEDURE TO DISCONNECT TRANSMISSION COOLER LINES.** POLICY: Information Only Removal Procedure This bulletin outlines the two methods of disconnecting the quick connectors on automatic transmission cooler lines, and provides the proper reconnect procedures. 1. Use a rag or soft brush to wipe the external surface of the connector and male line to remove loose dirt and road salt. Twist connector around the line or flush the joint with a mild soap penetrant such as Mopar General Purpose Lube MP-50 (P/N 4549626), to remove stubborn crusted contaminants. 2. Use an air nozzle to blow out accumulated dirt and road salt from the retainer area of the connector. Hand Removal Procedure Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T - Quick Connect Removal & Reconnect Procedure > Page 4296 1. Holding the line as shown, grasp connector body with fingers touching the retainer tabs (Figure 1). 2. Push line into connector until line stops (Figure 2). 3. Squeeze retainer tabs together until both tabs contact line (Figure 3). 4. Pull line out of the connector with other hand while retainer tabs are squeezed together (Figure 4). Tool Removal Procedure 1. Select the proper tool. For vehicles equipped with the 5.9L Cummins Diesel or the 8.0L gas engine (1/2" cooler lines), use Miller Special Tool 6931. All other vehicles use a 3/8" cooler line and require Miller Special Tool 6935. 2. Unlock the small tab on side of tool and open (Figure 5). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T - Quick Connect Removal & Reconnect Procedure > Page 4297 3. Wrap tool around line with smooth round end facing the connector (Figure 6). 4. Close removal tool and lock tab. Push removal tool up to connector (Figure 7). 5. Push removal tool into connector. Tool will push out retainer legs, pull connector over line bead (Figure 8). 6. Pull line connector while holding onto line with one hand and the connector with the other (Figure 9). Reconnect Procedure 1. After performing the service that required the line to be disconnected, wipe the line end with a clean rag. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T - Quick Connect Removal & Reconnect Procedure > Page 4298 2. Check the line surfaces for burrs on existing or replacement parts. 3. Apply a coating of clean transmission fluid over the entire male line end surface up to the bead. 4. Push the line into the connector until the retainer seats and a click is heard. Pull back on the line to ensure that the connector is locked in place (15-30 lbs.). Do not rely only on the audible click to confirm that a secure connection has been made. 5. Start the engine and check the connector for fluid leaks. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > Page 4299 Fluid Line/Hose: Specifications At Transmission ................................................................................................................................... ..................................................... 18 Nm (13 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > Page 4300 Fluid Line/Hose: Service and Repair NOTE: The transmission cooler lines are attached with quick connect fittings. The cooler lines and fittings are NOT serviceable. Damaged fittings or cooler lines are to be replaced as assemblies. REMOVAL 1. If fitting and cooler line are covered with dirt, mud, or grease, clean fitting and cooler line with MOPAR spray type carburetor or brake cleaner. 2. Disengage retainer on fitting and pull cooler line out of fitting. 3. Cover open ends of cooler lines and fittings to prevent dirt entry. 4. Inspect condition of fitting. Replace transmission fitting as an assembly if fitting body or retainer clip is damaged. INSTALLATION 1. If transmission or radiator fittings require replacement, apply MOPAR Lock N' Seal, or equivalent, to fitting threads before installation. 2. Wipe off cooler line and fitting with clean, dry cloth. 3. Insert cooler line into fitting. Then push line inward until retainer secures line. A snap or click will be heard and felt through the line when the retainer seats behind the cooler line flange. 4. Pull outward on cooler lines to verify that they are properly secured. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications Fluid Pan: Specifications TORQUE SPECIFICATIONS Bolt, Fluid Pan 42/44RE ...................................................................................................................... .............................................................................. 17 Nm (13 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm Fluid Pressure Sensor/Switch: Customer Interest A/T - Engine Bucking/Surging at 5,300 Rpm NO: 18-19-98 GROUP: Driveability DATE: Apr. 10, 1998 SUBJECT: Vehicle Bucking During Wide Open Throttle Acceleration MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE JAN 16, 1998 MDH (0116XX) EQUIPPED WITH GASOLINE ENGINES AND A 42/44/46 OR 47RE TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may experience bucking during wide open throttle (WOT) acceleration. The bucking occurs at approximately 5300 RPM. This condition may be caused by reaching the high RPM fuel shut off rev limit before the transmission can shift into the next higher gear and is most likely to occur with high electrical loads (high beams on, heated back lite, heated seats, radio, HVAC blower on MAX etc.). During high current demands, the generator may emit electrical noise that can affect the transmission governor pressure sensor output. If this occurs, the transmission may not shift properly to the next higher gear under (WOT) acceleration conditions and therefore reach the fuel shut off rev limiter. This may be seen most often between the 2-3 shift but can also be experienced between the 1-2 shift. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. NOTE: ONLY PERFORM THE FOLLOWING PROCEDURE SAFELY ON A HIGHWAY OR ROAD OBEYING ALL POSTED SPEED LIMITS AND LAWS. Attempt to duplicate the condition by switching on all accessory loads and driving the vehicle with WOT accelerations through a shift sequence to see if the engine will reach the fuel shut off rev limiter before the 2-3 or 1-2 shift is made. If the bucking condition is experienced at approximately 5300 RPM before making the appropriate upshifts, switch off all electrical loads and repeat the procedure. Repeat the procedure with the electrical loads on and off a second time. If the bucking occurs with the electrical loads on and does not occur with the loads off, perform the Repair Procedure. PARTS REQUIRED: 1 56041403AA Sensor, Governor Pressure REPAIR PROCEDURE: This bulletin involves installing a newly designed governor pressure sensor. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm > Page 4312 1. Following the procedures in the applicable service manual, replace the governor pressure sensor with p/n 56041403AA (Figure 1). 2. Check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-96-06-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm Fluid Pressure Sensor/Switch: All Technical Service Bulletins A/T - Engine Bucking/Surging at 5,300 Rpm NO: 18-19-98 GROUP: Driveability DATE: Apr. 10, 1998 SUBJECT: Vehicle Bucking During Wide Open Throttle Acceleration MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE JAN 16, 1998 MDH (0116XX) EQUIPPED WITH GASOLINE ENGINES AND A 42/44/46 OR 47RE TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may experience bucking during wide open throttle (WOT) acceleration. The bucking occurs at approximately 5300 RPM. This condition may be caused by reaching the high RPM fuel shut off rev limit before the transmission can shift into the next higher gear and is most likely to occur with high electrical loads (high beams on, heated back lite, heated seats, radio, HVAC blower on MAX etc.). During high current demands, the generator may emit electrical noise that can affect the transmission governor pressure sensor output. If this occurs, the transmission may not shift properly to the next higher gear under (WOT) acceleration conditions and therefore reach the fuel shut off rev limiter. This may be seen most often between the 2-3 shift but can also be experienced between the 1-2 shift. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. NOTE: ONLY PERFORM THE FOLLOWING PROCEDURE SAFELY ON A HIGHWAY OR ROAD OBEYING ALL POSTED SPEED LIMITS AND LAWS. Attempt to duplicate the condition by switching on all accessory loads and driving the vehicle with WOT accelerations through a shift sequence to see if the engine will reach the fuel shut off rev limiter before the 2-3 or 1-2 shift is made. If the bucking condition is experienced at approximately 5300 RPM before making the appropriate upshifts, switch off all electrical loads and repeat the procedure. Repeat the procedure with the electrical loads on and off a second time. If the bucking occurs with the electrical loads on and does not occur with the loads off, perform the Repair Procedure. PARTS REQUIRED: 1 56041403AA Sensor, Governor Pressure REPAIR PROCEDURE: This bulletin involves installing a newly designed governor pressure sensor. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm > Page 4318 1. Following the procedures in the applicable service manual, replace the governor pressure sensor with p/n 56041403AA (Figure 1). 2. Check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-96-06-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pressure Sensor/Switch: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: All Technical Service Bulletins TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pressure Sensor/Switch: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 4324 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pressure Sensor/Switch: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 4325 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pressure Sensor/Switch: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 4331 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pressure Sensor/Switch: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 4332 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > Page 4333 Fluid Pressure Sensor/Switch: Description and Operation NOTE: This input is used with 4-speed electronic transmissions only DESCRIPTION The transmission governor pressure sensor provides a signal proportional to the transmission governor pressure. OPERATION It provides feedback for control of the variable force solenoid, which regulates transmission governor pressure. CIRCUIT OPERATION The governor pressure sensor supplies the transmission pressure input to the Powertrain Control Module on circuit T25. Circuit T25 connects to cavity B29 of the PCM. Circuit K7 from cavity B31 of the PCM supplies 5 Volts to the sensor. The PCM provides ground for the governor pressure sensor on circuit K4. Circuit K4 connects to cavity A4 of the PCM. The governor pressure sensor is part of the transmission solenoid assembly. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications Fluid Pump: Specifications Mounting Bolts ..................................................................................................................................... .................................................... 20 Nm (15 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair > Disassembly Fluid Pump: Service and Repair Disassembly DISASSEMBLY 1. Remove seal ring from housing and reaction shaft support. 2. Mark pump housing and support assembly for alignment reference. 3. Remove bolts attaching pump body to support. 4. Separate support from pump housing. 5. Remove inner and outer gears from reaction shaft support. 6. If pump seal was not removed during transmission disassembly, remove seal with punch and hammer. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair > Disassembly > Page 4339 7. Remove front clutch thrust washer from support hub. OIL PUMP BUSHING REPLACEMENT 1. Remove pump bushing with Tool Handle C-4171 and Bushing Remover SP-3561 from Tool Set C-3887-d, or equivalents. 2. Install new pump bushing with Tool Handle C-4171 and Bushing Installer SP-5117, or equivalents. Bushing should be flush with pump housing bore. 3. Stake new pump bushing in two places with blunt punch. Remove burrs from stake points with knife blade afterward. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair > Disassembly > Page 4340 REACTION SHAFT SUPPORT BUSHING REMOVAL 1. Assemble Bushing Remover Tools SP-1191, 3633 and 5324, or equivalents. Do not clamp any part of reaction shaft or support in vise. 2. Hold Cup Tool SP-3633, or equivalent firmly against reaction shaft and thread remover SP-5324, or equivalent into bushing as far as possible by hand. Then thread remover tool 3-4 additional turns into bushing with a wrench. 3. Turn remover tool hex nut down against remover cup to pull bushing from shaft. Clean all chips from shaft after bushing removal. 4. Lightly grip old bushing in vise or with pliers and back remover tool out of bushing. 5. Assemble Bushing Installer Tools C-4171 and SP-5325, or equivalents. 6. Slide new bushing onto Installer Tool SP-5325, or equivalent. 7. Position reaction shaft support upright on a clean smooth surface. 8. Align bushing in bore. Then tap bushing into place until Bushing Installer SP-5325, or equivalent bottoms. 9. Clean reaction shaft support thoroughly after installing bushing. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair > Disassembly > Page 4341 Fluid Pump: Service and Repair Inspection 1. Clean pump and support components with solvent and dry them with compressed air. 2. Check condition of the seal rings and thrust washer on the reaction shaft support. The seal rings do not need to be replaced unless cracked, broken, or severely worn. 3. Inspect the pump and support components. Replace the pump or support if the seal ring grooves or machined surfaces are worn, scored, pitted, or damaged. Replace the pump gears if pitted, worn chipped, or damaged. 4. Inspect the pump bushing. Then check the reaction shaft support bushing. Replace either bushing only if heavily worn, scored or damaged. It is not necessary to replace the bushings unless they are actually damaged. 5. Install the gears in the pump body and measure pump component clearances as follows: a. Clearance between outer gear and reaction shaft housing should be 0.010 to 0.063 mm (0.0004 to 0.0025 inch). Clearance between inner gear and reaction shaft housing should be 0.025 to 0.177 mm (0.001 to 0.007 inch). Both clearances can be measured at the same time by: 1. Installing the pump gears in the pump housing. 2. Position an appropriate piece of Plastigage across both gears. 3. Align the plastigage to a flat area on the reaction shaft housing. 4. Install the reaction shaft to the pump housing. 5. Separate the reaction shaft housing from the pump housing and measure the Plastigage following the instructions supplied with it. b. Clearance between inner gear tooth and outer gear should be 0.08 to 0.19 mm (0.0035 to 0.0075 inch). Measure clearance with an appropriate feeler gauge. c. Clearance between outer gear and pump housing should also be 0.010 to 0.19 mm (0.0035 to 0.0075 inch). Measure clearance with an appropriate feeler gauge. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair > Disassembly > Page 4342 Fluid Pump: Service and Repair Assembly 1. Lubricate gear bore in pump housing with transmission fluid. 2. Lubricate pump gears with transmission fluid. 3. Support pump housing on wood blocks. 4. Install outer gear in pump housing. Gear can be installed either way (it is not a one-way fit). 5. Install pump inner gear. CAUTION: The pump inner gear is a one way fit. The bore on one side of the gear inside diameter (I.D.) is chamfered. Be sure the chamfered side faces forward (to front of pump). 6. Install new thrust washer on hub of reaction shaft support. Lubricate washer with transmission fluid or petroleum jelly. 7. If reaction shaft seal rings are being replaced, install new seal rings on support hub. Lubricate seal rings with transmission fluid or petroleum jelly after installation. Squeeze each ring until ring ends are securely hooked together. CAUTION: The reaction shaft support seal rings will break if overspread, or twisted. If new rings are being installed, spread them only enough for installation. Also be very sure the ring ends are securely hooked together after installation. Otherwise, the rings will either prevent pump installation, or break during installation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair > Disassembly > Page 4343 8. Install reaction shaft support on pump housing. 9. Align reaction support on pump housing. Use alignment marks made at disassembly. Or, rotate support until bolt holes in support and pump housing are all aligned (holes are offset for one-way fit). 10. Install all bolts that attach support to pump housing. Then tighten bolts finger tight. 11. Tighten support-to-pump bolts to required torque as follows: a. Reverse pump assembly and install it in transmission case. Position pump so bolts are facing out and are accessible. b. Secure pump assembly in case with 2 or 3 bolts, or with pilot studs. c. Tighten support-to-pump bolts to 20 Nm (15 ft. lbs.). d. Remove pump assembly from transmission case. 12. Install new oil seal in pump with Special Tool C-4193 and Tool Handle C-4171, or equivalents. Be sure seal lip faces inward. 13. Install new seal ring around pump housing. Be sure seal is properly seated in groove. 14. Lubricate lip of pump oil seal and O-ring seal with transmission fluid. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Governor: > 18-19-98 > Apr > 98 > A/T Engine Bucking/Surging at 5,300 Rpm Governor: Customer Interest A/T - Engine Bucking/Surging at 5,300 Rpm NO: 18-19-98 GROUP: Driveability DATE: Apr. 10, 1998 SUBJECT: Vehicle Bucking During Wide Open Throttle Acceleration MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE JAN 16, 1998 MDH (0116XX) EQUIPPED WITH GASOLINE ENGINES AND A 42/44/46 OR 47RE TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may experience bucking during wide open throttle (WOT) acceleration. The bucking occurs at approximately 5300 RPM. This condition may be caused by reaching the high RPM fuel shut off rev limit before the transmission can shift into the next higher gear and is most likely to occur with high electrical loads (high beams on, heated back lite, heated seats, radio, HVAC blower on MAX etc.). During high current demands, the generator may emit electrical noise that can affect the transmission governor pressure sensor output. If this occurs, the transmission may not shift properly to the next higher gear under (WOT) acceleration conditions and therefore reach the fuel shut off rev limiter. This may be seen most often between the 2-3 shift but can also be experienced between the 1-2 shift. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. NOTE: ONLY PERFORM THE FOLLOWING PROCEDURE SAFELY ON A HIGHWAY OR ROAD OBEYING ALL POSTED SPEED LIMITS AND LAWS. Attempt to duplicate the condition by switching on all accessory loads and driving the vehicle with WOT accelerations through a shift sequence to see if the engine will reach the fuel shut off rev limiter before the 2-3 or 1-2 shift is made. If the bucking condition is experienced at approximately 5300 RPM before making the appropriate upshifts, switch off all electrical loads and repeat the procedure. Repeat the procedure with the electrical loads on and off a second time. If the bucking occurs with the electrical loads on and does not occur with the loads off, perform the Repair Procedure. PARTS REQUIRED: 1 56041403AA Sensor, Governor Pressure REPAIR PROCEDURE: This bulletin involves installing a newly designed governor pressure sensor. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Governor: > 18-19-98 > Apr > 98 > A/T Engine Bucking/Surging at 5,300 Rpm > Page 4352 1. Following the procedures in the applicable service manual, replace the governor pressure sensor with p/n 56041403AA (Figure 1). 2. Check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-96-06-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Governor: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm Governor: All Technical Service Bulletins A/T - Engine Bucking/Surging at 5,300 Rpm NO: 18-19-98 GROUP: Driveability DATE: Apr. 10, 1998 SUBJECT: Vehicle Bucking During Wide Open Throttle Acceleration MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE JAN 16, 1998 MDH (0116XX) EQUIPPED WITH GASOLINE ENGINES AND A 42/44/46 OR 47RE TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may experience bucking during wide open throttle (WOT) acceleration. The bucking occurs at approximately 5300 RPM. This condition may be caused by reaching the high RPM fuel shut off rev limit before the transmission can shift into the next higher gear and is most likely to occur with high electrical loads (high beams on, heated back lite, heated seats, radio, HVAC blower on MAX etc.). During high current demands, the generator may emit electrical noise that can affect the transmission governor pressure sensor output. If this occurs, the transmission may not shift properly to the next higher gear under (WOT) acceleration conditions and therefore reach the fuel shut off rev limiter. This may be seen most often between the 2-3 shift but can also be experienced between the 1-2 shift. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. NOTE: ONLY PERFORM THE FOLLOWING PROCEDURE SAFELY ON A HIGHWAY OR ROAD OBEYING ALL POSTED SPEED LIMITS AND LAWS. Attempt to duplicate the condition by switching on all accessory loads and driving the vehicle with WOT accelerations through a shift sequence to see if the engine will reach the fuel shut off rev limiter before the 2-3 or 1-2 shift is made. If the bucking condition is experienced at approximately 5300 RPM before making the appropriate upshifts, switch off all electrical loads and repeat the procedure. Repeat the procedure with the electrical loads on and off a second time. If the bucking occurs with the electrical loads on and does not occur with the loads off, perform the Repair Procedure. PARTS REQUIRED: 1 56041403AA Sensor, Governor Pressure REPAIR PROCEDURE: This bulletin involves installing a newly designed governor pressure sensor. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Governor: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm > Page 4358 1. Following the procedures in the applicable service manual, replace the governor pressure sensor with p/n 56041403AA (Figure 1). 2. Check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-96-06-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Technical Service Bulletins > Page 4359 Governor: Locations Governor Pressure Sensor, Transmission Temperature Sensor, Governor Pressure Solenoid, Governor The governor pressure sender and the transmission fluid temperature thermistor are separate sensors in the same component. This component is attached to the governor body in the solenoid assembly of the valve body. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Technical Service Bulletins > Page 4360 Governor: Description and Operation ELECTRONIC GOVERNOR Governor pressure is controlled electronically. Components used for governor pressure control include: Governor body - Valve body transfer plate - Governor pressure solenoid valve - Governor pressure sensor - Fluid temperature thermistor - Throttle Position Sensor (TPS) - Transmission speed sensor - Powertrain Control Module (PCM) GOVERNOR PRESSURE SOLENOID VALVE The solenoid valve is a duty-cycle solenoid which regulates the governor pressure needed for upshifts and downshifts. It is an electro-hydraulic device located in the governor body on the valve body transfer plate. The inlet side of the solenoid valve is exposed to normal transmission line pressure. The outlet side of the valve leads to the valve body governor circuit. The solenoid valve regulates line pressure to produce governor pressure. The average current supplied to the solenoid controls governor pressure. One amp current produces zero kPa/psi governor pressure. Zero amps sets the maximum governor pressure. The Powertrain Control Module (PCM) turns on the bans control relay which supplies electrical power to the solenoid valve. Operating voltage is 12 volts (DC). The PCM controls the ground side of the solenoid using the governor pressure solenoid control circuit. GOVERNOR PRESSURE SENSOR The governor pressure sensor measures output pressure of the governor pressure solenoid valve. The sensor output signal provides the necessary feedback to the PCM. This feedback is needed to adequately control governor pressure. GOVERNOR BODY AND TRANSFER PLATE The transfer plate is designed to supply transmission line pressure to the governor pressure solenoid valve and to return governor pressure. The governor pressure solenoid valve is mounted in the governor body. The body is bolted to the lower side of the transfer plate. The transfer plate channels line pressure to the solenoid valve through the governor body. It also channels governor pressure from the solenoid valve to the governor circuit. It is the solenoid valve that develops the necessary governor pressure. GOVERNOR PRESSURE CURVES There are four governor pressure curves programmed into the transmission control module. The different curves allow the control module to adjust governor pressure for varying conditions. One curve is used for operation when fluid temperature is at, or below, 1°C (30°F). A second curve is Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Technical Service Bulletins > Page 4361 used when fluid temperature is at, or above, 10°C (50°F) during normal city or highway driving. A third curve is used during wide-open throttle operation. The fourth curve is used when driving with the transfer case in low range. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Service and Repair > Replacement Governor: Service and Repair Replacement REMOVAL 1. Hoist and support vehicle on safety stands. 2. Remove transmission fluid pan and filter. 3. Disengage wire connectors from pressure sensor and solenoid. 4. Remove screws holding pressure solenoid retainer to governor body. 5. Separate solenoid retainer from governor. 6. Pull solenoid from governor body. 7. Remove bolts holding governor body to valve body. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Service and Repair > Replacement > Page 4364 8. Separate governor body from valve body. 9. Remove governor body gasket. 10. Remove retainer holding pressure sensor to governor body. 11. Pull pressure sensor from governor body. NOTE: Before installing the pressure sensor and solenoid in the governor body, replace O-ring seals, clean the gasket surfaces and replace gasket. INSTALLATION 1. Lubricate O-ring on pressure sensor with transmission fluid. 2. Align pressure sensor to bore in governor body. 3. Push pressure sensor into governor body. 4. Install retainer to hold pressure sensor to governor body. 5. Place gasket in position on back of governor body. 6. Place governor body in position on valve body. 7. Install bolts to hold governor body to valve body. 8. Lubricate O-ring, on pressure solenoid, with transmission fluid. 9. Align pressure solenoid to bore in governor body. 10. Push solenoid into governor body. 11. Place solenoid retainer in position on governor. 12. Install screws to hold pressure solenoid retainer to governor body. 13. Engage wire connectors into pressure sensor and solenoid. 14. Install transmission fluid pan and (new) filter. 15. Lower vehicle and road test to verify repair. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Service and Repair > Replacement > Page 4365 Governor: Service and Repair Removal and Installation REMOVAL 1. Hoist and support vehicle on safety stands. 2. Remove transmission fluid pan and filter. Governor Solenoid And Pressure Sensor 3. Disengage wire connectors from pressure sensor and solenoid. 4. Remove screws holding pressure solenoid retainer to governor body. Pressure Solenoid Retainer 5. Separate solenoid retainer from governor. Pressure Solenoid And O-ring 6. Pull solenoid from governor body. 7. Remove bolts holding governor body to valve body. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Service and Repair > Replacement > Page 4366 Governor Body And Gasket 8. Separate governor body from valve body. 9. Remove governor body gasket. 10. Remove retainer holding pressure sensor to governor body. Pressure Sensor And Retainer 11. Pull pressure sensor from governor body. INSTALLATION NOTE: Before installing the pressure sensor and solenoid in the governor body, replace O-ring seals, clean the gasket surfaces and replace gasket. 1. Lubricate O-ring on pressure sensor with transmission fluid. 2. Align pressure sensor to bore in governor body. 3. Push pressure sensor into governor body. 4. Install retainer to hold pressure sensor to governor body. 5. Place gasket in position on back of governor body. 6. Place governor body in position on valve body. 7. Install bolts to hold governor body to valve body. 8. Lubricate O-ring, on pressure solenoid, with transmission fluid. 9. Align pressure solenoid to bore in governor body. 10. Push solenoid into governor body. 11. Place solenoid retainer in position on governor. 12. Install screws to hold pressure solenoid retainer to governor body. 13. Engage wire connectors into pressure sensor and solenoid. 14. Install transmission fluid pan and (new) filter. 15. Lower vehicle and road test to verify repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Overdrive Indicator Lamp > Component Information > Description and Operation Overdrive Indicator Lamp: Description and Operation SYSTEM OPERATION The overdrive-off indicator lamp gives the driver an indication that the automatic transmission overdrive has been locked out. The lamp is controlled by the Powertrain Control Module (PCM) on a hard-wired circuit to instrument cluster. The PCM uses an input from the momentary overdrive lockout switch on the end of the automatic transmission gearshift selector lever to decide whether to turn the lamp on or off. The PCM then controls the lamp ground based upon the overdrive lockout switch input and its internal programming. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Page 4371 Overdrive Indicator Lamp: Testing and Inspection The diagnosis found here addresses an inoperative overdrive-off indicator lamp condition. If the overdrive-off indicator lamp comes on and stays on with the engine running, refer to the proper Diagnostic Procedures for diagnosis of the Powertrain Control Module (PCM) in Powertrain Management /Computer and Control Systems and the transmission control system circuits in Transmission and Drivetrain. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check the fuse in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Turn the ignition switch to the On position. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the ignition switch as required. 3. Disconnect and isolate the battery negative cable. Unplug the gray PCM wire harness connector. Install a jumper wire between the overdrive lamp driver circuit cavity of the gray PCM wire harness connector and a good ground. Connect the battery negative cable. Turn the ignition switch to the On position. The overdrive-off indicator lamp should light. Remove the jumper wire and the lamp should turn off. If OK, refer to the proper Diagnostic Procedures for diagnosis of the Powertrain Control Module (PCM) in Powertrain Management/Computer and Control Systems and the transmission control system circuits in Transmission and Drivetrain. If not OK, go to Step 4. 4. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Remove the instrument cluster bezel and the cluster as described. Check for continuity between the overdrive lamp driver circuit cavity of the gray PCM wire harness connector and a good ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the short circuit as required. 5. Check for continuity between the overdrive lamp driver circuit cavities of the gray PCM wire harness connector and the cluster wire harness connector. There should be continuity If OK, replace the faulty bulb. If not OK, repair the open circuit as required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Shift Indicator > Component Information > Description and Operation Shift Indicator: Description and Operation SYSTEM OPERATION Vehicles equipped with a manual transmission have an upshift indicator lamp. The upshift indicator lamp gives an indication when the driver should shift to the next highest gear for the best fuel economy The lamp is turned on by the instrument cluster circuitry for about three seconds when the ignition switch is turned to the On position as a bulb test. After the bulb test, the lamp is controlled by the instrument cluster circuitry based upon a message received from the Powertrain Control Module (PCM) on the Chrysler Collision Detection (CCD) data bus. The PCM uses inputs from many sensors and its internal programming to decide whether the engine speed and load conditions are proper for a transmission upshift. The PCM then sends the proper message to the instrument cluster on the CCD data bus to turn the lamp on or off. The PCM will send a lamp-off message three to five seconds after a lamp-on message, if an upshift is not performed. The lamp will then remain off until the vehicle stops accelerating and is brought back into the range of lamp operation, or until the transmission is shifted into another gear. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Shift Indicator > Component Information > Description and Operation > Page 4375 Shift Indicator: Testing and Inspection NOTE: For complete testing, refer to Powertrain Management/Computers and Control Systems/Body Control Module/Testing and Inspection. See: Body and Frame/Body Control Systems/Central Timer Module ( CTM ) High Option/Testing and Inspection The diagnosis found here addresses an inoperative upshift indicator lamp condition. If lamp accuracy is suspect, diagnosis should be performed with a DRB scan tool. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. If the upshift indicator lamp fails to light during the bulb test (about three seconds after the ignition switch is turned to the On position), replace the upshift indicator lamp bulb with a known good unit. If the indicator lamp still fails to operate, diagnosis of the Powertrain Control Module (PCM) and the Chrysler Collision Detection (CCD) data bus should be performed with a DRB scan tool. For diagnosis of the upshift indicator lamp and the instrument cluster circuitry, see Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Instrument Cluster. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Service and Repair > Front Bearing Output Shaft: Service and Repair Front Bearing REMOVAL 1. Remove overdrive unit from the vehicle. 2. Remove overdrive gear-train from housing. 3. Remove snap ring holding output shaft front bearing to overdrive gear-train. 4. Pull bearing from output shaft. INSTALLATION 1. Place replacement bearing in position on gear-train with locating retainer groove toward the rear. 2. Push bearing onto shaft until the snap ring groove is visible. 3. Install snap ring to hold bearing onto output shaft. 4. Install overdrive gear-train into housing. 5. Install overdrive unit in vehicle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Service and Repair > Front Bearing > Page 4380 Output Shaft: Service and Repair Rear Bearing REMOVAL 1. Remove overdrive unit from the vehicle. 2. Remove overdrive gear-train from housing. 3. Remove snap ring holding output shaft rear bearing into overdrive housing. 4. Using a suitable driver inserted through the rear end of housing, drive bearing from housing. INSTALLATION 1. Place replacement bearing in position in housing. 2. Using a suitable driver, drive bearing into housing until the snap ring groove is visible. 3. Install snap ring to hold bearing into housing. 4. Install overdrive gear-train into housing. 5. Install overdrive unit in vehicle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft Bearing/Bushing, A/T > Component Information > Service and Repair Output Shaft Bearing/Bushing: Service and Repair REMOVAL 1. Remove overdrive housing yoke seal. 2. Insert Remover 6957, or equivalent into overdrive housing. Tighten tool to bushing and remove bushing. INSTALLATION 1. Align bushing oil hole with oil slot in overdrive housing. 2. Tap bushing into place with Installer 6951 and Handle C-4171, or equivalent. 3. Install new oil seal in housing using Seal Installer C-3995-A, or equivalent. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Component Information > Service and Repair > Replacement Overdrive Assembly: Service and Repair Replacement REMOVAL 1. Shift transmission into Park. 2. Raise vehicle. 3. Mark propeller shaft universal joint(s) and axle pinion yoke for alignment reference at installation. 4. Disconnect and remove propeller shaft(s). 5. Remove transmission oil pan, remove gasket, drain oil and reinstall pan. 6. If overdrive unit had malfunctioned, or if fluid is contaminated, remove entire transmission. If diagnosis indicated overdrive problems only, remove just the overdrive unit. 7. Support transmission with transmission jack. 8. Remove rear crossmember. 9. Remove vehicle speed sensor and speedometer adapter, if necessary. 10. Remove bolts attaching overdrive unit to transmission. CAUTION: Support the overdrive unit with a jack before moving it rearward. This is necessary to prevent damaging the intermediate shaft. Do not allow the shaft to support the entire weight of the overdrive unit. 11. Carefully work overdrive unit off intermediate shaft. Do not tilt unit during removal. Keep it as level as possible. a. If overdrive unit does not require service, immediately insert Alignment Tool 6227-2, or equivalent in splines of planetary gear and overrunning clutch to prevent splines from rotating out of alignment. If misalignment occurs, overdrive unit will have to be disassembled in order to realign splines. b. If overdrive unit requires service, refer to Overhaul. 12. Remove and retain overdrive piston thrust bearing. Bearing may remain on piston or in clutch hub during removal. 13. Position drain pan on workbench. 14. Place overdrive unit over drain pan. Tilt unit to drain residual fluid from case. 15. Examine fluid for clutch material or metal fragments. If fluid contains these items, overhaul will be necessary. 16. If overdrive unit does not require any service, leave alignment tool in position. Tool will prevent accidental misalignment of planetary gear and overrunning clutch splines. INSTALLATION 1. Be sure overdrive unit Alignment Tool 6227-2, or equivalent is fully seated before moving unit. If tool is not seated and gear splines rotate out of alignment, overdrive unit will have to be disassembled in order to realign splines. 2. If overdrive piston retainer was not removed during service and original case gasket is no longer reusable, prepare new gasket by trimming it. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Component Information > Service and Repair > Replacement > Page 4388 3. Cut out old case gasket around piston retainer with razor knife. 4. Use old gasket as template and trim new gasket to fit. 5. Position new gasket over piston retainer and on transmission case. Use petroleum jelly to hold gasket in place if necessary. Do not use any type of sealer to secure gasket. Use petroleum jelly only. 6. Install selective spacer on intermediate shaft, if removed. Spacer goes in groove just rearward of shaft rear splines. 7. Install thrust bearing in overdrive unit sliding hub. Use petroleum jelly to hold bearing in position. CAUTION: Be sure the shoulder on the inside diameter of the bearing is facing forward. 8. Verify that splines in overdrive planetary gear and overrunning clutch hub are aligned with Alignment Tool 6227-2, or equivalent. Overdrive unit cannot be installed if splines are not aligned. If splines have rotated out of alignment, unit will have to be disassembled to realign splines. 9. Carefully slide Alignment Tool 6227-2, or equivalent out of overdrive planetary gear and overrunning clutch splines. 10. Raise overdrive unit and carefully slide it straight onto intermediate shaft. Insert park rod into park lock reaction plug at same time. Avoid tilting overdrive during installation as this could cause planetary gear and overrunning clutch splines to rotate out of alignment. If this occurs, it will be necessary to remove and disassemble overdrive unit to realign splines. 11. Align slip-fit governor tubes and work overdrive unit forward on intermediate shaft until seated against transmission case. 12. Install bolts attaching overdrive unit to transmission unit. Tighten bolts in diagonal pattern to 34 Nm (26 ft. lbs). 13. Install crossmember. 14. Install speed sensor and speedometer adapter. Be sure to index adapter. 15. Connect speed sensor and overdrive wires. 16. Align and install propeller shaft. 17. If valve body was also removed, adjust bands, install valve body and install transmission oil pan and gasket. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Component Information > Service and Repair > Replacement > Page 4389 Overdrive Assembly: Service and Repair Overhaul Disassembly DISASSEMBLY 1. Remove transmission speed sensor and O-ring seal from overdrive case. 2. Remove overdrive piston thrust bearing. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Component Information > Service and Repair > Replacement > Page 4390 OVERDRIVE PISTON DISASSEMBLY 1. Remove overdrive piston thrust plate. Retain thrust plate. It is a select fit part and may possibly be reused. 2. Remove intermediate shaft spacer. Retain spacer. It is a select fit part and may possibly be reused. 3. Remove overdrive piston from retainer. OVERDRIVE CLUTCH PACK DISASSEMBLY 1. Remove overdrive clutch pack wire retaining ring. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Component Information > Service and Repair > Replacement > Page 4391 2. Remove overdrive clutch pack. NOTE: The 42RE transmission has three clutch discs and two clutch plates. 3. Note position of clutch pack components for assembly reference. OVERDRIVE GEAR-TRAIN DISASSEMBLY 1. Remove overdrive clutch wave spring. 2. Remove overdrive clutch reaction snap ring. Note that snap ring is located in same groove as wave spring. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Component Information > Service and Repair > Replacement > Page 4392 3. Remove Torx head screws that attach access cover and gasket to overdrive case. 4. Remove access cover and gasket. 5. Expand output shaft bearing snap ring with expanding-type snap ring pliers. Then push output shaft forward to release shaft bearing from locating ring. 6. Lift gear case up and off gear-train assembly. 7. Remove snap ring that retains rear bearing on output shaft. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Component Information > Service and Repair > Replacement > Page 4393 8. Remove rear bearing from output shaft. WARNING: The next step in disassembly involves compressing the direct clutch spring. It is extremely important that proper equipment be used to compress the spring as spring force is approximately 830 pounds. Use spring compressor tool 6227-1, or equivalent and a hydraulic shop press with a minimum ram travel of 5 - 6 inches. The press must also have a bed that can be adjusted up or down as required. Release clutch spring tension slowly and completely to avoid personal injury. DIRECT CLUTCH, HUB AND SPRING DISASSEMBLY 1. Mount gear-train assembly in shop press. 2. Position Compressor Tool 6227-1, or equivalent on clutch hub. Support output shaft flange with steel press plates as shown and center assembly under press ram. 3. Apply press pressure slowly. Compress hub and spring far enough to expose clutch hub retaining ring and relieve spring pressure on clutch pack snap ring. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Component Information > Service and Repair > Replacement > Page 4394 4. Remove direct clutch pack snap ring. 5. Remove direct clutch hub retaining ring. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Component Information > Service and Repair > Replacement > Page 4395 6. Release press load slowly and completely. 7. Remove Special Tool 6227-1, or equivalent. Then remove clutch pack from hub. GEAR-TRAIN DISASSEMBLY 1. Remove direct clutch hub and spring. 2. Remove sun gear and spring plate. Then remove planetary thrust bearing and planetary gear. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Component Information > Service and Repair > Replacement > Page 4396 3. Remove overrunning clutch assembly with expanding type snap ring pliers. Insert pliers into clutch hub. Expand pliers to grip hub splines and remove clutch with counterclockwise, twisting motion. 4. Remove thrust bearing from overrunning clutch hub. 5. Remove overrunning clutch from hub. 6. Mark position of annulus gear and direct clutch drum for assembly alignment reference. Use small center punch or scriber to make alignment marks. 7. Remove direct clutch drum rear retaining ring. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Component Information > Service and Repair > Replacement > Page 4397 8. Remove direct clutch drum outer retaining ring. 9. Mark annulus gear and output shaft for assembly alignment reference. Use punch or scriber to mark gear and shaft. 10. Remove snap ring that secures annulus gear on output shaft. Use two screwdrivers to unseat and work snap ring out of groove as shown. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Component Information > Service and Repair > Replacement > Page 4398 11. Remove annulus gear from output shaft. Use rawhide or plastic mallet to tap gear off shaft. GEAR CASE AND PARK LOCK DISASSEMBLY 1. Remove locating ring from gear case. 2. Remove park pawl shaft retaining bolt and remove shaft, pawl and spring. 3. Remove reaction plug snap ring and remove reaction plug. 4. Remove output shaft seal. Assembly GEAR-TRAIN AND DIRECT CLUTCH ASSEMBLY 1. Soak direct clutch and overdrive clutch discs in MOPAR ATF+4 transmission fluid. Allow discs to soak for 10 - 20 minutes. 2. Install new pilot bushing and clutch hub bushing in output shaft if necessary. Lubricate bushings with petroleum jelly, or transmission fluid 3. Install annulus gear on output shaft, if removed. Then install annulus gear regaining snap ring. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Component Information > Service and Repair > Replacement > Page 4399 4. Align and install clutch drum on annulus gear. Be sure drum is engaged in annulus gear lugs. 5. Install clutch drum outer retaining ring. 6. Slide clutch drum forward and install inner retaining ring. 7. Install rear bearing and snap ring on output shaft. Be sure locating ring groove in bearing is toward rear. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Component Information > Service and Repair > Replacement > Page 4400 8. Install overrunning clutch on hub. Note that clutch only fits one way. Shoulder on clutch should seat in small recess at edge of hub. 9. Install thrust bearing on overrunning clutch hub. Use generous amount of petroleum jelly to hold bearing in place for installation. Bearing fits one way only. Be sure bearing is seated squarely against hub. Reinstall bearing if it does not seat squarely. 10. Install overrunning clutch in output shaft. Insert snap ring pliers in hub splines. Expand pliers to grip hub. Then install assembly with counterclockwise, twisting motion. 11. Install planetary gear in annulus gear. Be sure planetary pinions are fully seated in annulus near before proceeding. 12. Coat planetary thrust bearing and bearing contact surface of spring plate with generous amount of petroleum jelly. This will help hold bearing in place during installation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Component Information > Service and Repair > Replacement > Page 4401 13. Install planetary thrust bearing on sun gear. Slide bearing onto gear and seat it against spring plate as shown. Bearing fits one way only. If it does not seat squarely against spring plate, remove and reposition bearing. 14. Install assembled sun gear, spring plate and thrust bearing. Be sure sun gear and thrust bearing are fully seated before proceeding. 15. Mount assembled output shaft, annulus gear, and clutch drum in shop press. Direct clutch spring, hub and clutch pack are easier to install with assembly mounted in press. 16. Align splines in hubs of planetary gear and overrunning clutch with Alignment tool 6227-2, or equivalent. Insert tool through sun gear and into splines of both hubs. Be sure alignment tool is fully seated before proceeding. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Component Information > Service and Repair > Replacement > Page 4402 17. Install direct clutch spring. Be sure spring is properly seated on spring plate. NOTE: The 42RE transmission has 6 direct clutch discs and 5 clutch plates. 18. Assemble and install direct clutch pack on hub as follows: a. Assemble clutch pack components. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Component Information > Service and Repair > Replacement > Page 4403 b. Install direct clutch reaction plate on clutch hub first. Note that one side of reaction plate is counterbored. Be sure this side faces rearward. Splines at rear of hub are raised slightly. Counterbore in plate fits over raised splines. Plate should be flush with this end of hub. c. Install first clutch disc followed by a steel plate until all discs and plates hake been installed. d. Install pressure plate. This is last clutch pack item to be installed. Be sure plate is installed with shoulder side facing upward. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Component Information > Service and Repair > Replacement > Page 4404 19. Install clutch hub and clutch pack on direct clutch spring. Be sure hub is started on sun gear splines before proceeding. WARNING: The next step in gear-train assembly involves compressing the direct clutch hub and spring. It is extremely important that proper equipment be used to compress the spring as spring force is approximately 830 pounds. Use compressor tool C-6227-1 and a hydraulic-type shop press with a minimum ram travel of 6 inches. The press must also have a bed that can be adjusted up or down as required. Release clutch spring tension slowly and completely to avoid personal injury. 20. Position Compressor Tool 6227-1, or equivalent on clutch hub. 21. Compress clutch hub and spring just enough to place tension on hub and hold it in place. 22. Slowly compress clutch hub and spring. Compress spring and hub only enough to expose ring grooves for clutch pack snap ring and clutch hub retaining ring. 23. Realign clutch pack on hub and seat clutch discs and plates in clutch drum. 24. Install direct clutch pack snap ring. Be very sure snap ring is fully seated in clutch drum ring groove. 25. Install clutch hub retaining ring. Be very sure retaining ring is fully seated in sun gear ring groove. 26. Slowly release press ram, remove compressor tools and remove gear-train assembly. GEAR CASE ASSEMBLY Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Component Information > Service and Repair > Replacement > Page 4405 1. Position park pawl and spring in case and install park pawl shaft. Verify that end of spring with 90° bend is hooked to pawl and straight end of spring is seated against case. 2. Install pawl shaft retaining bolt. Tighten bolt to 27 Nm (20 ft. lbs.) torque. 3. Install park lock reaction plug. Note that plug has locating pin at rear. Be sure pin is seated in hole in case before installing snap ring. 4. Install reaction plug snap-ring. Compress snap ring only enough for installation; do not distort it. 5. Install new seal in gear case. Use Handle C-4171 and Installer C-3995-A, or equivalents to seat seal in case. 6. Verify that tab ends of rear bearing locating ring extend into access hole in gear case. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Component Information > Service and Repair > Replacement > Page 4406 7. Support gear-train on Tool 6227-1, or equivalent. Be sure tool is securely seated in clutch hub. 8. Install overdrive gear case on gear-train. 9. Expand front bearing locating ring with snap ring pliers. Then slide case downward until locating ring locks in bearing groove and release snap ring. 10. Install locating ring access cover and gasket in overdrive unit case. OVERDRIVE CLUTCH ASSEMBLY 1. Install overdrive clutch reaction ring first. Reaction ring is flat with notched ends. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Component Information > Service and Repair > Replacement > Page 4407 2. Install wave spring on top of reaction ring. Reaction ring and wave ring both fit in same ring groove. Use screwdriver to seat each ring securely in groove. Also ensure that the ends of the two rings are offset from each other. NOTE: The 42RE transmission has 3 overdrive clutch discs and 2 plates. 3. Assemble overdrive clutch pack. 4. Install overdrive clutch reaction plate first. 5. Install first clutch disc followed by first clutch plate. Then install remaining clutch discs and plates in same order. 6. Install clutch pack pressure plate. 7. Install clutch pack wire-type retaining ring. INTERMEDIATE SHAFT SPACER SELECTION 1. Place overdrive unit in vertical position. Mount it on blocks, or in workbench with appropriate size mounting hole cut into it. Be sure unit is facing upward for access to direct clutch hub. Also be sure output shaft is not loaded and internal components are moved rearward for accurate measurement. 2. Determine correct thickness intermediate shaft spacer as follows: Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Component Information > Service and Repair > Replacement > Page 4408 a. Insert Special Tool 6312, or equivalent through sun gear, planetary gear and into pilot bushing in output shaft. Be sure tool bottoms against planetary shoulder. b. Position Gauge Tool 6311, or equivalent across face of overdrive case. Then position Dial Caliper C-4962, or equivalent over gauge tool. c. Extend sliding scale of dial caliper downward through gauge tool slot until scale contacts end of Gauge Alignment Tool 6312, or equivalent. Lock scale in place. Remove dial caliper tool and note distance measured. d. Select proper thickness end play spacer from spacer chart based on distance measured. e. Remove Gauge Alignment Tool 6312, or equivalent. OD THRUST PLATE SELECTION 1. Place overdrive unit in vertical position. Mount it on blocks, or in workbench with appropriate size mounting hole cut into it. Be sure unit is facing upward for access to direct clutch hub. Also be sure output shaft is not loaded and internal components are moved rearward for accurate measurement. 2. Determine correct thickness overdrive piston thrust plate as follows: a. Position Gauge Tool 6311, or equivalent across face of over drive case. Then position Dial Caliper C-4962, or equivalent over gauge tool. b. Measure distance to clutch hub thrust bearing seat at four points 90° apart. Then average measurements by adding them and dividing by 4. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Component Information > Service and Repair > Replacement > Page 4409 c. Select and install required thrust plate from information in thrust plate chart. 3. Leave Alignment Tool 6227-2, or equivalent in place. Tool will keep planetary and clutch hub splines in alignment until overdrive unit is ready for installation on transmission. 4. Transmission speed sensor can be installed at this time if desired. However, it is recommended that sensor not be installed until after overdrive unit is secured to transmission. OVERDRIVE PISTON ASSEMBLY 1. Install new seals on over drive piston. 2. Stand transmission case upright on bellhousing. 3. Position Guide Ring 8114-1, or equivalent on outer edge of overdrive piston retainer. 4. Position Seal Guide 8114-2, or equivalent on inner edge of overdrive piston retainer. 5. Install overdrive piston in overdrive piston retainer by: aligning locating lugs on overdrive piston to the two mating holes in retainer. a. Aligning locating lugs on overdrive piston to the two mating holes in retainer. b. Lubricate overdrive piston seals with MOPAR Door Ease, or equivalent. c. Install piston over Seal Guide 8114-2 and inside Guide Ring 8114-1, or equivalents. d. Push overdrive piston into position in retainer. e. Verify that the locating lugs entered the lug bores in the retainer. 6. Install intermediate shaft spacer on intermediate shaft. 7. Install overdrive piston thrust plate on overdrive piston. 8. Install overdrive piston thrust bearing on overdrive piston. 9. Install transmission speed sensor and O-ring seal in overdrive case. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Indicator Lamp > Component Information > Description and Operation Overdrive Indicator Lamp: Description and Operation SYSTEM OPERATION The overdrive-off indicator lamp gives the driver an indication that the automatic transmission overdrive has been locked out. The lamp is controlled by the Powertrain Control Module (PCM) on a hard-wired circuit to instrument cluster. The PCM uses an input from the momentary overdrive lockout switch on the end of the automatic transmission gearshift selector lever to decide whether to turn the lamp on or off. The PCM then controls the lamp ground based upon the overdrive lockout switch input and its internal programming. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Indicator Lamp > Component Information > Description and Operation > Page 4413 Overdrive Indicator Lamp: Testing and Inspection The diagnosis found here addresses an inoperative overdrive-off indicator lamp condition. If the overdrive-off indicator lamp comes on and stays on with the engine running, refer to the proper Diagnostic Procedures for diagnosis of the Powertrain Control Module (PCM) in Powertrain Management /Computer and Control Systems and the transmission control system circuits in Transmission and Drivetrain. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check the fuse in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Turn the ignition switch to the On position. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the ignition switch as required. 3. Disconnect and isolate the battery negative cable. Unplug the gray PCM wire harness connector. Install a jumper wire between the overdrive lamp driver circuit cavity of the gray PCM wire harness connector and a good ground. Connect the battery negative cable. Turn the ignition switch to the On position. The overdrive-off indicator lamp should light. Remove the jumper wire and the lamp should turn off. If OK, refer to the proper Diagnostic Procedures for diagnosis of the Powertrain Control Module (PCM) in Powertrain Management/Computer and Control Systems and the transmission control system circuits in Transmission and Drivetrain. If not OK, go to Step 4. 4. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Remove the instrument cluster bezel and the cluster as described. Check for continuity between the overdrive lamp driver circuit cavity of the gray PCM wire harness connector and a good ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the short circuit as required. 5. Check for continuity between the overdrive lamp driver circuit cavities of the gray PCM wire harness connector and the cluster wire harness connector. There should be continuity If OK, replace the faulty bulb. If not OK, repair the open circuit as required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Description and Operation > Switch Operation Overdrive Switch: Description and Operation Switch Operation The overdrive OFF (control) switch is located on the gearshift lever. The switch is a momentary contact device that signals the Powertrain Control Module (PCM) to toggle current status of the overdrive function. 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 Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Description and Operation > Switch Operation > Page 4418 Overdrive Switch: Description and Operation Overdrive Override Switch-PCM Input PURPOSE On vehicles equipped with an automatic transmission and overdrive, the powertrain control module (PCM) regulates the 3-4 overdrive up-shift and downshift through the overdrive solenoid. OPERATION This solenoid is located in the transmission. An overdrive/override push-button switch is located at the end of transmission shift lever. This solenoid is located in the transmission. An overdrive/override push-button switch is located at the end of the transmission shift lever. The overdrive/override push-button switch is normally open (overdrive allowed) when the lamp is not illuminated. It momentarily closes (overdrive not allowed) when the operator presses the switch and the lamp is illuminated. Overdrive will revert to ON (lamp off) each time the ignition switch in turned on. The transmission downshifts if the operator presses the override switch while in overdrive. CIRCUIT OPERATION Automatic transmission equipped vehicles may have an overdrive switch. The operator disables or enables overdrive when the switch is depressed. The overdrive switch consists of a switch connected to the Powertrain Control Module (PCM), an illumination lamp and an overdrive ON/OFF indicator lamp. If overdrive is currently enabled, it is disabled when the operator depresses the overdrive switch. Conversely, if the operator already disabled over-drive, it is enabled when the switch is depressed. Circuit T6 from the overdrive switch connects to cavity C13 of the PCM and provides the overdrive signal. The PCM turns the overdrive ON/OFF indicator lamp ON or OFF by providing a ground for the lamp on circuit T18. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Diagrams Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Service and Repair > Disassembly Planetary Gears: Service and Repair Disassembly 1. Remove planetary snap ring. 2. Remove front annulus and planetary assembly from driving shell. 3. Remove snap ring that retains front planetary gear in annulus gear. 4. Remove tabbed thrust washer and tabbed thrust plate from hub of front annulus. 5. Separate front annulus and planetary gears. 6. Remove front planetary gear front thrust washer from annulus gear hub. 7. Separate and remove driving shell, rear planetary and rear annulus from output shaft. 8. Remove front planetary rear thrust washer from driving shell. 9. Remove tabbed thrust washers from rear planetary gear. 10. Remove lock ring that retains sun gear in driving shell. Then remove sun gear, spacer and thrust plates. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Service and Repair > Disassembly > Page 4424 Planetary Gears: Service and Repair Assembly 1. Lubricate output shaft and planetary components with transmission fluid. Use petroleum jelly to lubricate and hold thrust washers and plates in position. 2. Assemble rear annulus gear and support if disassembled. Be sure support snap ring is seated and that shoulder-side of support faces rearward. 3. Install rear thrust washer on rear planetary gear. Use enough petroleum jelly to hold washer in place. Also be sure all four washer tabs are properly engaged in gear slots. 4. Install rear annulus over and onto rear planetary gear. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Service and Repair > Disassembly > Page 4425 5. Install assembled rear planetary and annulus gear on output shaft. Verify that assembly is fully seated on shaft. 6. Install front thrust washer on rear planetary gear. Use enough petroleum jelly to hold washer on gear. Be sure all four washer tabs are seated in slots. 7. Install spacer on sun gear. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Service and Repair > Disassembly > Page 4426 8. Install thrust plate on sun gear. Note that driving shell thrust plates are interchangeable. Use either plate on sun gear and at front/rear of shell. 9. Hold sun gear in place and install thrust plate over sun gear at rear of driving shell. 10. Position wood block on bench and support sun gear on block. This makes it easier to align and install sun gear lock ring. Keep wood block handy as it will also be used for gear-train end play check. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Service and Repair > Disassembly > Page 4427 11. Align rear thrust plate on driving shell and install sun gear lock ring. Be sure ring irefully seated in sun gear ring groove. 12. Install assembled driving shell and sun gear on output shaft. 13. Install rear thrust washer on front planetary gear. Use enough petroleum jelly to hold washer in place and be sure all four washer tabs are seated. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Service and Repair > Disassembly > Page 4428 14. Install front planetary gear on output shaft and in driving shell. 15. Install front thrust washer on front planetary gear. Use enough petroleum jelly to hold washer in place and be sure all four washer tabs are seated. 16. Assemble front annulus gear and support, if necessary. Be sure support snap ring is seated. 17. Install front annulus on front planetary. 18. Position thrust plate on front annulus gear support. Note that plate has two tabs on it. These tabs fit in notches of annulus hub. 19. Install thrust washer in front annulus. Align flat on washer with flat on planetary hub. Also be sure washer tab is facing up. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Service and Repair > Disassembly > Page 4429 20. Install front annulus snap ring. Use snap ring pliers to avoid distorting ring during installation. Also be sure ring is fully seated. 21. Install planetary selective snap ring with snap ring pliers. Be sure ring is fully seated. 22. Turn planetary gear-train assembly over so driving shell is facing workbench. Then support gear-train on wood block positioned under forward end of output shaft. This allows gear-train components to move forward for accurate end play check. 23. Check planetary gear-train end play with feeler gauge. Gauge goes between shoulder on output shaft and end of rear annulus support. 24. Gear-train end play should be 0.12 to 1.22 mm (0.005 to 0.048 inch). If end play is incorrect, snap ring (or thrust washers) may have to be replaced. Snap ring is available in three different thicknesses for adjustment purposes. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold Pressure Regulating Solenoid: Customer Interest A/T - Buzz/Whining in Reverse When Cold NUMBER: 21-08-99 GROUP: Transmission DATE: April 30, 1999 SUBJECT: "Buzz", "Whining", Or "Moaning" Like Noise From A Cold Transmission When Reverse Is Selected. OVERVIEW: This bulletin involves replacing the transmission regulator valve. MODELS: 1996 - 1999 (AB) Ram Van 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (TJ) Wrangler 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1999 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A RE OR RH AUTOMATIC TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may exhibit an intermittent noise from the transmission when reverse gear is selected. This noise has been described as a "buzz", whining", or "moaning" like noise. The noise is most noticeable when transmission fluid temperature is below 38 C. (100 F.). The condition is caused by a resonance of the transmission regulator valve system. Other items may cause regulator valve resonance, including air ingestion into the valve body or out of specification parts. These two items may be the result a possible cracked pump housing, a torn pump gasket, an under filled transmission, a restricted fluid filter or cooler flow, or an out of specification valve and/or valve body. You should remember these additional items / components when you perform your diagnosis. Vehicles built prior to August 1, 1995 may experience this condition if either a transmission valve body or an entire automatic transmission was replaced with components manufactured after August 1, 1995. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostics Procedure Manual, verify all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. For 1996 and 1997 model year product, review Technical Service Bulletin 21-11-97 Rev A to determine if it applies to this vehicle before attempting to complete the analysis or repairs described in this bulletin. In most instances, the sump temperature of vehicles exhibiting transmission regulator valve resonance in reverse has been less than 38 C. (100 F). If possible, allow the suspect vehicle to remain parked in a cool place overnight. Then perform the following steps: 1. Set the vehicle parking brake. 2. Start the engine (make certain windows are closed, to eliminate outside noise). 3. With brakes applied, place the transmission selector lever in reverse. 4. Listen for any buzz/moaning/whining like noises as the transmission sump temperature rises to normal operating temperature (180 - 210 degrees F). 5. If a buzz/moaning/whining like noise is present, perform the Repair Procedure. PARTS REQUIRED: 1 04130169 Valve, Steel Transmission Regulator Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold > Page 4438 1 02464324 Gasket, Transmission Pan AR 05010124AA Fluid, ATF Plus 3, Type 7176E EQUIPMENT REQUIRED: 1 C-3763 Gauge Tool, Throttle Pressure Adjustment REPAIR PROCEDURE: 1. Following the procedures in the applicable service manual, remove the valve body from the transmission (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - REMOVAL AND INSTALLATION). 2. Remove the screws holding the adjusting screw bracket and replace the regulator valve with p/n 04130169 (Figure 1). Install the adjusting screw bracket 3. Verify and adjust, if necessary, both the line pressure and the throttle pressure settings by following the procedures in the service manual (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section ADJUSTMENTS - VALVE BODY). 4. Following the procedures in the appropriate Service Manual, re-install the valve body with the new regulator valve into the transmission. 5. After filling the transmission with the proper automatic transmission fluid, and verifying correct fill level, check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section ADJUSTMENTS - TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-90 1.2 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold Pressure Regulating Solenoid: All Technical Service Bulletins A/T - Buzz/Whining in Reverse When Cold NUMBER: 21-08-99 GROUP: Transmission DATE: April 30, 1999 SUBJECT: "Buzz", "Whining", Or "Moaning" Like Noise From A Cold Transmission When Reverse Is Selected. OVERVIEW: This bulletin involves replacing the transmission regulator valve. MODELS: 1996 - 1999 (AB) Ram Van 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (TJ) Wrangler 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1999 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A RE OR RH AUTOMATIC TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may exhibit an intermittent noise from the transmission when reverse gear is selected. This noise has been described as a "buzz", whining", or "moaning" like noise. The noise is most noticeable when transmission fluid temperature is below 38 C. (100 F.). The condition is caused by a resonance of the transmission regulator valve system. Other items may cause regulator valve resonance, including air ingestion into the valve body or out of specification parts. These two items may be the result a possible cracked pump housing, a torn pump gasket, an under filled transmission, a restricted fluid filter or cooler flow, or an out of specification valve and/or valve body. You should remember these additional items / components when you perform your diagnosis. Vehicles built prior to August 1, 1995 may experience this condition if either a transmission valve body or an entire automatic transmission was replaced with components manufactured after August 1, 1995. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostics Procedure Manual, verify all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. For 1996 and 1997 model year product, review Technical Service Bulletin 21-11-97 Rev A to determine if it applies to this vehicle before attempting to complete the analysis or repairs described in this bulletin. In most instances, the sump temperature of vehicles exhibiting transmission regulator valve resonance in reverse has been less than 38 C. (100 F). If possible, allow the suspect vehicle to remain parked in a cool place overnight. Then perform the following steps: 1. Set the vehicle parking brake. 2. Start the engine (make certain windows are closed, to eliminate outside noise). 3. With brakes applied, place the transmission selector lever in reverse. 4. Listen for any buzz/moaning/whining like noises as the transmission sump temperature rises to normal operating temperature (180 - 210 degrees F). 5. If a buzz/moaning/whining like noise is present, perform the Repair Procedure. PARTS REQUIRED: 1 04130169 Valve, Steel Transmission Regulator Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold > Page 4444 1 02464324 Gasket, Transmission Pan AR 05010124AA Fluid, ATF Plus 3, Type 7176E EQUIPMENT REQUIRED: 1 C-3763 Gauge Tool, Throttle Pressure Adjustment REPAIR PROCEDURE: 1. Following the procedures in the applicable service manual, remove the valve body from the transmission (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - REMOVAL AND INSTALLATION). 2. Remove the screws holding the adjusting screw bracket and replace the regulator valve with p/n 04130169 (Figure 1). Install the adjusting screw bracket 3. Verify and adjust, if necessary, both the line pressure and the throttle pressure settings by following the procedures in the service manual (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section ADJUSTMENTS - VALVE BODY). 4. Following the procedures in the appropriate Service Manual, re-install the valve body with the new regulator valve into the transmission. 5. After filling the transmission with the proper automatic transmission fluid, and verifying correct fill level, check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section ADJUSTMENTS - TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-90 1.2 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: Customer Interest TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 4454 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 4455 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: All Technical Service Bulletins TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 4461 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 4462 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 4463 Control Module: Description and Operation This vehicle does not have a Transmission Control Module. Transmission control is accomplished through the Engine Control Module or Powertrain Control Module. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Torque Converter Clutch Relay > Component Information > Locations Torque Converter Clutch Relay: Locations Power Distribution Center Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Torque Converter Clutch Relay > Component Information > Locations > Page 4467 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Power Distribution Center Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4471 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4472 Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4473 Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4474 Transmission Control System Relay: Description and Operation CIRCUIT OPERATION Four Speed Automatic Transmission The electronic transmission relay powers the overdrive solenoid, torque convertor clutch solenoid, and governor pressure solenoid. All three solenoids are molded together. Power for the coil side of the relay is supplied on circuit T4. This circuit is controlled by the Powertrain Control Module (PCM), and is the feed for the generator. Ground for the coil side of the relay is controlled by the PCM on circuit T3. This circuit connects to cavity E30 of the PCM connector. When the PCM grounds the relay, the relay contacts connect circuit A14 to circuit T8. Circuit T8 powers the solenoids. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4475 Transmission Control System Relay: Testing and Inspection - Check the 20 Amp fuse in cavity 3 of the PDC Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair Seals and Gaskets: Service and Repair REMOVAL 1. Raise vehicle. 2. Mark propeller shaft and axle yoke for alignment reference. 3. Disconnect and remove propeller shaft. 4. Remove old seal with Seal Remover C-3985-B, or equivalent from overdrive housing. INSTALLATION 1. Place seal in position on overdrive housing. 2. Drive seal into overdrive housing with Seal Installer C-3996-A, or equivalent. 3. Carefully guide propeller shaft slip yoke into housing and onto output shaft splines. Align marks made at removal and connect propeller shaft to rear axle pinion yoke. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm Fluid Pressure Sensor/Switch: Customer Interest A/T - Engine Bucking/Surging at 5,300 Rpm NO: 18-19-98 GROUP: Driveability DATE: Apr. 10, 1998 SUBJECT: Vehicle Bucking During Wide Open Throttle Acceleration MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE JAN 16, 1998 MDH (0116XX) EQUIPPED WITH GASOLINE ENGINES AND A 42/44/46 OR 47RE TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may experience bucking during wide open throttle (WOT) acceleration. The bucking occurs at approximately 5300 RPM. This condition may be caused by reaching the high RPM fuel shut off rev limit before the transmission can shift into the next higher gear and is most likely to occur with high electrical loads (high beams on, heated back lite, heated seats, radio, HVAC blower on MAX etc.). During high current demands, the generator may emit electrical noise that can affect the transmission governor pressure sensor output. If this occurs, the transmission may not shift properly to the next higher gear under (WOT) acceleration conditions and therefore reach the fuel shut off rev limiter. This may be seen most often between the 2-3 shift but can also be experienced between the 1-2 shift. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. NOTE: ONLY PERFORM THE FOLLOWING PROCEDURE SAFELY ON A HIGHWAY OR ROAD OBEYING ALL POSTED SPEED LIMITS AND LAWS. Attempt to duplicate the condition by switching on all accessory loads and driving the vehicle with WOT accelerations through a shift sequence to see if the engine will reach the fuel shut off rev limiter before the 2-3 or 1-2 shift is made. If the bucking condition is experienced at approximately 5300 RPM before making the appropriate upshifts, switch off all electrical loads and repeat the procedure. Repeat the procedure with the electrical loads on and off a second time. If the bucking occurs with the electrical loads on and does not occur with the loads off, perform the Repair Procedure. PARTS REQUIRED: 1 56041403AA Sensor, Governor Pressure REPAIR PROCEDURE: This bulletin involves installing a newly designed governor pressure sensor. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm > Page 4488 1. Following the procedures in the applicable service manual, replace the governor pressure sensor with p/n 56041403AA (Figure 1). 2. Check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-96-06-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm Fluid Pressure Sensor/Switch: All Technical Service Bulletins A/T - Engine Bucking/Surging at 5,300 Rpm NO: 18-19-98 GROUP: Driveability DATE: Apr. 10, 1998 SUBJECT: Vehicle Bucking During Wide Open Throttle Acceleration MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE JAN 16, 1998 MDH (0116XX) EQUIPPED WITH GASOLINE ENGINES AND A 42/44/46 OR 47RE TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may experience bucking during wide open throttle (WOT) acceleration. The bucking occurs at approximately 5300 RPM. This condition may be caused by reaching the high RPM fuel shut off rev limit before the transmission can shift into the next higher gear and is most likely to occur with high electrical loads (high beams on, heated back lite, heated seats, radio, HVAC blower on MAX etc.). During high current demands, the generator may emit electrical noise that can affect the transmission governor pressure sensor output. If this occurs, the transmission may not shift properly to the next higher gear under (WOT) acceleration conditions and therefore reach the fuel shut off rev limiter. This may be seen most often between the 2-3 shift but can also be experienced between the 1-2 shift. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. NOTE: ONLY PERFORM THE FOLLOWING PROCEDURE SAFELY ON A HIGHWAY OR ROAD OBEYING ALL POSTED SPEED LIMITS AND LAWS. Attempt to duplicate the condition by switching on all accessory loads and driving the vehicle with WOT accelerations through a shift sequence to see if the engine will reach the fuel shut off rev limiter before the 2-3 or 1-2 shift is made. If the bucking condition is experienced at approximately 5300 RPM before making the appropriate upshifts, switch off all electrical loads and repeat the procedure. Repeat the procedure with the electrical loads on and off a second time. If the bucking occurs with the electrical loads on and does not occur with the loads off, perform the Repair Procedure. PARTS REQUIRED: 1 56041403AA Sensor, Governor Pressure REPAIR PROCEDURE: This bulletin involves installing a newly designed governor pressure sensor. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm > Page 4494 1. Following the procedures in the applicable service manual, replace the governor pressure sensor with p/n 56041403AA (Figure 1). 2. Check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-96-06-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > Page 4495 Fluid Pressure Sensor/Switch: Description and Operation NOTE: This input is used with 4-speed electronic transmissions only DESCRIPTION The transmission governor pressure sensor provides a signal proportional to the transmission governor pressure. OPERATION It provides feedback for control of the variable force solenoid, which regulates transmission governor pressure. CIRCUIT OPERATION The governor pressure sensor supplies the transmission pressure input to the Powertrain Control Module on circuit T25. Circuit T25 connects to cavity B29 of the PCM. Circuit K7 from cavity B31 of the PCM supplies 5 Volts to the sensor. The PCM provides ground for the governor pressure sensor on circuit K4. Circuit K4 connects to cavity A4 of the PCM. The governor pressure sensor is part of the transmission solenoid assembly. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Description and Operation > Switch Operation Overdrive Switch: Description and Operation Switch Operation The overdrive OFF (control) switch is located on the gearshift lever. The switch is a momentary contact device that signals the Powertrain Control Module (PCM) to toggle current status of the overdrive function. 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 Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Description and Operation > Switch Operation > Page 4500 Overdrive Switch: Description and Operation Overdrive Override Switch-PCM Input PURPOSE On vehicles equipped with an automatic transmission and overdrive, the powertrain control module (PCM) regulates the 3-4 overdrive up-shift and downshift through the overdrive solenoid. OPERATION This solenoid is located in the transmission. An overdrive/override push-button switch is located at the end of transmission shift lever. This solenoid is located in the transmission. An overdrive/override push-button switch is located at the end of the transmission shift lever. The overdrive/override push-button switch is normally open (overdrive allowed) when the lamp is not illuminated. It momentarily closes (overdrive not allowed) when the operator presses the switch and the lamp is illuminated. Overdrive will revert to ON (lamp off) each time the ignition switch in turned on. The transmission downshifts if the operator presses the override switch while in overdrive. CIRCUIT OPERATION Automatic transmission equipped vehicles may have an overdrive switch. The operator disables or enables overdrive when the switch is depressed. The overdrive switch consists of a switch connected to the Powertrain Control Module (PCM), an illumination lamp and an overdrive ON/OFF indicator lamp. If overdrive is currently enabled, it is disabled when the operator depresses the overdrive switch. Conversely, if the operator already disabled over-drive, it is enabled when the switch is depressed. Circuit T6 from the overdrive switch connects to cavity C13 of the PCM and provides the overdrive signal. The PCM turns the overdrive ON/OFF indicator lamp ON or OFF by providing a ground for the lamp on circuit T18. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4504 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. 4. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 5. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 6. Test continuity of new switch with 12V test lamp. 7. Connect switch wires and lower vehicle. 8. Top off transmission fluid level. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Sensor Mounting ................................................................................................................................. ..................................................... 27 Nm (20 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 4508 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 4509 Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Shaft Speed Sensor-PCM Input Transmission Speed Sensor: Description and Operation Output Shaft Speed Sensor-PCM Input This sensor generates a signal to the PCM relating to the speed of the transmission main drive shaft. NOTE: This input is used with 4-speed electronic transmissions only. CIRCUIT OPERATION Four Speed Automatic Transmission The output shaft speed sensor generates a signal indicating the speed of the transmission output shaft. Circuits T13 and T14 connect the sensor to the Powertrain Control Module (PCM). Circuit T13 connects to cavity B25 of the PCM. Circuit T14 connects to cavity B28. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Shaft Speed Sensor-PCM Input > Page 4512 Transmission Speed Sensor: Description and Operation Sensor Operation The speed sensor is located in the overdrive gear case. The sensor is positioned over the park gear and monitors transmission output shaft rotating speed. Speed sensor signals are triggered by the park gear lugs as they rotate past the sensor pickup face. Input signals from the sensor are sent to the transmission control module for processing. The vehicle speed sensor also serves as a backup for the transmission speed sensor. Signals from this sensor are shared with the powertrain control module. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Page 4513 Transmission Speed Sensor: Service and Repair Removal Transmission Speed Sensor Removal Installation 1. Remove transmission speed sensor and O-ring seal from overdrive case. Installation 1. Install transmission speed sensor and O-ring seal in overdrive case. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations Governor Pressure Sensor, Transmission Temperature Sensor, Governor Pressure Solenoid, Governor The transmission temperature sensor is located in the transmission solenoid assembly in the valve body. The governor pressure sender and the transmission fluid temperature thermistor are separate sensors in the same component. This component is attached to the governor body in the solenoid assembly of the valve body. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission Temperature Sensor - Description and Operation Transmission Temperature Sensor/Switch: Description and Operation Transmission Temperature Sensor - Description and Operation Transmission fluid temperature readings are supplied to the transmission control module by the thermistor. The temperature readings are used to control engagement of the fourth gear overdrive clutch, the converter clutch, and governor pressure. Normal resistance value for the thermistor at room temperature is approximately 1000 ohms. The PCM prevents engagement of the converter clutch and overdrive clutch, when fluid temperature is below approximately 10 °C (50 °F). If fluid temperature exceeds 126 °C (260 °F), the PCM causes a 4-3 downshift and engage the converter clutch. Engagement is according to the third gear converter clutch engagement schedule. The overdrive OFF lamp in the instrument panel illuminates when the shift back to third occurs. The transmission will not allow fourth gear operation until fluid temperature decreases to approximately 110 °C (230 °F). The thermistor is part of the governor pressure sensor assembly and is immersed in transmission fluid at all times. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission Temperature Sensor - Description and Operation > Page 4519 Transmission Temperature Sensor/Switch: Description and Operation Transmission Temperature Sensor - PCM Input NOTE: This input is used in the shift operation for 4-speed electronic transmissions only. The temperature data is used for: torque converter clutch operation, overdrive shift, low temperature shift compensation, wide open throttle shift strategy and governor pressure transducer calibration. CIRCUIT OPERATION The transmission temperature sensor is located in the transmission solenoid assembly. The sensor is a variable resistor, as transmission temperature changes the resistance in the sensor changes. Circuit T34 connects from the Powertrain Control Module (PCM) to the sensor. Ground for the sensor is supplied on circuit K4. This circuit is the ground circuit for many of the components used in the fuel/ignition system. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations O/D (3-4) Solenoid, TCC Solenoid, Governor Pressure Sensor, Governor Pressure Solenoid Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Page 4523 Shift Solenoid: Description and Operation The shift valves are moved by a combination of throttle and governor pressure. The governor pressure is generated by electrical components. The conditions under which a shift to fourth will not occur are: - Overdrive switch is Off - Transmission fluid temperature is below 10 °C (50 °F) or above 121 °C (250 °F) - Shift to third not yet completed - Vehicle speed too low for 3-4 shift to occur - Battery temperature below -5 °F Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Testing and Inspection Shift Cable: Testing and Inspection Gearshift cable adjustment is important because it positions the valve body manual valve. Incorrect adjustment will cause creeping in Neutral, premature clutch wear, delayed engagement in any gear, or a no-start in Park or Neutral position. Proper operation of the park/neutral position switch will provide a quick check of cable adjustment. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Testing and Inspection > Page 4528 Shift Cable: Adjustments GENERAL INFORMATION Check adjustment by starting the engine in Park and Neutral. Adjustment is OK if the engine starts only in these positions. Adjustment is incorrect if the engine starts in one but not both positions. If the engine starts in any position other than Park or Neutral, or if the engine will not start at all, the park/ neutral position switch may be faulty. PROCEDURE 1. Shift transmission into Park. 2. Release cable adjuster lock (underneath the power brake booster) to unlock cable. 3. Raise vehicle. 4. Slide cable eyelet off transmission shift lever. 5. Verify transmission shift lever is in Park detent by moving lever fully rearward. Last rearward detent is Park position. 6. Verify positive engagement of transmission park lock by attempting to rotate propeller shaft. Shaft will not rotate when park lock is engaged. 7. Slide cable eyelet onto transmission shift lever. 8. Lower vehicle and check engine starting. Engine should start only in Park and Neutral. 9. Lock shift cable by pressing cable adjuster clamp down until it snaps into place. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Testing and Inspection > Page 4529 Shift Cable: Service and Repair REMOVAL 1. Shift transmission into Park. 2. Remove nuts retaining the shift cable housing to the dash panel. 3. Disconnect cable at lower column lever and feed cable through dash panel opening to underside of vehicle. 4. Raise vehicle. 5. Disengage cable eyelet at transmission shift lever and pull cable adjuster out of mounting bracket. Remove old cable from vehicle. INSTALLATION 1. Snap the cable into the transmission bracket so the retaining ears are engaged and connect cable end fitting onto the manual control lever ball stud. 2. Lower vehicle. 3. Route cable through hole in dash panel. Seat cable bracket to dash panel. Install retaining nuts to cable housing bracket studs inside the vehicle at the dash panel. 4. Place the auto transmission manual shift control lever in "Park" detent (rear-most) position and rotate prop shaft to ensure transmission is in park. 5. Connect shift cable to shifter lever by snapping cable retaining ears into shifter bracket and press cable end fitting into lever. 6. Check for proper operation of Park/Neutral switch. 7. If the gearshift cable is out of adjustment, refer to Adjustments section. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Speedometer Gear, A/T > Component Information > Service and Repair Speedometer Gear, A/T: Service and Repair NOTE: Rear axle gear ratio and tire size determine speedometer pinion requirements. REMOVAL 1. Raise vehicle. 2. Disconnect wires from vehicle speed sensor. 3. Remove adapter clamp and screw. 4. Remove speed sensor and speedometer adapter as assembly. 5. Remove speed sensor retaining screw and remove sensor from adapter. 6. Remove speedometer pinion from adapter. 7. Inspect sensor and adapter O-rings. Remove and discard O-rings if worn or damaged. 8. Inspect terminal pins in speed sensor. Clean pins with MOPAR electrical spray cleaner if dirty or oxidized. Replace sensor if faulty, or pins are loose, severely corroded, or damaged. INSTALLATION 1. Thoroughly clean adapter flange and adapter mounting surface in housing. Surfaces must be clean for proper adapter alignment and speedometer operation. 2. Install new O-rings on speed sensor and speedometer adapter if necessary. 3. Lubricate sensor and adapter O-rings with transmission fluid. 4. Install vehicle speed sensor in speedometer adapter. Tighten sensor attaching screw to 2 - 3 Nm (15 - 27 inch lbs.) torque. 5. Install speedometer pinion in adapter. 6. Count number of teeth on speedometer pinion. Do this before installing assembly in housing. Then lubricate pinion teeth with transmission fluid. 7. Note index numbers on adapter body. These numbers will correspond to number of teeth on pinion. 8. Install speedometer assembly in housing. 9. Rotate adapter until required range numbers are at 6 o'clock position. Be sure range index numbers correspond to number of teeth on pinion gear. 10. Install speedometer adapter clamp and retaining screw. Tighten clamp screw to 10 - 12 Nm (90 - 110 inch lbs.) torque. 11. Connect wires to vehicle speed sensor. 12. Lower vehicle and top off transmission fluid level if necessary. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Testing and Inspection Throttle Valve Cable/Linkage: Testing and Inspection Transmission throttle valve cable adjustment is extremely important to proper operation. This adjustment positions the throttle valve, which controls shift speed, quality, and part-throttle downshift sensitivity. If cable setting is too loose, early shifts and slippage between shifts may occur. If the setting is too tight, shifts may be delayed and part throttle downshifts may be very sensitive. Shift-cable adjustment is important because it positions the valve body manual valve. Incorrect adjustment will cause creeping in NEUTRAL, premature clutch wear, delayed engagement in any gear, or the engine will not crank in PARK or NEUTRAL position. Proper operation of the park/neutral position switch will provide a quick check of shift cable adjustment. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Testing and Inspection > Page 4536 Throttle Valve Cable/Linkage: Adjustments GENERAL INFORMATION The transmission throttle valve is operated by the valve body throttle lever. The throttle lever is actuated by a cable connected to the engine throttle body lever. A lock button at the engine end of the cable provides for cable adjustment. A correctly adjusted throttle valve cable, will cause the throttle lever on the transmission to move simultaneously with the throttle body lever from the idle position. Proper adjustment allows simultaneous movement without causing the transmission throttle lever to move ahead of, or lag behind the throttle body lever. For kickdown and line pressure adjustments See: Valve Body CHECK 1. Turn ignition key to OFF position. 2. Remove air cleaner. 3. Verify that throttle body lever is at curb idle position. Then verify that transmission throttle lever is also at idle (full forward) position. 4. Slide cable off attachment stud on throttle body lever. 5. Compare position of cable end to attachment stud on throttle body lever: a. Cable end and attachment stud should be aligned (or centered on one another) to within 1 mm (0.039 inch) in either direction. b. If cable end and attachment stud are misaligned (off center), cable will have to be adjusted as described in following procedure. 6. Reconnect cable end to attachment stud. Then with aid of a helper, observe movement of transmission throttle lever and lever on throttle body. a. If both levers move simultaneously from idle to half-throttle and back to idle position, adjustment is correct. b. If transmission throttle lever moves ahead of, or lags behind throttle body lever, cable adjustment will be necessary. Or, if throttle body lever prevents transmission lever from returning to closed position, cable adjustment will be necessary. PROCEDURE 1. Turn ignition switch to OFF position and shift into Park. 2. Remove air cleaner. 3. Disconnect cable end from attachment stud on throttle body. 4. Verify that transmission throttle lever is in idle (full forward) position. Then be sure lever on throttle body is at curb idle position. 5. Insert a small screwdriver under edge of retaining clip and remove retaining clip. 6. Center cable end on attachment stud to within 1 mm (0.039 inch) and release cable button. 7. Install retaining clip onto cable: housing. 8. Check cable adjustment. Be sure transmission throttle lever and lever on throttle body move simultaneously and as described in cable adjustment checking procedure. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications Torque Converter: Specifications To Flex Plate Bolt ................................................................................................................................ ..................................................... 31 Nm (23 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications > Page 4540 Torque Converter: Description and Operation GENERAL INFORMATION The torque converter is a hydraulic device that couples the engine crankshaft to the transmission. The torque converter consists of an outer shell with an internal turbine, a stator, an overrunning clutch, an impeller, and an electronically applied converter clutch. Torque multiplication is created when the stator directs the hydraulic flow from the turbine to rotate the impeller in the direction the engine crankshaft is turning. The turbine transfers power to the planetary gear sets in the transmission. The transfer of power into the impeller assists torque multiplication. At low vehicle-speed, the overrunning clutch holds the stator stationary (during torque multiplication) and allows the stator to freewheel at high vehicle speed. The converter clutch engagement reduces engine speed. Clutch engagement also provides reduced transmission fluid temperatures. The torque converter hub drives the transmission oil (fluid) pump. The torque converter is a sealed, welded unit that is not repairable and is serviced as an assembly. CAUTION: The torque converter must be replaced if a transmission failure results in large amounts of metal or fiber contamination in the fluid. CONVERTER DRAINBACK VALVE The drainback valve is located in the transmission cooler outlet (pressure) line. The valve prevents fluid from draining from the converter into the cooler and lines when the vehicle is shut down for lengthy periods. Production valves have a hose nipple at one end, while the opposite end is threaded for a flare fitting. All valves have an arrow (or similar mark) to indicate direction of flow through the valve. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications > Page 4541 Torque Converter: Service and Repair REMOVAL 1. Remove transmission and torque converter from vehicle. 2. Place a suitable drain pan under the converter housing end of the transmission. CAUTION: Verify that transmission is secure on the lifting device or work surface, the center of gravity of the transmission will shift when the torque converter is removed creating an unstable condition. - The torque converter is a heavy unit. Use caution when separating the torque converter from the transmission. 3. Pull the torque converter forward until the center hub clears the oil pump seal. 4. Separate the torque converter from the transmission. NOTE: Check converter hub and drive notches for sharp edges, burrs, scratches, or nicks. Polish the hub and notches with 320/400 grit paper or crocus cloth if necessary. The hub must be smooth to avoid damaging the pump seal at installation. INSTALLATION 1. Lubricate converter hub and oil pump seal lip with transmission fluid. 2. Place torque converter in position on transmission. CAUTION: Do not damage oil pump seal or bushing while inserting torque converter into the front of the transmission. 3. Align torque converter to oil pump seal opening. 4. Insert torque converter hub into oil pump. 5. While pushing torque converter inward, rotate converter until converter is fully seated in the oil pump gears. 6. Check converter seating with a scale and straightedge. Surface of converter lugs should be 1/2 inch to rear of straightedge when converter is fully seated. 7. If necessary, temporarily secure converter with C-clamp attached to the converter housing. 8. Install the transmission in the vehicle. 9. Fill the transmission with the recommended fluid. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Check Valve > Component Information > Service and Repair Torque Converter Check Valve: Service and Repair The converter drainback check valve is located in the cooler outlet (pressure) line near the radiator lower tank. The valve prevents fluid drainback when the vehicle is parked for lengthy periods. The valve check ball is spring loaded and has an opening pressure of approximately 2 psi. The valve is serviced as an assembly; it is not repairable. Do not clean the valve if restricted, or contaminated by sludge, or debris. If the valve fails, or if a transmission malfunction occurs that generates sludge and or clutch particles and metal shavings, the valve must be replaced. The valve must be removed whenever the cooler and lines are reverse flushed. The valve can be flow tested when necessary. The procedure is exactly the same as for flow testing a cooler. If the valve is restricted, installed backwards, or in the wrong line, it will cause an overheating condition and possible transmission failure. CAUTION: The drainback valve is a one-way flow device. It must be properly oriented in terms of flow direction for the cooler to function properly. The valve must be installed in the pressure line. Otherwise flow will be blocked and would cause an overheating condition and eventual transmission failure. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates Torque Converter Clutch: Technical Service Bulletins Engine Controls/Emissions/A/T - Manual Updates NUMBER: 26-06-98 GROUP: Miscellaneous DATE: June, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 2.5L, 3.9L, 5.2L, 5.9L 8.0L SFI/CNG/Diesel Diagnostic Manual - Publication Number 81-699-96041 DESCRIPTION OF CHANGES Revision to the diagnostic trouble codes Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 4549 56 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 4550 57 Revisions to the Throttle Position Sensor test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 4551 162 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 4552 166 Revisions to the Evap. Purge Flow Monitor tests Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 4553 374 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 4554 375 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 4555 377 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 4556 379 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 4557 379A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 4558 379B Revision to the EGR system Failure tests Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 4559 432 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 4560 433 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 4561 434 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 4562 435 Revision to the torque convertor clutch - no drop at lock up test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 4563 465 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 4564 467 Revision to the no temp rise seen at intake heater test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 4565 514 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 4566 515 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 4567 516 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 4568 517 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 4569 518 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 4570 519 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 4571 520 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 4572 521 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 4573 521A Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 4574 521B Revision to the 12 volt supply relay test Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Technical Service Bulletins > Engine Controls/Emissions/A/T - Manual Updates > Page 4575 571 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Technical Service Bulletins > Page 4576 Torque Converter Clutch: Description and Operation Converter clutch engagement in third or fourth gear range is controlled by sensor inputs to the powertrain control module. Inputs that determine clutch engagement are: coolant temperature, engine rpm, vehicle speed, throttle position, and manifold vacuum. The torque converter clutch is engaged by the clutch solenoid on the valve body. The clutch can be engaged in third and fourth gear ranges depending on overdrive control switch position. If the overdrive control switch is in the normal ON position, the clutch will engage after the shift to fourth gear, and above approximately 72 km/h (45 mph). If the control switch is in the OFF position, the clutch will engage after the shift to third gear, at approximately 56 km/h (35 mph) at light throttle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Relay > Component Information > Locations Torque Converter Clutch Relay: Locations Power Distribution Center Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Relay > Component Information > Locations > Page 4580 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations O/D (3-4) Solenoid, TCC Solenoid, Governor Pressure Sensor, Governor Pressure Solenoid Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Power Distribution Center Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations > Page 4587 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations > Page 4588 Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations > Page 4589 Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations > Page 4590 Transmission Control System Relay: Description and Operation CIRCUIT OPERATION Four Speed Automatic Transmission The electronic transmission relay powers the overdrive solenoid, torque convertor clutch solenoid, and governor pressure solenoid. All three solenoids are molded together. Power for the coil side of the relay is supplied on circuit T4. This circuit is controlled by the Powertrain Control Module (PCM), and is the feed for the generator. Ground for the coil side of the relay is controlled by the PCM on circuit T3. This circuit connects to cavity E30 of the PCM connector. When the PCM grounds the relay, the relay contacts connect circuit A14 to circuit T8. Circuit T8 powers the solenoids. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations > Page 4591 Transmission Control System Relay: Testing and Inspection - Check the 20 Amp fuse in cavity 3 of the PDC Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications Transmission Cooler: Specifications Auxiliary Cooler Bolts .......................................................................................................................... ................................................ 10 Nm (90 inch lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications > Page 4595 Transmission Cooler: Description and Operation LOCATION The automatic transmission oil is cooled when it passes through a cooler in the radiator lower tank. LEAKS In case of a leak in the transmission oil cooler, engine coolant may become mixed with transmission fluid. Transmission fluid may also have entered the engine cooling system. Both cooling system and transmission should be drained and inspected in the event cooler is leaking. AUXILIARY COOLER Oil-to-air (auxiliary) transmission coolers are mounted ahead of radiator. They operate in conjunction with main cooler located in radiator side tank. The transmission oil is routed through main cooler in radiator side tank first. It is then routed through auxiliary cooler before returning to transmission. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications > Page 4596 Transmission Cooler: Testing and Inspection OIL COOLER FLOW CHECK After the new or repaired transmission has been installed and filled, the oil cooler flow should be checked using the following procedure: 1. Disconnect the From cooler line at the transmission and place a collecting container under the disconnected line. 2. Run the engine at curb idle speed, with the shift selector in neutral. 3. If the fluid flow is intermittent or takes more than 20 seconds to collect one quart, the cooler should be replaced. CAUTION: With the fluid set at the proper level, fluid collection should not exceed (1) quart or internal damage to the transmission may occur. 4. If flow is found to be within acceptable limits, reconnect the cooler line. Then fill transaxle to the proper level, using the approved type of automatic transmission fluid. FLUSHING COOLERS AND TUBES When a transmission failure has contaminated the fluid, the oil cooler(s) must be flushed. The cooler bypass valve in the transmission must be replaced also. The torque converter must also be replaced. This will insure that metal particles or sludged oil are not later transferred back into the reconditioned (or replaced) transmission. There are two different procedures for flushing coolers and lines. The recommended procedure is to use Tool 6906 Cooler Flusher. The other procedure is to use a hand suction gun and mineral spirits. WARNING: Wear protective eye-wear that meets the requirements of OSHA and ANSI Z87.1-1968. Wear standard industrial rubber gloves. - Keep lighted cigarettes, sparks, flames, and other ignition sources away from the area to prevent the ignition of combustible liquids and gases. Keep a class (B) Fire extinguisher in the area where the flusher will be used. - Keep the area well ventilated. - Do not let flushing solvent come in contact with your eyes or skin: if eye contamination occurs, flush eyes with water for 15 to 20 seconds. Remove contaminated clothing and wash affected skin with soap and water. Seek medical attention. COOLER FLUSH USING TOOL 6906 1. Remove cover plate filler plug on Tool 6906, or equivalent. Fill reservoir 1/2 to 3/4 full of fresh flushing solution. Flushing solvents are petroleum based solutions generally used to clean automatic transmission components. DO NOT use solvents containing acids, water, gasoline, or any other corrosive liquids. 2. Reinstall filler plug on Tool 6906, or equivalent. 3. Verify pump power switch is turned OFF. Connect red alligator clip to positive (+) battery post. Connect black (-) alligator clip to a good ground. 4. Disconnect the cooler lines at the transmission. NOTE: When flushing transmission cooler and lines, ALWAYS reverse flush. 5. Connect the BLUE pressure line to the OUTLET (From) cooler line. 6. Connect the CLEAR return line to the INLET (To) cooler line 7. Turn pump ON for two to three minutes to flush cooler(s) and lines. Monitor pressure readings and clear return lines. Pressure readings should stabilize below 20 psi. for vehicles equipped with a single cooler and 30 psi. for vehicles equipped with dual coolers. If flow is intermittent or exceeds these pressures, replace cooler. 8. Turn pump OFF. 9. Disconnect CLEAR suction line from reservoir at cover plate. Disconnect CLEAR return line at cover plate, and place it in a drain pan. 10. Turn pump ON for 30 seconds to purge flushing solution from cooler and lines. Turn pump OFF. 11. Place CLEAR suction line into a one quart container of MOPAR type 9602 automatic transmission fluid. 12. Turn pump ON until all transmission fluid is removed from the one quart container and lines. This purges any residual cleaning solvent from the transmission cooler and lines. Turn pump OFF. 13. Disconnect alligator clips from battery. Reconnect flusher lines to cover plate, and remove flushing adapters from cooler lines. COOLER FLUSH USING SUCTION GUN AND MINERAL SPIRITS 1. Disconnect the cooler lines at the transmission. 2. Using a hand suction gun filled with mineral spirits, reverse flush the cooler. Force mineral spirits into the From Cooler line of the cooler and catch the exiting spirits from the To Cooler line. Observe for the presence of debris in the exiting fluid. Continue until fluid exiting is clear and free from debris. 3. Using compressed air (under 40 psi) in intermittent spurts, blow any remaining mineral spirits from the cooler, again in the reverse direction. 4. Pump one (1) quart of automatic transmission fluid through the cooler before reconnecting. 5. If at any stage of the cleaning process, the cooler does not freely pass fluid, the cooler must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications > Page 4597 Transmission Cooler: Service and Repair NOTE: Vehicles equipped with plastic radiator tanks will require special crimping tools for servicing. The servicing should be performed by a qualified repair facility. ^ Once repaired or replacement radiator has been installed. ^ Refill cooling system and inspect for leaks. Refer to Cooling System. ^ If transmission operates properly after repairing leak, drain transmission and torque converter while hot. ^ Remove transmission oil pan and inspect for sludge and/or rust. ^ Inspect for a dirty or plugged inlet filter. If none of these conditions are found, transmission may not require reconditioning. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4601 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. 4. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 5. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 6. Test continuity of new switch with 12V test lamp. 7. Connect switch wires and lower vehicle. 8. Top off transmission fluid level. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Pressure Test Port, A/T > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Sensor Mounting ................................................................................................................................. ..................................................... 27 Nm (20 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 4608 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 4609 Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Shaft Speed Sensor-PCM Input Transmission Speed Sensor: Description and Operation Output Shaft Speed Sensor-PCM Input This sensor generates a signal to the PCM relating to the speed of the transmission main drive shaft. NOTE: This input is used with 4-speed electronic transmissions only. CIRCUIT OPERATION Four Speed Automatic Transmission The output shaft speed sensor generates a signal indicating the speed of the transmission output shaft. Circuits T13 and T14 connect the sensor to the Powertrain Control Module (PCM). Circuit T13 connects to cavity B25 of the PCM. Circuit T14 connects to cavity B28. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Shaft Speed Sensor-PCM Input > Page 4612 Transmission Speed Sensor: Description and Operation Sensor Operation The speed sensor is located in the overdrive gear case. The sensor is positioned over the park gear and monitors transmission output shaft rotating speed. Speed sensor signals are triggered by the park gear lugs as they rotate past the sensor pickup face. Input signals from the sensor are sent to the transmission control module for processing. The vehicle speed sensor also serves as a backup for the transmission speed sensor. Signals from this sensor are shared with the powertrain control module. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Page 4613 Transmission Speed Sensor: Service and Repair Removal Transmission Speed Sensor Removal Installation 1. Remove transmission speed sensor and O-ring seal from overdrive case. Installation 1. Install transmission speed sensor and O-ring seal in overdrive case. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations Governor Pressure Sensor, Transmission Temperature Sensor, Governor Pressure Solenoid, Governor The transmission temperature sensor is located in the transmission solenoid assembly in the valve body. The governor pressure sender and the transmission fluid temperature thermistor are separate sensors in the same component. This component is attached to the governor body in the solenoid assembly of the valve body. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission Temperature Sensor - Description and Operation Transmission Temperature Sensor/Switch: Description and Operation Transmission Temperature Sensor - Description and Operation Transmission fluid temperature readings are supplied to the transmission control module by the thermistor. The temperature readings are used to control engagement of the fourth gear overdrive clutch, the converter clutch, and governor pressure. Normal resistance value for the thermistor at room temperature is approximately 1000 ohms. The PCM prevents engagement of the converter clutch and overdrive clutch, when fluid temperature is below approximately 10 °C (50 °F). If fluid temperature exceeds 126 °C (260 °F), the PCM causes a 4-3 downshift and engage the converter clutch. Engagement is according to the third gear converter clutch engagement schedule. The overdrive OFF lamp in the instrument panel illuminates when the shift back to third occurs. The transmission will not allow fourth gear operation until fluid temperature decreases to approximately 110 °C (230 °F). The thermistor is part of the governor pressure sensor assembly and is immersed in transmission fluid at all times. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission Temperature Sensor - Description and Operation > Page 4619 Transmission Temperature Sensor/Switch: Description and Operation Transmission Temperature Sensor - PCM Input NOTE: This input is used in the shift operation for 4-speed electronic transmissions only. The temperature data is used for: torque converter clutch operation, overdrive shift, low temperature shift compensation, wide open throttle shift strategy and governor pressure transducer calibration. CIRCUIT OPERATION The transmission temperature sensor is located in the transmission solenoid assembly. The sensor is a variable resistor, as transmission temperature changes the resistance in the sensor changes. Circuit T34 connects from the Powertrain Control Module (PCM) to the sensor. Ground for the sensor is supplied on circuit K4. This circuit is the ground circuit for many of the components used in the fuel/ignition system. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications Valve Body: Specifications Mounting Bolts ..................................................................................................................................... ............................................... 12 Nm (100 inch lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > Page 4623 Transmission Solenoids Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Diagrams > Exploded Views Valve Body: Exploded Views Upper Housing Control Valve Locations Shuttle And Boost Valve Components Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Diagrams > Exploded Views > Page 4626 Upper Housing Shift Valve And Pressure Plug Locations Lower Housing Shift Valves And Springs Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Diagrams > Exploded Views > Page 4627 Upper Housing Valves, Plug, Springs And Brackets Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Diagrams > Exploded Views > Page 4628 Transmission Solenoid Connector Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Diagrams > Page 4629 Valve Body: Description and Operation CIRCUIT OPERATION Four Speed Transmissions The Torque Convertor Clutch (TCC) solenoid, overdrive solenoid and governor pressure solenoid are molded together. They are only used on four-speed automatic transmissions. Circuit T8 from the electronic transmission relay supplies power for the solenoids. The Powertrain Control Module (PCM) operates each solenoid individually by providing ground for each solenoid on separate circuits. The PCM provides ground for the TCC on circuit K54. Circuit K54 connects to cavity B11 of the PCM. - The PCM supplies ground for the overdrive solenoid on circuit T60. Circuit T60 connects to cavity B21 of the PCM. - On circuit T7, the PCM provides ground for the governor pressure solenoid. Circuit T7 connects to cavity B8 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Diagrams > Page 4630 Valve Body: Adjustments GENERAL INFORMATION There are two control pressure adjustments on the valve body; Line Pressure - Throttle Pressure Line and throttle pressures are interdependent because each affects shift quality and timing. As a result, both adjustments must be performed properly and in the correct sequence. Adjust line pressure first and throttle pressure last. LINE PRESSURE ADJUSTMENT Measure distance from the valve body to the inner edge of the adjusting screw with an accurate steel scale. Distance should be 33.4 mm (1-5/16 inch). If adjustment is required, turn the adjusting screw in, or out, to obtain required distance setting. NOTE: The 33.4 mm (1-5/16 inch) setting is an approximate setting. Manufacturing tolerances may make it necessary to vary from this dimension to obtain desired pressure. One complete turn of the adjusting screw changes line pressure approximately 1-2/3 psi (9 kPa). Turning the adjusting screw counterclockwise increases pressure while turning the screw clockwise decreases pressure. THROTTLE PRESSURE ADJUSTMENT Insert Gauge Tool C-3763, or equivalent between the throttle lever cam and the kickdown valve stem. Push the gauge tool inward to compress the kickdown valve against the spring and bottom the throttle valve. Maintain pressure against kickdown valve spring. Turn throttle lever stop screw until the screw head touches throttle lever tang and the throttle lever cam touches gauge tool. NOTE: The kickdown valve spring must be fully compressed and the kickdown valve completely bottomed to obtain correct adjustment. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation Valve Body: Service and Repair Removal and Installation NOTES: The valve body can be removed for service without having to remove the transmission assembly. The valve body can be disassembled for cleaning and inspection of the individual components. The only replaceable valve body components are: - Manual lever. - Manual lever washer, seal, E-clip, and shaft seal. - Manual lever detent ball. - Throttle lever. - Fluid filter - Pressure adjusting screw bracket - Governor pressure solenoid. - Governor pressure sensor. - Converter clutch/overdrive solenoid assembly and harness (includes sump temperature thermistor). - Governor housing gasket. - Solenoid case connector O-rings. The remaining valve body components are serviced only as part of a complete valve body assembly. REMOVAL 1. Shift transmission into NEUTRAL. 2. Raise vehicle. 3. Remove gearshift and throttle levers from shaft of valve body manual lever. 4. Disconnect wires at solenoid case connector. 5. Position drain pan under transmission oil pan. 6. Remove transmission oil pan and gasket. 7. Remove fluid filter from valve body. 8. Remove bolts attaching valve body to transmission. 9. Lower valve body enough to remove accumulator piston and springs. 10. Work manual lever shaft and electrical connector out of transmission case. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4633 11. Lower valve body, rotate valve body away from case, pull park rod out of sprag, and remove valve body. INSTALLATION 1. Check condition of O-ring seals on valve body harness connector. Replace seals on connector body if cut or worn. 2. Check condition of manual lever shaft seal in transmission case. Replace seal if lip is cut or worn. Install new seal with 15/16 deep well socket. 3. Check condition of seals on accumulator piston. Install new piston seals, if necessary. 4. Place valve body manual lever in low (1 position) so ball on park lock rod will be easier to install in sprag. 5. Lubricate shaft of manual lever with petroleum jelly. This will ease inserting shaft through seal in case. 6. Lubricate seal rings on valve body harness connector with petroleum jelly. 7. Position valve body in case and work end of park lock rod into and through pawl sprag. Turn propeller shaft to align sprag and park lock teeth if necessary. The rod will click as it enters pawl. Move rod to check engagement. CAUTION: It is possible for the park rod to displace into a cavity just above the pawl sprag during installation. Make sure the rod is actually engaged in the pawl and has not displaced into this cavity. 8. Install accumulator springs and piston into case. Then swing valve body over piston and outer spring to hold it in place. 9. Align accumulator piston and outer spring, manual lever shaft and electrical connector in case. 10. Then seat valve body in case and install one or two bolts to hold valve body in place. 11. Tighten valve body bolts alternately and evenly to 11 Nm (100 inch lbs.) torque. 12. Install new fluid filter on valve body. Tighten filter screws to 4 Nm (35 inch lbs.) torque. 13. Install throttle and gearshift levers on valve body manual lever shaft. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4634 14. Check and adjust front and rear bands if necessary. 15. Connect solenoid case connector wires. 16. Install oil pan and new gasket. Tighten pan bolts to 17 Nm (13 ft. lbs.) torque. 17. Lower vehicle and fill transmission with MOPAR ATF+4, type 9602 fluid. 18. Check and adjust gearshift and throttle valve cables, if necessary. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4635 Valve Body: Service and Repair Disassembly Lower Housing Disassembly 1. Remove timing valve cover. 2. Remove 3-4 timing valve and spring. 3. Remove 3-4 quick fill valve, spring and plug. 4. Remove 3-4 shift valve and spring. Lower Housing Shift Valves And Springs 5. Remove converter clutch valve, spring and plug. 6. Remove converter clutch timing valve, retainer and valve spring. Main Component Body CAUTION: Do not clamp any valve body component in a vise. This practice can damage the component resulting in unsatisfactory operation after assembly and installation. Do not use pliers to remove any of the valves, plugs or springs and do not force any of the components out or into place. The valves and valve body housings will be damaged if force is used. Tag or mark the valve body springs for reference as they are removed. Do not allow them to become intermixed. 1. Remove fluid filter. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4636 Governor Pressure Solenoid And Sensor Wire Locations 2. Disconnect wires from governor pressure sensor and solenoid. Governor Body And Retainer Plate Attaching Screw 3. Remove screws attaching governor body and retainer plate to transfer plate. Governor Body And Gasket 4. Remove retainer plate, governor body and gasket from transfer plate. 5. Disconnect wires from governor pressure sensor, if not done previously. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4637 Governor Pressure Sensor 6. Remove governor pressure sensor from governor body. Sensor is retained in body with M-shaped spring clip. Remove clip with small pointed tool and slide sensor out of body. Governor Pressure Solenoid 7. Remove governor pressure solenoid by pulling it straight out of bore in governor body. Remove and discard solenoid O-rings if worn, cut, or torn. 8. Remove transmission fluid filter. Solenoid Harness Case Connector Shoulder Bolt 9. Remove small shoulder bolt that secures solenoid harness case connector to 3-4 accumulator housing. Retain shoulder bolt. Either tape it to harness or thread it back into accumulator housing after connector removal. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4638 Unhooking Solenoid Harness From Accumulator Cover Plate 10. Unhook overdrive/converter solenoid harness from 3-4 accumulator cover plate. Solenoid Assembly Screws 11. Turn valve body over and remove screws that attach overdrive/converter solenoid assembly to valve body. Solenoid Assembly 12. Remove solenoid and harness assembly from valve body. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4639 Boost Valve Cover Location 13. Remove boost valve cover. Boost Valve Components 14. Remove boost valve retainer, valve spring and boost valve. Detent Ball And Spring 15. Secure detent ball and spring with Retainer Tool 6583. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4640 Park Rod 16. Remove park rod E-clip and separate rod from manual lever. Throttle Lever E-Clip And Washer 17. Remove E-clip and washer that retains throttle lever shaft in manual lever. Manual And Throttle Lever 18. Remove manual lever and throttle lever. Rotate and lift manual lever off valve body and throttle lever shaft. Then slide throttle lever out of valve body. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4641 Detent Ball And Spring 19. Position pencil magnet next to detent housing to catch detent ball and spring. Then carefully remove Retainer Tool 6583 and remove detent ball and spring. Adjusting Screw Bracket Fastener 20. Remove screws attaching pressure adjusting screw bracket to valve body and transfer plate. Hold bracket firmly against spring tension while removing last screw. Adjusting Screw Bracket And Spring 21. Remove adjusting screw bracket, line pressure adjusting screw, pressure regulator valve spring and switch valve spring. Do not remove throttle pressure adjusting screw from bracket and do not disturb setting of either adjusting screw during removal. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4642 Upper Housing Control Valve Locations 22. Turn upper housing over and remove switch valve, regulator valve and spring, and manual valve. 23. Remove kickdown detent, kickdown valve, and throttle valve and spring. Accumulator Housing Screw Locations 24. Loosen left-side 3-4 accumulator housing attaching screw about 2-3 threads. Then remove center and right-side housing attaching screws. Shift And Converter Clutch Valve Springs And Plug 25. Carefully rotate 3-4 accumulator housing upward and remove 3-4 shift valve spring and converter clutch valve plug and spring. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4643 Accumulator Housing, Valve Springs And Plug 26. Remove left-side screw and remove 3-4 accumulator housing from valve body. Boost Valve Tube Brace 27. Bend back tabs on boost valve tube brace. Boost Valve Tube 28. Remove boost valve connecting tube. Disengage tube from upper housing port first. Then rock opposite end of tube back and forth to work it out of lower housing. CAUTION: Do not use tools to loosen or pry the connecting tube out of the valve body housings. Loosen and remove the tube by hand only. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4644 Lower Housing 29. Turn valve body over so lower housing is facing upward. In this position, the two check balls in upper housing will remain in place and not fall out when lower housing and separator plate are removed. 30. Remove screws attaching valve body lower housing to upper housing and transfer plate. Note position of boost valve tube brace for assembly reference. 31. Remove lower housing and overdrive separator plate from transfer plate. ECE Check Ball 32. Remove the ECE check ball from the transfer plate. The ECE check ball is approximately 4.8 mm (3/16 inch) in diameter. Transfer Plate 33. Remove transfer plate from upper housing. 34. Turn transfer plate over so upper housing separator plate is facing upward. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4645 Upperhousing Separator Plate 35. Remove upper housing separator plate from transfer plate. Note position of filter in separator plate for assembly reference. Rear Clutch And Rear Servo Check Ball Locations 36. Remove rear clutch and rear servo check balls from transfer plate. Note check ball location for assembly reference. Upper Housing Disassembly Check Ball Locations In Upper Housing 1. Note location of check balls in valve body upper housing. Then remove the one large diameter and the six smaller diameter check balls. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4646 Shuttle Valve E-Clip And Secondary Spring Location 2. Remove governor plug and shuttle valve covers. Shuttle And Boost Valve Components 3. Remove E-clip that secures shuttle valve secondary spring on valve stem. 4. Remove throttle plug, primary spring, shuttle valve, secondary spring, and spring guides. 5. Remove boost valve retainer, spring and valve if not previously removed. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4647 Upper Housing Control Valve Locations 6. Remove throttle plug and 1-2 and 2-3 governor plugs. Upper Housing Shift Valve And Pressure Plug Locations 7. Turn upper housing around and remove limit valve and shift valve covers. 8. Remove limit valve housing. Then remove retainer, spring, limit valve, and 2-3 throttle plug from limit valve housing. 9. Remove 1-2 shift control valve and spring. 10. Remove 1-2 shift valve and spring. 11. Remove 2-3 shift valve and spring from valve body. 12. Remove pressure plug cover. 13. Remove line pressure plug, sleeve, throttle pressure plug and spring. 3-4 Accumulator 1. Remove end plate from housing. 2. Remove piston spring. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4648 Accumulator Housing Components 3. Remove piston. Remove and discard piston seals. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4649 Valve Body: Service and Repair Cleaning and Inspection Upper Housing Valves, Plug, Springs And Brackets Clean the valve housings, valves, plugs, springs, and separator plates with a standard parts cleaning solution only. Do not use gasoline, kerosene, or any type of caustic solution. Do not immerse any of the electrical components in cleaning solution. Clean the governor solenoid and sensor and the dual solenoid and harness assembly by wiping them off with dry shop towels only. Dry all except the electrical parts with compressed air. Make sure all passages are clean and free from obstructions. Do not use rags or shop towels to dry or wipe off valve body components. Lint from these materials can stick to valve body parts, interfere with valve operation, and clog filters and fluid passages. Wipe the governor pressure sensor and solenoid valve with dry, lint free shop towels only. The O-rings on the sensor and solenoid valve are the only serviceable components. Be sure the vent ports in the solenoid valve are open and not blocked by dirt or debris. Replace the valve and/or sensor only when DRB scan tool diagnosis indicates this is necessary. Or, if either part has sustained physical damage (dented, deformed, broken, etc.). CAUTION: Do not turn the small screw at the end of the solenoid valve for any reason. Turning the screw in either direction will ruin solenoid calibration and result in solenoid failure. In addition, the filter on the solenoid valve is NOT serviceable. Do not try to remove the filter as this will damage the valve housing. Inspect the throttle and manual valve levers and shafts (Fig. 258). Do not attempt to straighten a bent shaft or correct a loose lever. Replace these components if worn, bent, loose or damaged in any way. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4650 Inspect all of the valve body mating surfaces for scratches, nicks, burrs, or distortion. Use a straightedge to check surface flatness. Minor scratches may be removed with crocus cloth using only very light pressure. Minor distortion of a valve body mating surface may be corrected by smoothing the surface with a sheet of crocus cloth. Position the crocus cloth on a surface plate, sheet of plate glass or equally flat surface. If distortion is severe or any surfaces are heavily scored, the valve body will have to be replaced. CAUTION: Many of the valves and plugs, such as the throttle valve, shuttle valve plug, 1-2 shift valve and 1-2 governor plug, are made of coated aluminum. Aluminum components are identified by the dark color of the special coating applied to the surface (or by testing with a magnet). Do not sand aluminum valves or plugs under any circumstances. This practice could damage the special coating causing the valves/plugs to stick and bind. Inspect the valves and plugs for scratches, burrs, nicks, or scores. Minor surface scratches on steel valves and plugs can be removed with crocus cloth but do not round off the edges of the valve or plug lands. Maintaining sharpness of these edges is vitally important. The edges prevent foreign matter from lodging between the valves and plugs and the bore. Inspect all the valve and plug bores in the valve body. Use a penlight to view the, bore interiors. Replace the valve body if any bores are distorted or scored. Inspect all of the valve body springs. The springs must be free of distortion, warpage or broken coils. Check the two separator plates for distortion or damage of any kind. Inspect the upper housing, lower housing, 3-4 accumulator housing, and transfer plate carefully. Be sure all fluid passages are clean and clear. Check condition of the upper housing and transfer plate check balls as well. The check balls and ball seats must not be worn or damaged. Trial fit each valve and plug in its bore to check freedom of operation. When clean and dry, the valves and plugs should drop freely into the bores. Valve body bores do not change dimensionally with use. If the valve body functioned correctly when new, it will continue to operate properly after cleaning and inspection. It should not be necessary to replace a valve body assembly unless it is damaged in handling. The only serviceable valve body components are listed below. The remaining valve body components are serviced only as part of a complete valve body assembly. Serviceable parts are: - Dual solenoid and harness assembly - Solenoid gasket - Solenoid case connector O-rings and shoulder bolt - Switch valve and spring - Pressure adjusting screw and bracket assembly - Throttle lever - Manual lever and shaft seal - Throttle lever shaft seal, washer, and E-clip - Fluid filter and screws - Detent ball and spring - Valve body screws - Governor pressure solenoid - Governor pressure sensor and retaining clip - Park lock rod and E-clip Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4651 Valve Body: Service and Repair Assembly Assembly Precaution CAUTION: Do not force valves or plugs into place during reassembly. If the valve body bores, valves and plugs are free of distortion or burrs, the valve body components should all slide into place easily. In addition, do not overtighten the transfer plate and valve body screws during reassembly. Overtightening can distort the housings resulting in valve sticking, cross leakage and unsatisfactory operation. Tighten valve body screws to recommended torque only. NOTE: Follow assembly steps in order shown for proper valve body assembly. Boost Valve and Brace Assembly Boost Valve Tube 1. Position valve body assembly so lower housing is facing upward. 2. Lubricate tube ends and housing ports with transmission fluid or petroleum jelly. 3. Start tube in lower housing port first. Then swing tube downward and work opposite end of tube into upper housing port. 4. Insert and seat each end of tube in housings. Boost Valve Tube And Brace 5. Slide tube brace under tube and into alignment with valve body screw holes. 6. Install and finger tighten three screws that secure tube brace to valve body housings. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4652 Securing Boost Valve Tube With Brace Tabs 7. Bend tube brace tabs up and against tube to hold it in position. 8. Tighten all valve body housing screws to 4 Nm (35 inch lbs.) torque after tube and brace are installed. Tighten screws in diagonal pattern starting at center and working outward. Governor Body, Sensor and Solenoid Assembly 1. Turn valve body assembly over so accumulator side of transfer plate is facing down. Governor Pressure Sensor 2. Install new O-rings on governor pressure solenoid and sensor. 3. Lubricate solenoid and sensor O-rings with clean transmission fluid. 4. Install governor pressure sensor in governor body. Then secure sensor with M-shaped retaining clip. Governor Pressure Solenoid 5. Install governor pressure solenoid in governor body. Push solenoid in until it snaps into place in body. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4653 Governor Body And Gasket 6. Position governor body gasket on transfer plate. Pressure Solenoid Retainer 7. Install retainer plate on governor body and around solenoid. Be sure solenoid connector is positioned in retainer cutout. 8. Align screw holes in governor body and transfer plate. Then install and tighten governor body screws to 4 Nm (35 inch lbs.) torque. Governor Pressure Sensor And Solenoid Connectors 9. Connect harness wires to governor pressure solenoid and governor pressure sensor. 10. Perform Line Pressure and Throttle Pressure adjustments, refer to adjustment section for proper procedures. 11. Install fluid filter and pan. 12. Lower vehicle. 13. Fill transmission with recommended fluid and road test vehicle to verify repair. Lower Housing Disassembly Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4654 Lower Housing Shift Valves And Springs 1. Lubricate valves, springs, and the housing valve and plug bores with clean transmission fluid. 2. Install 3-4 timing valve spring and valve in lower housing. 3. Install 3-4 quick fill valve in lower housing. 4. Install 3-4 quick fill valve spring and plug in housing. 5. Install timing valve end plate. Tighten end plate screws to 4 Nm (35 inch lbs.) torque. Transfer Plate Assembly Rear Clutch And Rear Servo Sheck Ball Locations 1. Install rear clutch and rear servo check balls in transfer plate. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4655 Seperator Plate Filter Screen Installation 2. Install filter screen in upper housing separator plate. Brace Plate 3. Align and position upper housing separator plate on transfer plate. 4. Install brace plate. Tighten brace attaching screws to 4 Nm (35 inch lbs.) torque. 5. Install remaining separator plate attaching screws. Tighten screws to 4 Nm (35 inch lbs.) torque. Upper and Lower Housing Assembly Check Ball Locations In Upper Housing 1. Position upper housing so internal passages and check ball seats are facing upward. Then install check balls in housing. Eight check balls are used. The single large check ball is approximately 8.7 mm (11/32 inch) diameter. The single small check ball is approximately 4.8 mm (3/16 inch) in diameter. The remaining 6 check balls are approximately 6.3 mm (1/4 inch) in diameter. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4656 Installing Transfer Plate On Upper Housing 2. Position assembled transfer plate and upper housing separator plate on upper housing. Be sure filter screen is seated in proper housing recess. ECE Check Ball 3. Install the ECE check ball into the transfer plate. The ECE check ball is approximately 4.8 mm (3/16 inch) in diameter. Lower Housing Separator Plate 4. Position lower housing separator plate on transfer plate. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4657 Installing Lower Housing On Transfer Plate And Upper Housing 5. Install lower housing on assembled transfer plate and upper housing. 6. Install and start all valve body screws by hand except for the screws to hold the boost valve tube brace. Save those screws for later installation. Then tighten screws evenly to 4 Nm (35 inch lbs.) torque. Start at center and work out to sides when tightening screws. Upper Housing Valve and Plug Assembly Shuttle And Boost Valve Components Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4658 Upper Housing Control Valve Locations Upper Housing Shift Valve And Pressure Plug Locations Refer to figures to perform the following steps. 1. Lubricate valves, plugs, springs with clean transmission fluid. 2. Assemble regulator valve line pressure plug, sleeve, throttle plug and spring. Insert assembly in upper housing and install cover plate. Tighten cover plate screws to 4 Nm (35 inch lbs.) torque. 3. Install 1-2 and 2-3 shift valves and springs. 4. Install 1-2 shift control valve and spring. 5. Install retainer, spring, limit valve, and 2-3 throttle plug from limit valve housing. 6. Install limit valve housing and cover plate. Tighten screws to 4 Nm (35 inch lbs.). 7. Install shuttle valve as follows: a. Insert plastic guides in shuttle valve secondary spring and install spring on end of valve. b. Install shuttle valve into housing. c. Hold shuttle valve in place. d. Compress secondary spring and install E-clip in groove at end of shuttle valve. e. Verify that spring and E-clip are properly seated before proceeding. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4659 8. Install shuttle valve cover plate. Tighten cover plate screws to 4 Nm (35 inch lbs.) torque. 9. Install 1-2 and 2-3 valve governor plugs in valve body. 10. Install shuttle valve primary spring and throttle plug. 11. Align and install governor plug cover. Tighten cover screws to 4 Nm (35 inch lbs.) torque. Valve Body Final Assembly and Adjustment 1. Install boost valve, valve spring, retainer and cover plate. Tighten cover plate screws to 4 Nm (35 inch lbs.) torque. 2. Insert manual lever detent spring in upper housing. Detent Ball Spring 3. Position detent ball on end of spring. Then hold detent ball and spring in detent housing with Retainer Tool 6583. 4. Install throttle lever in upper housing. Then install manual lever over throttle lever and start manual lever into housing. 5. Align manual lever with detent ball and manual valve. Hold throttle lever upward. Then press down on manual lever until fully seated. Remove detent ball retainer tool after lever is seated. 6. Then install manual lever seal, washer and E-clip. Manual And Throttle Lever Alignment 7. Verify that throttle lever is aligned with end of kickdown valve stem and that manual lever arm is engaged in manual valve. 8. Position line pressure adjusting screw in adjusting screw bracket. 9. Install spring on end of line pressure regulator valve. 10. Install switch valve spring on tang at end of adjusting screw bracket. 11. Install manual valve. 12. Install throttle valve and spring. 13. Install kickdown valve and detent. 14. Install pressure regulator valve. 15. Install switch valve. 16. Position adjusting screw bracket on valve body. Align valve springs and press bracket into place. Install short, upper bracket screws first and long bottom screw last. Verify that valve springs and bracket are properly aligned. Then tighten all three bracket screws to 4 Nm (35 inch lbs.) torque. 17. Lubricate solenoid case connector O-rings and shaft of manual lever with light coat of petroleum jelly. 18. Obtain new fluid filter for valve body but do not install filter at this time. 19. If line pressure and/or throttle pressure adjustment screw settings were not disturbed, continue with overhaul or reassembly. However, if adjustment screw settings were moved or changed, readjust as described in Valve Body Control Pressure Adjustment procedure. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4660 Solenoid Harness Case Connector Shoulder Bolt 20. Attach solenoid case connector to 3-4 accumulator with shoulder-type screw. Connector has small locating tang that fits in dimple at top of accumulator housing. Seat tang in dimple before tightening connector screw. 21. Install solenoid assembly and gasket. Tighten solenoid attaching screws to 8 Nm (72 inch lbs.) torque. Solenoid Harness Routing 22. Verify that solenoid wire harness is properly routed. Solenoid harness must be clear of manual lever and park rod and not be pinched between accumulator housing and cover. 3-4 Accumulator Assembly Installation Converter Clutch And 3-4 Shift Valve Springs 1. Position converter clutch valve and 3-4 shift valve springs in housing. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4661 2. Loosely attach accumulator housing with right-side screw. Install only one screw at this time as accumulator must be free to pivot upward for ease of installation. 3. Install 3-4 shift valve and spring. 4. Install converter clutch timing valve and spring. 5. Position plug on end of converter clutch valve spring. Then compress and hold springs and plug in place with fingers of one hand. 6. Swing accumulator housing upward over valve springs and plug. Seating 3-4 Accumulator On Lower Housing 7. Hold accumulator housing firmly in place and install remaining two attaching screws. Be sure springs and clutch valve plug are properly seated. Tighten screws to 4 Nm (35 inch lbs.). 3-4 Accumulator Assembly 2 1. Position converter clutch valve and 3-4 shift valve springs in housing. 2. Loosely attach accumulator housing with right-side screw. Install only one screw at this time as accumulator must be free to pivot upward for ease of installation. 3. Install 3-4 shift valve and spring. 4. Install converter clutch timing valve and spring. 5. Position plug on end of converter clutch valve spring. Then compress and hold springs and plug in place with fingers of one hand. 6. Swing accumulator housing upward over valve springs and plug. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4662 7. Hold accumulator housing firmly in place and install remaining two attaching screws. Be sure springs and clutch valve plug are properly seated. Tighten screws to 4 Nm (35 inch lbs.). 3-4 Accumulator Reassembly Accumulator Housing Components 1. Lubricate accumulator piston, seals and housing piston bore with clean transmission fluid. 2. Install new seal rings on accumulator piston. 3. Install piston and spring in housing. 4. Install end plate on housing. 3-4 Accumulator 1 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4663 1. Lubricate accumulator piston, seals and housing piston bore with clean transmission fluid. 2. Install new seal rings on accumulator piston. 3. Install piston and spring in housing. 4. Install end plate on housing. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair Clutch Disc: Service and Repair REMOVAL 1. Raise vehicle. 2. Remove transmission and clutch housing as assembly. 3. If clutch cover is only being removed for access to another component, mark position of cover on flywheel with small punch marks. 4. Loosen clutch cover bolts evenly and in rotation to relieve spring tension. Loosen bolts a few threads at a time to avoid warping cover. 5. Completely remove cover bolts, clutch cover, and clutch disc. INSTALLATION 1. Clean-heel surface with solvent. Scuff sand surface with 120/180 grit emery cloth to remove minor scratches and glazing. 2. Check clutch disc for runout and free operation on input shaft splines. 3. Lubricate crankshaft pilot bearing with MOPAR high temperature bearing grease, or equivalent. 4. Position clutch disc to flywheel. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > Page 4668 5. Insert alignment tool or spare input shaft through clutch disc and into pilot bearing. 6. Verify that disc hub is positioned correctly. Side of hub marked Flywheel Side" should face flywheel. 7. Position clutch cover over disc and on flywheel. 8. Install all clutch cover bolts finger tight. 9. Tighten cover bolts evenly (and in rotation) a few threads at a time. Cover bolts must be tightened evenly and to specified torque to avoid distorting cover. 10. Tighten clutch cover bolts to following torque: - 5/16 inch diameter bolts to 23 Nm (17 ft. lbs.). - 3/8 inch diameter bolts to 41 Nm (30 ft. lbs.). 11. Apply light coat of MOPAR high temperature bearing grease to splines of transmission input shaft and to release bearing slide surface of front bearing retainer. Do not over lubricate shaft splines. This could result in grease contamination of disc. 12. Install transmission and clutch housing a assembly. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Specifications Clutch Fluid: Specifications CLUTCH FLUID Use DOT 3 brake fluid. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid Reservoir > Component Information > Specifications Clutch Fluid Reservoir: Specifications Mounting Screws ................................................................................................................................. .................................................... 5 Nm (40 inch lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid Reservoir > Component Information > Specifications > Page 4676 Clutch Fluid Reservoir: Service and Repair NOTE: The factory installed hydraulic linkage has a quick disconnect at the slave cylinder. This fitting should not be disconnected or tampered with. The hydraulic linkage is serviced as an assembly only. The individual components that form the linkage assembly cannot be overhauled or serviced separately. "Chrysler does not provide a procedure to bleed the clutch hydraulic system". REMOVAL 1. Raise and support vehicle. 2. Remove nuts attaching slave cylinder to clutch housing. 3. Remove slave cylinder from housing. 4. Remove hydraulic fluid line from body clips, if necessary. 5. Lower vehicle. 6. Remove clip holding clutch master cylinder push rod to clutch pedal. 7. Slide clutch master cylinder push rod off clutch pedal pin. 8. Remove nuts holding clutch master cylinder to dash panel. 9. Verify that cap on clutch master cylinder reservoir is tight to avoid undue spillage during removal. 10. Remove screws attaching clutch fluid reservoir to dash panel. 11. Pull clutch master cylinder from dash panel. 12. Remove hydraulic linkage components from vehicle. INSTALLATION 1. Tighten cap on clutch fluid reservoir to avoid spillage during installation. 2. Position cylinders, connecting lines, and reservoir in vehicle. 3. Insert clutch master cylinder in dash panel. 4. Position reservoir on dash panel and install reservoir screws. Tighten screws to 5 Nm (40 inch lbs.) torque. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid Reservoir > Component Information > Specifications > Page 4677 5. Install nut to hold clutch master cylinder to dash panel. Tighten nuts to 54 Nm (40 ft. lbs.). 6. Install clutch master cylinder push rod on clutch pedal pin. Secure rod with retaining clip. 7. Raise vehicle. 8. Insert slave cylinder push rod through clutch housing opening and into release lever. Be sure end of rod is securely engaged in release lever. Check this before installing cylinder attaching nuts. 9. Install and tighten slave cylinder attaching nuts to 23 Nm (200 inch lbs.) torque. 10. Insert clutch fluid line in body clips, if necessary. Verify that fluid line from master cylinder to slave cylinder is properly routed. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Specifications Clutch Master Cylinder: Specifications Mounting Nuts ..................................................................................................................................... ..................................................... 54 Nm (40 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Specifications > Page 4681 Clutch Master Cylinder: Service and Repair NOTE: The factory installed hydraulic linkage has a quick disconnect at the slave cylinder. This fitting should not be disconnected or tampered with. The hydraulic linkage is serviced as an assembly only. The individual components that form the linkage assembly cannot be overhauled or serviced separately. "Chrysler does not provide a procedure to bleed the clutch hydraulic system". REMOVAL 1. Raise and support vehicle. 2. Remove nuts attaching slave cylinder to clutch housing. 3. Remove slave cylinder from housing. 4. Remove hydraulic fluid line from body clips, if necessary. 5. Lower vehicle. 6. Remove clip holding clutch master cylinder push rod to clutch pedal. 7. Slide clutch master cylinder push rod off clutch pedal pin. 8. Remove nuts holding clutch master cylinder to dash panel. 9. Verify that cap on clutch master cylinder reservoir is tight to avoid undue spillage during removal. 10. Remove screws attaching clutch fluid reservoir to dash panel. 11. Pull clutch master cylinder from dash panel. 12. Remove hydraulic linkage components from vehicle. INSTALLATION 1. Tighten cap on clutch fluid reservoir to avoid spillage during installation. 2. Position cylinders, connecting lines, and reservoir in vehicle. 3. Insert clutch master cylinder in dash panel. 4. Position reservoir on dash panel and install reservoir screws. Tighten screws to 5 Nm (40 inch lbs.) torque. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Specifications > Page 4682 5. Install nut to hold clutch master cylinder to dash panel. Tighten nuts to 54 Nm (40 ft. lbs.). 6. Install clutch master cylinder push rod on clutch pedal pin. Secure rod with retaining clip. 7. Raise vehicle. 8. Insert slave cylinder push rod through clutch housing opening and into release lever. Be sure end of rod is securely engaged in release lever. Check this before installing cylinder attaching nuts. 9. Install and tighten slave cylinder attaching nuts to 23 Nm (200 inch lbs.) torque. 10. Insert clutch fluid line in body clips, if necessary. Verify that fluid line from master cylinder to slave cylinder is properly routed. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Specifications Clutch Slave Cylinder: Specifications Mounting Nuts ..................................................................................................................................... ................................................ 23 Nm (200 inch lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Specifications > Page 4686 Clutch Slave Cylinder: Service and Repair NOTE: The factory installed hydraulic linkage has a quick disconnect at the slave cylinder. This fitting should not be disconnected or tampered with. The hydraulic linkage is serviced as an assembly only. The individual components that form the linkage assembly cannot be overhauled or serviced separately. "Chrysler does not provide a procedure to bleed the clutch hydraulic system". REMOVAL 1. Raise and support vehicle. 2. Remove nuts attaching slave cylinder to clutch housing. 3. Remove slave cylinder from housing. 4. Remove hydraulic fluid line from body clips, if necessary. 5. Lower vehicle. 6. Remove clip holding clutch master cylinder push rod to clutch pedal. 7. Slide clutch master cylinder push rod off clutch pedal pin. 8. Remove nuts holding clutch master cylinder to dash panel. 9. Verify that cap on clutch master cylinder reservoir is tight to avoid undue spillage during removal. 10. Remove screws attaching clutch fluid reservoir to dash panel. 11. Pull clutch master cylinder from dash panel. 12. Remove hydraulic linkage components from vehicle. INSTALLATION 1. Tighten cap on clutch fluid reservoir to avoid spillage during installation. 2. Position cylinders, connecting lines, and reservoir in vehicle. 3. Insert clutch master cylinder in dash panel. 4. Position reservoir on dash panel and install reservoir screws. Tighten screws to 5 Nm (40 inch lbs.) torque. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Specifications > Page 4687 5. Install nut to hold clutch master cylinder to dash panel. Tighten nuts to 54 Nm (40 ft. lbs.). 6. Install clutch master cylinder push rod on clutch pedal pin. Secure rod with retaining clip. 7. Raise vehicle. 8. Insert slave cylinder push rod through clutch housing opening and into release lever. Be sure end of rod is securely engaged in release lever. Check this before installing cylinder attaching nuts. 9. Install and tighten slave cylinder attaching nuts to 23 Nm (200 inch lbs.) torque. 10. Insert clutch fluid line in body clips, if necessary. Verify that fluid line from master cylinder to slave cylinder is properly routed. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch > Component Information > Service and Repair Hydraulic Hose: Service and Repair NOTE: The factory installed hydraulic linkage has a quick disconnect at the slave cylinder. This fitting should not be disconnected or tampered with. The hydraulic linkage is serviced as an assembly only. The individual components that form the linkage assembly cannot be overhauled or serviced separately. "Chrysler does not provide a procedure to bleed the clutch hydraulic system". REMOVAL 1. Raise and support vehicle. 2. Remove nuts attaching slave cylinder to clutch housing. 3. Remove slave cylinder from housing. 4. Remove hydraulic fluid line from body clips, if necessary. 5. Lower vehicle. 6. Remove clip holding clutch master cylinder push rod to clutch pedal. 7. Slide clutch master cylinder push rod off clutch pedal pin. 8. Remove nuts holding clutch master cylinder to dash panel. 9. Verify that cap on clutch master cylinder reservoir is tight to avoid undue spillage during removal. 10. Remove screws attaching clutch fluid reservoir to dash panel. 11. Pull clutch master cylinder from dash panel. 12. Remove hydraulic linkage components from vehicle. INSTALLATION 1. Tighten cap on clutch fluid reservoir to avoid spillage during installation. 2. Position cylinders, connecting lines, and reservoir in vehicle. 3. Insert clutch master cylinder in dash panel. 4. Position reservoir on dash panel and install reservoir screws. Tighten screws to 5 Nm (40 inch lbs.) torque. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch > Component Information > Service and Repair > Page 4691 5. Install nut to hold clutch master cylinder to dash panel. Tighten nuts to 54 Nm (40 ft. lbs.). 6. Install clutch master cylinder push rod on clutch pedal pin. Secure rod with retaining clip. 7. Raise vehicle. 8. Insert slave cylinder push rod through clutch housing opening and into release lever. Be sure end of rod is securely engaged in release lever. Check this before installing cylinder attaching nuts. 9. Install and tighten slave cylinder attaching nuts to 23 Nm (200 inch lbs.) torque. 10. Insert clutch fluid line in body clips, if necessary. Verify that fluid line from master cylinder to slave cylinder is properly routed. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Service and Repair Clutch Pedal Assembly: Service and Repair REMOVAL 1. Remove retaining clip securing push rod on clutch pedal. 2. Slide push rod off clutch pedal pin. 3. Remove snap ring and washer attaching clutch pedal to the pivot shaft. 4. Slide pedal off pivot shaft and remove pedal. 5. Remove and inspect bushings in pedal bore. Replace bushings if worn or cracked. INSTALLATION 1. Lubricate pedal bushings and shaft with a silicone grease or with MOPAR multi-mileage grease. 2. Install bushings in pedal bore and on pin. 3. Install pedal on pivot shaft. 4. Secure pedal on shaft with washer and snap ring. 5. Connect push rod to pedal and secure rod with retaining clip. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Description and Operation Clutch Switch: Description and Operation A clutch pedal position switch has been added to the starter circuit. The switch, which is in circuit with the starter solenoid, requires that the clutch pedal be fully depressed in order to start the engine. The switch is located on the clutch master cylinder push rod. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Release Bearing, M/T > Component Information > Service and Repair Clutch Release Bearing: Service and Repair REMOVAL 1. Remove transmission. 2. Disconnect release bearing from fork and remove bearing. INSTALLATION 1. Inspect release bearing slide surface of transmission front bearing retainer. Replace retainer if slide surface is scored, worn or cracked. 2. Inspect release fork and fork pivot. Be sure pivot is secure and in good condition. Be sure fork is not distorted or worn. Replace release fork retainer spring if bent or damaged in any way. 3. Lightly lubricate pilot bearing, input shaft splines, bearing retainer slide surface, fork pivot and release fork pivot surface with MOPAR high temperature bearing grease. 4. Install release fork and bearing. Be sure fork and bearing are properly secured. 5. Install transmission. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pilot Bearing > Component Information > Service and Repair Pilot Bearing: Service and Repair REMOVAL 1. Remove transmission. 2. Remove clutch cover and disc. 3. Use a suitable blind hole puller to remove pilot bearing. INSTALLATION 1. Clean bearing bore with solvent and wipe dry with shop towel. 2. Lubricate new pilot bearing with MOPAR high temperature grease. 3. Position and start new bearing in bearing bore by hand. Note that pilot bearing has-seal at one end. Install bearing so seal is facing outward toward transmission. 4. Seat pilot bearing with clutch alignment tool. Keep bearing straight during installation. Do not allow bearing to become cocked. Tap bearing into place until flush with edge of bearing bore. Do not recess bearing. 5. Install transmission. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications Pressure Plate: Specifications TORQUE SPECIFICATIONS BOLTS, CLUTCH COVER NOTE: Tighten bolts evenly and in rotation a few threads at a time. 2.5 L ......................................... .............................................................................................................................................................. .. 28 Nm (21 ft. lbs.) 5/16 bolts ............................................................................................................ ...................................................................................... 23 Nm (17 ft. lbs.) 3/8 bolts .......................... .............................................................................................................................................................. ............ 41 Nm (30 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Specifications Carrier Bearings: Specifications Bearing Cap Bolts ................................................................................................................................ ................................................. 136 Nm (100 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Specifications > Page 4712 Carrier Bearings: Service and Repair REMOVAL 1. Remove differential case from axle housing. 2. Remove the bearings from the differential case with Puller/Press C-293-PA and Adapters C-293-48 and Plug SP-3289, or equivalents. INSTALLATION 1. Install differential side bearings. Use Installer C-4340 with handle C-4171, or equivalents. 2. Install differential case in axle housing. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > Recalls for Differential Case: > 892 > Sep > 00 > Recall - Fuel Tube/Brake Hose Wear Through Technical Service Bulletin # 892 Date: 000901 Recall - Fuel Tube/Brake Hose Wear Through September 2000 Safety Recall No. 892 Fuel Tube Isolator and Axle Vent Hose Clip Models 1997 (AN) Dodge Dakota Club Cab (131" Wheel Base) NOTE: Safety Recall No.870 and 891 also involve the axle vent hose clip repair. Dakotas involved in Recall No. 892 are NOT included in either Recall No.870 or 891. Dealers must verify which recall the truck is involved in prior to completing the service procedure. ^ Safety Recall No.870 applies to 1997-2000 model year trucks equipped with a 2.5L engine and involves the axle vent hose clip and a power steering hose bracket. ^ Safety Recall No.891 applies to 1997-2000 model year trucks that only require the axle vent hose clip. IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The chassis fuel tube on about 90,000 of the above vehicles may contact the cab underbody. Prolonged fuel tube contact may cause the tube to rub through and leak. Fuel leakage in the presence of an ignition source can result in an underbody fire. In addition, the rear brake hose may contact the rear axle vent hose. Prolonged brake hose contact may cause the hose to rub through and leak, resulting in a partial brake system loss and increased stopping distance. The increased stopping distance can cause an accident without warning. Repair The chassis fuel tube must be inspected for evidence of contact and/or wear. All fuel tubes must have an isolator installed and fuel tubes that show signs of wear from contact with the underbody must be replaced. In addition, the rear brake hose must be inspected for evidence of contact and/or wear. The rear axle vent hose must also be shortened and repositioned. Rear brake hoses that have ribs worn smooth from contact with the vent hose must be replaced. Alternate Transportation If inspection determines that fuel tube and/or brake hose replacement is required and the vehicle must be held overnight, dealers should attempt to minimize customer inconvenience by placing the owner in a loaner vehicle. Parts Information A. Fuel Tube and Axle Vent Hose Isolator Package Part Number Description CBK48920 Fuel Tube and Axle Vent Hose Isolator Package Each package contains a fuel tube isolator and a vent hose isolator clip. Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Isolator Packages to service about 25% of those vehicles. B. Chassis Fuel Tube Part Number Description 52127884AC Chassis Fuel Tube Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Fuel Tubes to service about 10% of those vehicles. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > Recalls for Differential Case: > 892 > Sep > 00 > Recall - Fuel Tube/Brake Hose Wear Through > Page 4721 C. Rear Brake Hose Part Number Description 52008984AE Rear Brake Hose Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Brake Hoses to service about 10% of those vehicles. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown: Add the cost of the part(s) plus applicable dealer allowance to your claim. NOTE: Vehicles involved in Recall No.892 are NOT included in either Recall No.870 or 891. Accordingly, claims submitted for Recall No.870 or 891 on vehicles involved in Recall No.892 will be rejected. See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return Not required Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD892". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner letter is shown. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > Recalls for Differential Case: > 892 > Sep > 00 > Recall - Fuel Tube/Brake Hose Wear Through > Page 4722 Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. A. Inspect Chassis Fuel Tube 1. Raise the vehicle on an appropriate hoist. 2. Inspect the chassis fuel tube for evidence of wear from contact with the vehicle underbody where it is routed over the frame crossmember just behind the evaporative canister mounting bracket (Figure 1). ^ If there is evidence of wear from contact with the underbody, the chassis fuel tube must be replaced and a rubber isolator must be installed on the new fuel tube. Continue with Section B Replace Chassis Fuel Tube. ^ If there is NO evidence of contact, install a rubber isolator on the fuel tube as follows: a. Clean the fuel tube with brake clean (Mopar PN 04897150AA or equivalent). b. Fill the cavity of the provided rubber isolator with RTV Sealant (Mopar PN 82300234 or equivalent). c. Snap the isolator over the area of the tube that is closest to the underbody (Figure 1). Position the isolator with the slit toward the ground. d. Continue with Section C--Inspect Rear Brake Hose. NOTE: It is acceptable, and likely, that the rubber isolator will be in contact with the vehicle underbody. Do NOT bend the fuel tube to avoid contact with the underbody. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > Recalls for Differential Case: > 892 > Sep > 00 > Recall - Fuel Tube/Brake Hose Wear Through > Page 4723 B. Replace Chassis Fuel Tube 1. Lower the vehicle. 2. Remove the Power Distribution Center (PDC) cover. 3. Remove the fuel pump relay from the PDC. 4. Start the engine and let it run until it runs out of fuel. Then attempt to start the engine two more times. 5. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 6. Install the fuel pump relay into the PDC and install the PDC cover. 7. Raise the vehicle on the hoist. 8. Position two (2) tall jack stands under the left (driver) side of the cab (Figure 2). 9. Remove the two (2) left side cab mounting bolts (Figure 2). 10. Loosen, but do not remove, the two (2) right passenger) side cab mounting bolts. 11. Carefully lower the vehicle on the hoist until the left side of the cab is supported by the jack stands and the cab has been raised 2-3 inches above the frame. CAUTION: Do NOT raise the cab of the vehicle more than 3 inches or damage to cab may result. 12. Disconnect the vapor hoses from the evaporative canister. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > Recalls for Differential Case: > 892 > Sep > 00 > Recall - Fuel Tube/Brake Hose Wear Through > Page 4724 13. Remove the three (3) bolts that attach the evaporative canister bracket to the frame rail (Figure 3). Set the evaporative canister and bracket assembly aside. 14. Remove the two (2) chassis fuel tube P-clip bolts along the top of the frame rail and one P-clip on the transmission crossmember. 15. Disconnect the chassis fuel tube from the fuel pump module. 16. Disconnect the fuel vent hose from the vent tube near the fuel tank. 17. Disconnect the chassis fuel tube from the engine compartment fuel line. 18. Disconnect the three (3) electrical harness clips from the top of the frame rail near the fuel tank. 19. Remove the fuel tube from the frame rail clip near the transmission crossmember. 20. Remove the chassis fuel tube by pulling it forward and out from under the vehicle. 21. Transfer the vapor tube and P-clips from the old fuel tube to the new fuel tube. 22. With a helper to assist you, install the new chassis fuel tube. CAUTION: Be careful not to kink the plastic tubing at the rear of the fuel tube assembly. 23. Secure the fuel tube into the frame rail clip. 24. Connect the fuel tube to the engine compartment fuel line. Pull back on the quick connect fitting to ensure that it is fully connected. 25. Connect the fuel tube to the fuel pump module. Pull back on the quick connect fitting to ensure that it is fully connected. 26. Connect the vapor hose to the vapor tube. 27. Secure the electrical harness to the frame rail with the three (3) harness clips. 28. Install the three (3) fuel tube P-clip bolts. Tighten the bolts securely. 29. Install the evaporative canister and bracket assembly (Figure 3). Tighten the canister bracket bolts to 90 in-lbs (10 Nm). 30. Connect the vapor hoses to the canister. 31. Fill the cavity of the provided rubber isolator with RTV Sealant (Mopar PN 82300234 or equivalent). 32. Snap the isolator over the area of the new fuel tube near the canister that is closest to the underbody. Position the isolator with the slit toward the ground. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > Recalls for Differential Case: > 892 > Sep > 00 > Recall - Fuel Tube/Brake Hose Wear Through > Page 4725 31. Raise the vehicle on the hoist and remove the jack stands. 32. Install the two left side cab bolts (Figure 3). Tighten the cab bolts to 60 ft-lbs (81 Nm). 33. Tighten the two right cab bolts to 60 ft-lbs (81 Nm). 34. Lower the vehicle. 35. Connect the negative battery cable. 36. Start the vehicle and check for any fuel leaks. 37. Continue with Section C - Inspect Rear Brake Hose. C. Inspect Rear Brake Hose 1. Raise the vehicle on an appropriate hoist. 2. Inspect the rear brake hose for evidence of contact with the rear axle vent hose (Figure 4). ^ If the ribs on the brake hose surface are worn smooth from contact with the vent hose, the brake hose must be replaced and the rear axle vent hose must be shortened and repositioned.Continue with Section D - Replace Rear Brake Hose. ^ If the ribs on the brake hose surface are NOT worn smooth, the rear axle vent hose must be shortened and repositioned. Continue with Section E - Reposition and Clip the Rear Axle Vent Hose. D. Replace Rear Brake Hose NOTE: Only those vehicles that have a worn brake hose, as determined by the inspection in Section C, require replacement. Very few vehicles are expected to require brake hose replacement. 1. Lower the vehicle. 2. Depress and hold the brake pedal using a brake pedal prop rod. NOTE: Keeping the brake pedal in the "applied" position makes bleeding the brakes faster and easier since only the rear brakes will require bleeding. 3. Raise the vehicle on the hoist. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > Recalls for Differential Case: > 892 > Sep > 00 > Recall - Fuel Tube/Brake Hose Wear Through > Page 4726 4. Disconnect the rear chassis brake tube from the rear brake hose and cap the brake tube (Figure 5). NOTE: DO NOT allow brake fluid to drip or spill on painted surfaces as this may damage the paint. If brake fluid contacts a painted surface, flush with water immediately. 5. Remove the retaining clip and disconnect the rear brake hose from the mounting bracket. 6. Disconnect the left and right rear brake tubes from the rear brake hose (Figure 6). 7. Remove the brake hose bracket nut from the RWAL/ABS speed sensor bracket (Figure 6). 8. Remove the rear brake hose from the clips and discard the brake hose. 9. Install the new brake hose into the clips. 10. Install the brake hose bracket onto the RWAL/ABS speed sensor bracket (Figure 6). Tighten the bracket nut to 195 in-lbs (24 Nm). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > Recalls for Differential Case: > 892 > Sep > 00 > Recall - Fuel Tube/Brake Hose Wear Through > Page 4727 11. Connect the left and right brake tubes to the new brake hose (Figure 6). Tighten the brake tube fittings to 145 in-lbs (16 Nm). 12. Install the other end of the brake hose into the mounting bracket and install the retaining clip (Figure 5). 13. Connect the rear chassis brake tube to the rear brake hose (Figure 5). Tighten the brake tube fitting to 145 in-lbs (16 Nm). 14. Bleed the left and right rear brake circuits as follows: a. Attach a clear plastic hose to the right rear bleeder screw and feed the hose into a clear jar containing enough fresh brake fluid to submerge the end of the hose. b. Have a helper pump the brake pedal three or four times and then hold it in the down position. c. With the pedal in the down position, open the bleeder screw at least one full turn. d. Once the brake pedal has dropped, close the bleeder screw. After the bleeder screw is closed, release the brake pedal. e. Repeat steps b through d until all trapped air is removed from the right rear brake circuit (usually four or five times). f. Repeat steps a through e for the left rear brake circuit. 15. Top off the master cylinder with brake fluid and inspect brake hose connections to insure that there are no leaks. 16. Continue with Section E - Reposition and Clip the Rear Axle Vent Hose. E. Reposition and Clip the Rear Axle Vent Hose 1. Disconnect the vent hose from the nipple on the rear axle housing (Figure 7). 2. Mark the vent hose 3" (75 mm) from the end of the hose that was disconnected from the axle (Figure 7). Cut the vent hose at the mark and discard the cut-off piece. 3. Mark the vent hose 4" (100 mm) from the new cut end. 4. Connect the vent hose to the axle nipple. IMPORTANT: Make sure that the vent hose is NOT routed between the rear brake hose and the wiring harness as shown in Figure 7. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > Recalls for Differential Case: > 892 > Sep > 00 > Recall - Fuel Tube/Brake Hose Wear Through > Page 4728 5. Install the provided isolator clip on the vent hose at the mark made in Step 3 (Figure 8). 6. Attach the other end of the isolator clip to the parking brake cable so that the vent hose is routed away from the brake hose and perpendicular to the axle (Figure 8). 7. Lower the vehicle. 8. Verify proper brake operation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > Recalls for Differential Case: > 892 > Sep > 00 > Recall - Fuel Tube/Brake Hose Wear Through > Page 4729 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > Recalls for Differential Case: > 891 > Aug > 00 > Recall - Axle Vent Rubs Through Brake Hose Technical Service Bulletin # 891 Date: 000801 Recall - Axle Vent Rubs Through Brake Hose August 2000 Safety Recall No.891-Axle Vent Hose Clip Models 1997-2000 (AN) Dodge Dakota NOTE: This recall applies to most of the above vehicles built through August 20, 1999 (MDH082007). NOTE: Safety Recall No.870 and 892 combine the axle vent hose clip with another repair. Dealers should verify which recall the vehicle is involved in prior to completing the service procedure. ^ Safety Recall No.870 applies to 1997-2000 model year trucks equipped with a 2.5L engine and involves the axle vent hose clip and a power steering hose bracket. ^ Safety Recall No.892 applies to 1997 model year club cab (131" W.B.) trucks and involves the axle vent hose clip and a rear fuel tube isolator. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to stop sale and complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The rear brake hose on about 309,000 of the above vehicles may contact the rear axle vent hose. Prolonged brake hose contact may cause the hose to rub through and leak, resulting in a partial brake system loss and increased stopping distance. The increased stopping distance can cause an accident without warning. Repair The rear brake hose must be inspected for evidence of contact and/or wear. The rear axle vent hose must also be shortened and repositioned. Brake hoses that have ribs worn smooth from contact with the vent hose must be replaced. Alternate Transportation If inspection determines that brake hose replacement is required and the vehicle must be held overnight, dealers should attempt to minimize customer inconvenience by placing the owner in a loaner vehicle. Parts Information A. Axle Vent Hose Isolator Clip Part Number Description 56021260 Axle Vent Hose Isolator Clip Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Isolator Clips to service about 25% of those vehicles. B. Rear Brake Hose Part Number Description 52008984AE Rear Brake Hose Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Brake Hoses to service about 10% of those vehicles. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > Recalls for Differential Case: > 891 > Aug > 00 > Recall - Axle Vent Rubs Through Brake Hose > Page 4734 service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown: Add the cost of the part(s) plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD891". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner letter is shown. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. A. Inspect Rear Brake Hose 1. Raise the vehicle on an appropriate hoist. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > Recalls for Differential Case: > 891 > Aug > 00 > Recall - Axle Vent Rubs Through Brake Hose > Page 4735 2. Inspect the rear brake hose for evidence of contact with the rear axle vent hose (Figure 1). ^ If the ribs on the brake hose surface are worn smooth from contact with the vent hose, the brake hose must be replaced and the rear axle vent hose must be shortened and repositioned. Continue with Section "B" - Replace Rear Brake Hose. ^ If the ribs on the brake hose surface are NOT worn smooth, the rear axle vent hose must be shortened and repositioned. Continue with Section "C" - Reposition and Clip Rear Axle Vent Hose. B. Replace Rear Brake Hose NOTE: Only those vehicles that have a worn brake hose, as determined by the inspection in Section "A", require replacement. Very few vehicles are expected to require brake hose replacement. 1. Lower the vehicle. 2. Depress and hold the brake pedal using a brake pedal prop rod. NOTE: Keeping the brake pedal in the "applied" position makes bleeding the brakes faster and easier since only the rear brakes will require bleeding. 3. Raise the vehicle on the hoist. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > Recalls for Differential Case: > 891 > Aug > 00 > Recall - Axle Vent Rubs Through Brake Hose > Page 4736 4. Disconnect the rear chassis brake tube from the rear brake hose and cap the brake tube (Figure 2). NOTE: DO NOT allow brake fluid to drip or spill on painted surfaces as this may damage the paint. If brake fluid contacts a painted surface, flush with water immediately. 5. Remove the retaining clip and disconnect the rear brake hose from the mounting bracket. 6. Disconnect the left and right rear brake tubes from the rear brake hose (Figure 3). 7. Remove the brake hose bracket nut from the RWAL/ABS speed sensor bracket (Figure 3). 8. Remove the rear brake hose from the clips and discard the brake hose. 9. Install the new brake hose into the clips. 10. Install the brake hose bracket onto the RWAL/ABS speed sensor bracket (Figure 3). Tighten the bracket nut to 195 in-lbs (24 Nm). 11. Connect the left and right brake tubes to the new brake hose (Figure 3). Tighten the brake tube fittings to 145 in-lbs (16 Nm). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > Recalls for Differential Case: > 891 > Aug > 00 > Recall - Axle Vent Rubs Through Brake Hose > Page 4737 12. Install the other end of the brake hose into the mounting bracket and install the retaining clip (Figure 2). 13. Connect the rear chassis brake tube to the rear brake hose (Figure 2). Tighten the brake tube fining to 145 in-lbs (16 Nm). 14. Bleed the left and right rear brake circuits as follows: a. Attach a clear plastic hose to the right rear bleeder screw and feed the hose into a clear jar containing enough fresh brake fluid to submerge the end of the hose. b. Have a helper pump the brake pedal three or four times and then hold it in the down position. c. With the pedal in the down position, open the bleeder screw at least one full turn. d. Once the brake pedal has dropped, close the bleeder screw. After the bleeder screw is closed, release the brake pedal. e. Repeat steps b through d until all trapped air is removed from the right rear brake circuit (usually four or five times). f. Repeat steps a through e for the left rear brake circuit. 15. Inspect brake hose connections to insure that there are no leaks. 16. Continue with Section "C - Reposition and Clip the Rear Axle Vent Hose." C. Reposition and Clip the Rear Axle Vent Hose 1. Disconnect the vent hose from the nipple on the rear axle housing (Figure 4). 2. Mark the vent hose about 3" (75 mm) from the end of the hose that was disconnected from the axle (Figure 4). Cut the vent hose at the mark and discard the cut-off piece. 3. Mark the vent hose about 4" (100 mm) from the new cut end. 4. Connect the vent hose to the axle nipple. IMPORTANT: Make sure that the vent hose is NOT routed between the rear brake hose and the wiring harness as shown in Figure 4. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > Recalls for Differential Case: > 891 > Aug > 00 > Recall - Axle Vent Rubs Through Brake Hose > Page 4738 5. Install the provided isolator clip on the vent hose at the mark made in Step 3 (Figure 5). 6. Attach the other end of the isolator clip to the parking brake cable so that the vent hose is routed away from the brake hose and perpendicular to the axle (Figure 5). 7. Lower the vehicle. 8. Verify proper brake operation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > Recalls for Differential Case: > 891 > Aug > 00 > Recall - Axle Vent Rubs Through Brake Hose > Page 4739 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Case: > 892 > Sep > 00 > Recall Fuel Tube/Brake Hose Wear Through Technical Service Bulletin # 892 Date: 000901 Recall - Fuel Tube/Brake Hose Wear Through September 2000 Safety Recall No. 892 Fuel Tube Isolator and Axle Vent Hose Clip Models 1997 (AN) Dodge Dakota Club Cab (131" Wheel Base) NOTE: Safety Recall No.870 and 891 also involve the axle vent hose clip repair. Dakotas involved in Recall No. 892 are NOT included in either Recall No.870 or 891. Dealers must verify which recall the truck is involved in prior to completing the service procedure. ^ Safety Recall No.870 applies to 1997-2000 model year trucks equipped with a 2.5L engine and involves the axle vent hose clip and a power steering hose bracket. ^ Safety Recall No.891 applies to 1997-2000 model year trucks that only require the axle vent hose clip. IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The chassis fuel tube on about 90,000 of the above vehicles may contact the cab underbody. Prolonged fuel tube contact may cause the tube to rub through and leak. Fuel leakage in the presence of an ignition source can result in an underbody fire. In addition, the rear brake hose may contact the rear axle vent hose. Prolonged brake hose contact may cause the hose to rub through and leak, resulting in a partial brake system loss and increased stopping distance. The increased stopping distance can cause an accident without warning. Repair The chassis fuel tube must be inspected for evidence of contact and/or wear. All fuel tubes must have an isolator installed and fuel tubes that show signs of wear from contact with the underbody must be replaced. In addition, the rear brake hose must be inspected for evidence of contact and/or wear. The rear axle vent hose must also be shortened and repositioned. Rear brake hoses that have ribs worn smooth from contact with the vent hose must be replaced. Alternate Transportation If inspection determines that fuel tube and/or brake hose replacement is required and the vehicle must be held overnight, dealers should attempt to minimize customer inconvenience by placing the owner in a loaner vehicle. Parts Information A. Fuel Tube and Axle Vent Hose Isolator Package Part Number Description CBK48920 Fuel Tube and Axle Vent Hose Isolator Package Each package contains a fuel tube isolator and a vent hose isolator clip. Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Isolator Packages to service about 25% of those vehicles. B. Chassis Fuel Tube Part Number Description 52127884AC Chassis Fuel Tube Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Fuel Tubes to service about 10% of those vehicles. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Case: > 892 > Sep > 00 > Recall Fuel Tube/Brake Hose Wear Through > Page 4745 C. Rear Brake Hose Part Number Description 52008984AE Rear Brake Hose Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Brake Hoses to service about 10% of those vehicles. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown: Add the cost of the part(s) plus applicable dealer allowance to your claim. NOTE: Vehicles involved in Recall No.892 are NOT included in either Recall No.870 or 891. Accordingly, claims submitted for Recall No.870 or 891 on vehicles involved in Recall No.892 will be rejected. See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return Not required Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD892". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner letter is shown. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Case: > 892 > Sep > 00 > Recall Fuel Tube/Brake Hose Wear Through > Page 4746 Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. A. Inspect Chassis Fuel Tube 1. Raise the vehicle on an appropriate hoist. 2. Inspect the chassis fuel tube for evidence of wear from contact with the vehicle underbody where it is routed over the frame crossmember just behind the evaporative canister mounting bracket (Figure 1). ^ If there is evidence of wear from contact with the underbody, the chassis fuel tube must be replaced and a rubber isolator must be installed on the new fuel tube. Continue with Section B Replace Chassis Fuel Tube. ^ If there is NO evidence of contact, install a rubber isolator on the fuel tube as follows: a. Clean the fuel tube with brake clean (Mopar PN 04897150AA or equivalent). b. Fill the cavity of the provided rubber isolator with RTV Sealant (Mopar PN 82300234 or equivalent). c. Snap the isolator over the area of the tube that is closest to the underbody (Figure 1). Position the isolator with the slit toward the ground. d. Continue with Section C--Inspect Rear Brake Hose. NOTE: It is acceptable, and likely, that the rubber isolator will be in contact with the vehicle underbody. Do NOT bend the fuel tube to avoid contact with the underbody. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Case: > 892 > Sep > 00 > Recall Fuel Tube/Brake Hose Wear Through > Page 4747 B. Replace Chassis Fuel Tube 1. Lower the vehicle. 2. Remove the Power Distribution Center (PDC) cover. 3. Remove the fuel pump relay from the PDC. 4. Start the engine and let it run until it runs out of fuel. Then attempt to start the engine two more times. 5. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 6. Install the fuel pump relay into the PDC and install the PDC cover. 7. Raise the vehicle on the hoist. 8. Position two (2) tall jack stands under the left (driver) side of the cab (Figure 2). 9. Remove the two (2) left side cab mounting bolts (Figure 2). 10. Loosen, but do not remove, the two (2) right passenger) side cab mounting bolts. 11. Carefully lower the vehicle on the hoist until the left side of the cab is supported by the jack stands and the cab has been raised 2-3 inches above the frame. CAUTION: Do NOT raise the cab of the vehicle more than 3 inches or damage to cab may result. 12. Disconnect the vapor hoses from the evaporative canister. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Case: > 892 > Sep > 00 > Recall Fuel Tube/Brake Hose Wear Through > Page 4748 13. Remove the three (3) bolts that attach the evaporative canister bracket to the frame rail (Figure 3). Set the evaporative canister and bracket assembly aside. 14. Remove the two (2) chassis fuel tube P-clip bolts along the top of the frame rail and one P-clip on the transmission crossmember. 15. Disconnect the chassis fuel tube from the fuel pump module. 16. Disconnect the fuel vent hose from the vent tube near the fuel tank. 17. Disconnect the chassis fuel tube from the engine compartment fuel line. 18. Disconnect the three (3) electrical harness clips from the top of the frame rail near the fuel tank. 19. Remove the fuel tube from the frame rail clip near the transmission crossmember. 20. Remove the chassis fuel tube by pulling it forward and out from under the vehicle. 21. Transfer the vapor tube and P-clips from the old fuel tube to the new fuel tube. 22. With a helper to assist you, install the new chassis fuel tube. CAUTION: Be careful not to kink the plastic tubing at the rear of the fuel tube assembly. 23. Secure the fuel tube into the frame rail clip. 24. Connect the fuel tube to the engine compartment fuel line. Pull back on the quick connect fitting to ensure that it is fully connected. 25. Connect the fuel tube to the fuel pump module. Pull back on the quick connect fitting to ensure that it is fully connected. 26. Connect the vapor hose to the vapor tube. 27. Secure the electrical harness to the frame rail with the three (3) harness clips. 28. Install the three (3) fuel tube P-clip bolts. Tighten the bolts securely. 29. Install the evaporative canister and bracket assembly (Figure 3). Tighten the canister bracket bolts to 90 in-lbs (10 Nm). 30. Connect the vapor hoses to the canister. 31. Fill the cavity of the provided rubber isolator with RTV Sealant (Mopar PN 82300234 or equivalent). 32. Snap the isolator over the area of the new fuel tube near the canister that is closest to the underbody. Position the isolator with the slit toward the ground. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Case: > 892 > Sep > 00 > Recall Fuel Tube/Brake Hose Wear Through > Page 4749 31. Raise the vehicle on the hoist and remove the jack stands. 32. Install the two left side cab bolts (Figure 3). Tighten the cab bolts to 60 ft-lbs (81 Nm). 33. Tighten the two right cab bolts to 60 ft-lbs (81 Nm). 34. Lower the vehicle. 35. Connect the negative battery cable. 36. Start the vehicle and check for any fuel leaks. 37. Continue with Section C - Inspect Rear Brake Hose. C. Inspect Rear Brake Hose 1. Raise the vehicle on an appropriate hoist. 2. Inspect the rear brake hose for evidence of contact with the rear axle vent hose (Figure 4). ^ If the ribs on the brake hose surface are worn smooth from contact with the vent hose, the brake hose must be replaced and the rear axle vent hose must be shortened and repositioned.Continue with Section D - Replace Rear Brake Hose. ^ If the ribs on the brake hose surface are NOT worn smooth, the rear axle vent hose must be shortened and repositioned. Continue with Section E - Reposition and Clip the Rear Axle Vent Hose. D. Replace Rear Brake Hose NOTE: Only those vehicles that have a worn brake hose, as determined by the inspection in Section C, require replacement. Very few vehicles are expected to require brake hose replacement. 1. Lower the vehicle. 2. Depress and hold the brake pedal using a brake pedal prop rod. NOTE: Keeping the brake pedal in the "applied" position makes bleeding the brakes faster and easier since only the rear brakes will require bleeding. 3. Raise the vehicle on the hoist. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Case: > 892 > Sep > 00 > Recall Fuel Tube/Brake Hose Wear Through > Page 4750 4. Disconnect the rear chassis brake tube from the rear brake hose and cap the brake tube (Figure 5). NOTE: DO NOT allow brake fluid to drip or spill on painted surfaces as this may damage the paint. If brake fluid contacts a painted surface, flush with water immediately. 5. Remove the retaining clip and disconnect the rear brake hose from the mounting bracket. 6. Disconnect the left and right rear brake tubes from the rear brake hose (Figure 6). 7. Remove the brake hose bracket nut from the RWAL/ABS speed sensor bracket (Figure 6). 8. Remove the rear brake hose from the clips and discard the brake hose. 9. Install the new brake hose into the clips. 10. Install the brake hose bracket onto the RWAL/ABS speed sensor bracket (Figure 6). Tighten the bracket nut to 195 in-lbs (24 Nm). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Case: > 892 > Sep > 00 > Recall Fuel Tube/Brake Hose Wear Through > Page 4751 11. Connect the left and right brake tubes to the new brake hose (Figure 6). Tighten the brake tube fittings to 145 in-lbs (16 Nm). 12. Install the other end of the brake hose into the mounting bracket and install the retaining clip (Figure 5). 13. Connect the rear chassis brake tube to the rear brake hose (Figure 5). Tighten the brake tube fitting to 145 in-lbs (16 Nm). 14. Bleed the left and right rear brake circuits as follows: a. Attach a clear plastic hose to the right rear bleeder screw and feed the hose into a clear jar containing enough fresh brake fluid to submerge the end of the hose. b. Have a helper pump the brake pedal three or four times and then hold it in the down position. c. With the pedal in the down position, open the bleeder screw at least one full turn. d. Once the brake pedal has dropped, close the bleeder screw. After the bleeder screw is closed, release the brake pedal. e. Repeat steps b through d until all trapped air is removed from the right rear brake circuit (usually four or five times). f. Repeat steps a through e for the left rear brake circuit. 15. Top off the master cylinder with brake fluid and inspect brake hose connections to insure that there are no leaks. 16. Continue with Section E - Reposition and Clip the Rear Axle Vent Hose. E. Reposition and Clip the Rear Axle Vent Hose 1. Disconnect the vent hose from the nipple on the rear axle housing (Figure 7). 2. Mark the vent hose 3" (75 mm) from the end of the hose that was disconnected from the axle (Figure 7). Cut the vent hose at the mark and discard the cut-off piece. 3. Mark the vent hose 4" (100 mm) from the new cut end. 4. Connect the vent hose to the axle nipple. IMPORTANT: Make sure that the vent hose is NOT routed between the rear brake hose and the wiring harness as shown in Figure 7. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Case: > 892 > Sep > 00 > Recall Fuel Tube/Brake Hose Wear Through > Page 4752 5. Install the provided isolator clip on the vent hose at the mark made in Step 3 (Figure 8). 6. Attach the other end of the isolator clip to the parking brake cable so that the vent hose is routed away from the brake hose and perpendicular to the axle (Figure 8). 7. Lower the vehicle. 8. Verify proper brake operation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Case: > 892 > Sep > 00 > Recall Fuel Tube/Brake Hose Wear Through > Page 4753 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Case: > 891 > Aug > 00 > Recall Axle Vent Rubs Through Brake Hose Technical Service Bulletin # 891 Date: 000801 Recall - Axle Vent Rubs Through Brake Hose August 2000 Safety Recall No.891-Axle Vent Hose Clip Models 1997-2000 (AN) Dodge Dakota NOTE: This recall applies to most of the above vehicles built through August 20, 1999 (MDH082007). NOTE: Safety Recall No.870 and 892 combine the axle vent hose clip with another repair. Dealers should verify which recall the vehicle is involved in prior to completing the service procedure. ^ Safety Recall No.870 applies to 1997-2000 model year trucks equipped with a 2.5L engine and involves the axle vent hose clip and a power steering hose bracket. ^ Safety Recall No.892 applies to 1997 model year club cab (131" W.B.) trucks and involves the axle vent hose clip and a rear fuel tube isolator. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to stop sale and complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The rear brake hose on about 309,000 of the above vehicles may contact the rear axle vent hose. Prolonged brake hose contact may cause the hose to rub through and leak, resulting in a partial brake system loss and increased stopping distance. The increased stopping distance can cause an accident without warning. Repair The rear brake hose must be inspected for evidence of contact and/or wear. The rear axle vent hose must also be shortened and repositioned. Brake hoses that have ribs worn smooth from contact with the vent hose must be replaced. Alternate Transportation If inspection determines that brake hose replacement is required and the vehicle must be held overnight, dealers should attempt to minimize customer inconvenience by placing the owner in a loaner vehicle. Parts Information A. Axle Vent Hose Isolator Clip Part Number Description 56021260 Axle Vent Hose Isolator Clip Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Isolator Clips to service about 25% of those vehicles. B. Rear Brake Hose Part Number Description 52008984AE Rear Brake Hose Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Brake Hoses to service about 10% of those vehicles. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Case: > 891 > Aug > 00 > Recall Axle Vent Rubs Through Brake Hose > Page 4758 service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown: Add the cost of the part(s) plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD891". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner letter is shown. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. A. Inspect Rear Brake Hose 1. Raise the vehicle on an appropriate hoist. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Case: > 891 > Aug > 00 > Recall Axle Vent Rubs Through Brake Hose > Page 4759 2. Inspect the rear brake hose for evidence of contact with the rear axle vent hose (Figure 1). ^ If the ribs on the brake hose surface are worn smooth from contact with the vent hose, the brake hose must be replaced and the rear axle vent hose must be shortened and repositioned. Continue with Section "B" - Replace Rear Brake Hose. ^ If the ribs on the brake hose surface are NOT worn smooth, the rear axle vent hose must be shortened and repositioned. Continue with Section "C" - Reposition and Clip Rear Axle Vent Hose. B. Replace Rear Brake Hose NOTE: Only those vehicles that have a worn brake hose, as determined by the inspection in Section "A", require replacement. Very few vehicles are expected to require brake hose replacement. 1. Lower the vehicle. 2. Depress and hold the brake pedal using a brake pedal prop rod. NOTE: Keeping the brake pedal in the "applied" position makes bleeding the brakes faster and easier since only the rear brakes will require bleeding. 3. Raise the vehicle on the hoist. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Case: > 891 > Aug > 00 > Recall Axle Vent Rubs Through Brake Hose > Page 4760 4. Disconnect the rear chassis brake tube from the rear brake hose and cap the brake tube (Figure 2). NOTE: DO NOT allow brake fluid to drip or spill on painted surfaces as this may damage the paint. If brake fluid contacts a painted surface, flush with water immediately. 5. Remove the retaining clip and disconnect the rear brake hose from the mounting bracket. 6. Disconnect the left and right rear brake tubes from the rear brake hose (Figure 3). 7. Remove the brake hose bracket nut from the RWAL/ABS speed sensor bracket (Figure 3). 8. Remove the rear brake hose from the clips and discard the brake hose. 9. Install the new brake hose into the clips. 10. Install the brake hose bracket onto the RWAL/ABS speed sensor bracket (Figure 3). Tighten the bracket nut to 195 in-lbs (24 Nm). 11. Connect the left and right brake tubes to the new brake hose (Figure 3). Tighten the brake tube fittings to 145 in-lbs (16 Nm). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Case: > 891 > Aug > 00 > Recall Axle Vent Rubs Through Brake Hose > Page 4761 12. Install the other end of the brake hose into the mounting bracket and install the retaining clip (Figure 2). 13. Connect the rear chassis brake tube to the rear brake hose (Figure 2). Tighten the brake tube fining to 145 in-lbs (16 Nm). 14. Bleed the left and right rear brake circuits as follows: a. Attach a clear plastic hose to the right rear bleeder screw and feed the hose into a clear jar containing enough fresh brake fluid to submerge the end of the hose. b. Have a helper pump the brake pedal three or four times and then hold it in the down position. c. With the pedal in the down position, open the bleeder screw at least one full turn. d. Once the brake pedal has dropped, close the bleeder screw. After the bleeder screw is closed, release the brake pedal. e. Repeat steps b through d until all trapped air is removed from the right rear brake circuit (usually four or five times). f. Repeat steps a through e for the left rear brake circuit. 15. Inspect brake hose connections to insure that there are no leaks. 16. Continue with Section "C - Reposition and Clip the Rear Axle Vent Hose." C. Reposition and Clip the Rear Axle Vent Hose 1. Disconnect the vent hose from the nipple on the rear axle housing (Figure 4). 2. Mark the vent hose about 3" (75 mm) from the end of the hose that was disconnected from the axle (Figure 4). Cut the vent hose at the mark and discard the cut-off piece. 3. Mark the vent hose about 4" (100 mm) from the new cut end. 4. Connect the vent hose to the axle nipple. IMPORTANT: Make sure that the vent hose is NOT routed between the rear brake hose and the wiring harness as shown in Figure 4. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Case: > 891 > Aug > 00 > Recall Axle Vent Rubs Through Brake Hose > Page 4762 5. Install the provided isolator clip on the vent hose at the mark made in Step 3 (Figure 5). 6. Attach the other end of the isolator clip to the parking brake cable so that the vent hose is routed away from the brake hose and perpendicular to the axle (Figure 5). 7. Lower the vehicle. 8. Verify proper brake operation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Case: > 891 > Aug > 00 > Recall Axle Vent Rubs Through Brake Hose > Page 4763 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Specifications Differential Cover: Specifications Mounting Bolts ..................................................................................................................................... .................................................... 41 Nm (30 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Front Axle - 194FIA Differential Oil Capacity Lube Capacity ...................................................................................................................................... ............................................... 1.72 liters (3.60 pints) 8 1/4 Axle Differential Oil Capacity Lube Capacity ...................................................................................................................................... ................................................ 2.22 Liters (4.7 pints) Trac-lok Additive .............................................. ........................................................................................................................................ 148 ml (5 ounces) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 4771 Fluid - Differential: Fluid Type Specifications Differential Fluid Type Grade ................................................................................................................................................... ................................................................... API GL-5 Viscosity .............................................................................................................................................. ..................................................................... 80W-90 If equipped with TRAC-LOK, include the specified amount of friction modifier. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Page 4772 Fluid - Differential: Service Precautions DO NOT over fill differential beyond normal fluid level. Fluid foaming and damage may occur. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Specifications > Rear Pinion Gear: Specifications Rear Shaft Nut Minimum .............................................................................................................................. ................................................ 285 Nm (210 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 9 1/4 Differential Pinion Gear: Service and Repair 9 1/4 Differential NOTE: The ring and pinion gears are serviced in a matched set. Do not replace the pinion gear without replacing the ring gear. REMOVAL 1. Remove differential from the axle housing. 2. Mark pinion yoke and propeller shaft for installation alignment. 3. Disconnect propeller shaft from pinion yoke. Using suitable wire, tie propeller shaft to underbody. 4. Using Yoke Holder 6719, or equivalent to hold yoke and remove the pinion yoke nut and washer. 5. Using Remover C-452, or equivalent, remove the pinion yoke from pinion shaft. 6. Partially install pinion nut onto pinion to protect the threads. 7. Remove the pinion gear from housing. Catch the pinion with your hand to prevent it from falling and being damaged. 8. Remove the pinion shaft seal with suitable pry tool or slide-hammer mounted screw. 9. Remove oil slinger, if equipped, and front pinion bearing. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 9 1/4 Differential > Page 4779 10. Remove the front pinion bearing cup with Remover C-4345 and Handle C-4171, or equivalents. 11. Remove the rear bearing cup from housing. Use Remover C-4307 and Handle C-4171, or equivalents. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 9 1/4 Differential > Page 4780 12. Remove the collapsible preload spacer. 13. Remove the rear bearing from the pinion with Puller/Press C-293-PA and Adapters C-29347, or equivalents. Place 4 adapter blocks so they do not damage the bearing cage. 14. Remove the depth shims from the pinion gear shaft. Record the thickness of the depth shims. INSTALLATION 1. Apply Copy Door Ease, or equivalent, stick lubricant to outside surface of bearing cup. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 9 1/4 Differential > Page 4781 2. Install the pinion rear bearing cup with Installer C-4308 and Driver Handle C-4171, or equivalents. 3. Ensure cup is correctly seated. 4. Apply MOPAR Door Ease, or equivalent, stick lubricant to outside surface of bearing cup. 5. Install the pinion front bearing cup with 6. Install pinion front bearing, and oil slinger, if equipped. 7. Apply a light coating of gear lubricant on the lip of pinion seal. Install seal with Installer C-4076-B and Handle C-4735-1, or equivalents. NOTE: Pinion depth shims are placed between the rear pinion bearing cone and pinion gear to achieve proper ring and pinion gear mesh. If the factory installed ring and pinion gears are reused, the pinion depth shim should not require replacement. If required, refer to Pinion Gear Depth to select the proper thickness shim before installing rear pinion bearing. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 9 1/4 Differential > Page 4782 8. Place the proper thickness depth shim on the pinion gear. 9. Install the rear bearing and slinger, if equipped, on the pinion gear with Installer 6448, or equivalent. 10. Install a new collapsible preload spacer on pinion shaft and install pinion gear in housing. 11. Install pinion gear in housing. 12. Install yoke with Installer C-3718 and Yoke Holder 6719, or equivalents. 13. Install the yoke washer and a new nut on the pinion gear and tighten the pinion nut until there is zero bearing end-play. It will not be possible at this point to achieve zero bearing end-play if a new collapsible spacer was installed. 14. Tighten the nut to 285 Nm (210 ft. lbs.). CAUTION: Never loosen pinion gear nut to decrease pinion gear bearing rotating torque and never exceed specified preload torque. If preload torque or rotating torque is exceeded a new collapsible spacer must be installed. The torque sequence will then have to be repeated. 15. Using Yoke Holder 6719, crush collapsible spacer until bearing end play is taken up. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 9 1/4 Differential > Page 4783 16. Slowly tighten the nut in 6.8 Nm (60 inch lbs.) increments until the desired rotating torque is achieved. Measure the rotating torque frequently to avoid over crushing the collapsible spacer. 17. Check bearing rotating torque with an inch pound torque wrench. The torque necessary to rotate the pinion gear should be: - Original Bearings: 1 to 3 Nm (10 to 20 inch lbs.). - New Bearings: 2 to 5 Nm (15 to 35 inch lbs.). 18. Install propeller shaft. 19. Install differential in housing. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 9 1/4 Differential > Page 4784 Pinion Gear: Service and Repair With 9 1/4 Differential NOTE: The ring and pinion gears are serviced in a matched set. Do not replace the pinion gear without replacing the ring gear. REMOVAL 1. Remove differential from the axle housing. 2. Mark pinion yoke and propeller shaft for installation alignment. 3. Disconnect propeller shaft from pinion yoke. Using suitable wire, tie propeller shaft to underbody. 4. Using Yoke Holder 6719 to hold yoke and remove the pinion yoke nut and washer. Pinion Yoke Removal 5. Using Remover C-452, remove the pinion yoke from pinion shaft. 6. Partially install pinion nut onto pinion to protect the threads. Remove Pinion Gear 7. Remove the pinion gear from housing. Catch the pinion with your hand to prevent it from falling and being damaged. 8. Remove the pinion shaft seal with suitable pry tool or slide-hammer mounted screw. 9. Remove oil slinger, if equipped, and front pinion bearing. 10. Remove the front pinion bearing cup with Bearing Removal Tool Set 6310 and Adapter Foot 6310-9. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 9 1/4 Differential > Page 4785 Rear Bearing Cup Removal 11. Remove the rear bearing cup from housing. Use Remover C-4309 and Handle C-4171 for the 9 1/4 axle. Collapsible Spacer 12. Remove the collapsible preload spacer. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 9 1/4 Differential > Page 4786 Rear Bearing Removal 13. Remove the rear bearing from the pinion with Puller/Press C-293-PA and Adapters C-29337. Place 4 adapter blocks so they do not damage the bearing cage. 14. Remove the depth shims from the pinion gear shaft. Record the thickness of the depth shims. INSTALLATION 1. Apply MOPAR Door Ease, or equivalent, stick lubricant to outside surface of bearing cup. Pinion Rear Bearing Cup Installation 2. Install the pinion rear bearing cup with Installer C-4310 and Driver Handle C-4171. 3. Ensure cup is correctly seated. 4. Apply MOPAR Door Ease, or equivalent, stick lubricant to outside surface of bearing cup. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 9 1/4 Differential > Page 4787 Pinion Front Bearing Cup Installation 5. Install the pinion front bearing cup with Installer D-129 and Handle C-4171. 6. Install pinion front bearing, and oil slinger, if equipped. 7. Apply a light coating of gear lubricant on the lip of pinion seal. 8. Install seal with Installer C-3860-A and Handle C-4171. NOTE: Pinion depth shims are placed between the rear pinion bearing cone and pinion gear to achieve proper ring and pinion gear mesh. If the factory installed ring and pinion gears are reused, the pinion depth shim should not require replacement. If required, refer to Pinion Gear Depth to select the proper thickness shim before installing rear pinion bearing. 9. Place the proper thickness depth shim on the pinion gear. Shaft Rear Bearing Installation 10. Install the rear bearing and slinger, if equipped, on the pinion gear with Installer C-3095. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 9 1/4 Differential > Page 4788 Collapsible Preload Spacer 11. Install a new collapsible preload spacer on pinion shaft and install pinion gear in housing. 12. Install pinion gear in housing. 13. Install yoke with Installer C-3718 and Yoke Holder 6719. 14. Install the yoke washer and a new nut on the pinion gear and tighten the pinion nut until there is zero bearing end-play. It will not be possible at this point to achieve zero bearing end-play if a new collapsible spacer was installed. 15. Tighten the nut to 285 Nm (210 ft. lbs.). CAUTION: Never loosen pinion gear nut to decrease pinion gear bearing rotating torque and never exceed specified preload torque. If preload torque or rotating torque is exceeded a new collapsible spacer must be installed. The torque sequence will then have to be repeated. 16. Using Yoke Holder 6719, crush collapsible spacer until bearing end play is taken up. Check Pinion Gear Rotating Torque 17. Slowly tighten the nut in 6.8 Nm (5 ft. lbs.) increments until the desired rotating torque is achieved. Measure the rotating torque frequently to avoid over crushing the collapsible spacer. 18. Check bearing rotating torque with an inch pound torque wrench. The torque necessary to rotate the pinion gear should be: - Original Bearings - 1 to 3 Nm (10 to 20 inch lbs.). - New Bearings - 2 to 5 Nm (15 to 35 inch lbs.). 19. Install propeller shaft. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 9 1/4 Differential > Page 4789 20. Install differential in housing. FINAL ASSEMBLY Typical Housing Cover With Sealant 1. Scrape the residual sealant from the housing and cover mating surfaces. Clean the mating surfaces with mineral spirits. Apply a bead of MOPAR Silicone Rubber Sealant, or equivalent, on the housing cover. Install the housing cover within 5 minutes after applying the sealant. 2. Install the cover on the differential with the attaching bolts. Install the identification tag. Tighten the cover bolts to 41 Nm (30 ft. lbs.) torque. CAUTION: Overfilling the differential can result in lubricant foaming and overheating. 3. Refill the differential housing with gear lubricant. Refer to the Lubricant Specifications section for the gear lubricant requirements. 4. Install the fill hole plug. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Specifications Ring Gear: Specifications Mounting Bolt ....................................................................................................................................... ................................................... 95 Nm (70 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Specifications > Page 4793 Ring Gear: Service and Repair NOTE: The ring and pinion gears are serviced in a matched set. Do not replace the ring gear without replacing the pinion gear. REMOVAL 1. Remove differential from axle housing. 2. Place differential case in a suitable vise with soft metal jaw protectors. 3. Remove bolts holding ring gear to differential case. 4. Using a soft hammer, drive ring gear from differential case. 5. Use a brass drift and slowly tap the exciter ring from the differential case. CAUTION: Do not reuse the bolts that held the ring gear to the differential case. The bolts can fracture causing extensive damage. INSTALLATION 1. Invert the differential case. 2. Position exciter ring on differential case. 3. Using a brass drift, slowly and evenly tap the exciter ring into position. 4. Position ring gear on the differential case and start two ring gear bolts. This will provide case-to-ring gear bolt hole alignment. 5. Invert the differential case in the vise. 6. Install new ring gear bolts and alternately tighten to 102 Nm (75 ft. lbs.) torque. 7. Install differential in axle housing and verify Rear mesh and contact pattern. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair Seals and Gaskets: Service and Repair REMOVAL 1. Raise and support the vehicle. 2. Scribe a mark on the universal joint, pinion yoke, and pinion shaft for reference. 3. Disconnect the propeller shaft from the pinion yoke. Secure the propeller shaft in an upright position to prevent damage to the rear universal joint. 4. Remove the wheel and tire assemblies. 5. Remove the brake drums to prevent any drag. The drag may cause a false bearing preload torque measurement. 6. Rotate the pinion yoke three or four times. 7. Measure the amount of torque necessary to rotate the pinion gear with a (inch lbs.) dial-type torque wrench. Record the torque reading for installation reference. 8. Hold the yoke with Wrench 6719, or equivalent. Remove the pinion shaft nut and washer. 9. Remove the yoke with Remover C-452, or equivalent. 10. Remove the pinion shaft seal with suitable pry tool or slide-hammer mounted screw. INSTALLATION 1. Clean the seal contact surface in the housing bore. 2. Examine the splines on the pinion shaft for burrs or wear. Remove any burrs and clean the shaft. 3. Inspect pinion yoke for cracks, worn splines and worn seal contact surface. Replace yoke if necessary. NOTE: The outer perimeter of the seal is pre-coated with a special sealant. An additional application of sealant is not required. 4. Apply a light coating of gear lubricant on the lip of pinion seal. 5. Install the new pinion shaft seal with Installer C-4076-B and Handle C-4735-1, or equivalents. NOTE: The seal is correctly installed when the seal flange contacts the face of the differential housing flange. 6. Position the pinion yoke on the end of the shaft with the reference marks aligned. 7. Seat yoke on pinion shaft with Installer C-3718 and Wrench 6719, or equivalents. 8. Remove the tools and install the pinion yoke washer. The convex side of the washer must face outward. CAUTION: Do not exceed the minimum tightening torque when installing the pinion yoke retaining nut at this point. Damage to collapsible spacer or bearings may result. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Page 4797 9. Hold pinion yoke with Yoke Holder 6719, or equivalent and tighten shaft nut to 285 Nm (210 ft. lbs.). Rotate pinion shaft several revolutions to ensure the hearing rollers are seated. 10. Rotate the pinion shaft using an (inch lbs.) torque wrench. Rotating torque should be equal to the reading recorded during removal, plus an additional 0.56 Nm (5 inch lbs.). CAUTION: Never loosen pinion gear nut to decrease pinion gear bearing rotating torque aped never exceed specified preload torque. If preload torque is exceeded a new collapsible spacer must be installed. The torque sequence will then have to be repeated. 11. If the rotating torque is low, use Yoke Holder 6719, or equivalent to hold the pinion yoke and tighten the pinion shaft nut in 6.8 Nm (60 inch lbs.) increments until proper rotating torque is achieved. NOTE: The bearing rotating torque should be constant during a complete revolution of the pinion. If the rotating torque varies, this indicates a binding condition. 12. The seal replacement is unacceptable if the final pinion nut torque is less than 285 Nm (210 ft. lbs.). 13. Install the propeller shaft with the installation reference marks aligned. 14. Tighten the universal joint yoke clamp screws to 19 Nm (14 ft. lbs.). 15. Install the brake drums. 16. Install wheel and tire assemblies and lower the vehicle. 17. Check the differential housing lubricant level. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair Axle Shaft: Service and Repair REMOVAL 1. Raise and support vehicle. Ensure that the transmission is in neutral. 2. Remove wheel and tire assembly. 3. Remove brake drum. Refer to Brakes and Traction Control, for proper procedure. 4. Clean all foreign material from housing cover area. 5. Loosen housing cover bolts. Drain lubricant from the housing and axle shaft tubes. Remove housing cover. 6. Rotate differential case so that pinion mate gear shaft lock screw is accessible. Remove lock screw and pinion mate gear shaft from differential case. 7. Push axle shaft inward and remove axle shaft C-clip lock from the axle shaft. 8. Remove axle shaft. Use care to: prevent damage to axle shaft bearing and seal, which will remain in axle shaft tube. 9. Inspect axle shaft seal for leakage or damage. 10. Inspect roller bearing contact surface on axle shaft for signs of brinelling, galling and pitting. If any of these conditions exist, the axle shaft and/or bearing and seal must be replaced. INSTALLATION 1. Lubricate bearing bore and seal lip with gear lubricant. Insert axle shaft through seal, bearing, and engage it into side gear splines. NOTE: Use care to prevent shaft splines from damaging axle shaft seal lip. 2. Insert C-clip lock in end of axle shaft. Push axle shaft outward to seat C-clip lock in side gear. 3. Insert pinion mate shaft into differential case and through thrust washers and pinion gears. 4. Align hole in shaft with hole in the differential case and install lock screw with Loctite on the threads. Tighten lock screw to 11 Nm (96 inch lbs.) torque. 5. Install cover and add fluid. 6. Install brake drum. Refer to Brakes and Traction Control, for proper procedures. 7. Install wheel and tire. 8. Lower vehicle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair Seals and Gaskets: Service and Repair REMOVAL 1. Remove axle shaft. 2. Remove axle shaft seal from the end of the axle tube with a small pry bar. NOTE: The seal and bearing can be removed at the same time with the bearing removed tool. 3. Remove the axle shaft bearing from the axle tube with Bearing Removal Tool Set 6310, using Adapter Foot 6310-9, or equivalents. NOTE: Do not install the original axle shaft seal. Always install a new seal. INSTALLATION 1. Wipe the axle tube bore clean. Remove any old sealer or burrs from the tube. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Page 4806 2. Install the axle shaft bearing with Installer C-4198 and Handle C-4171, or equivalents. Ensure that the bearing part number is against the installer. Verify that the bearing in installed straight and the tool fully contacts the axle tube when seating the bearing. 3. Install a new axle seal with Installer C-4076-B and Handle C-4735-1, or equivalents. When the tool contacts the axle tube, the seal is installed to the correct depth. 4. Coat the lip of the seal with axle lubricant for protection prior to installing the axle shaft. 5. Install the axle shaft. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Front Hub Seals - Grease Purge Explanation Wheel Bearing: Technical Service Bulletins Front Hub Seals - Grease Purge Explanation NUMBER: 02-06-99 Rev. A GROUP: Suspension DATE: Dec. 17, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-06-99, DATED JUNE 11, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF 4X2 MODELS AND ADDITIONAL MODEL YEARS. SUBJECT: Front Wheel Bearing Grease Is Evident On The Bearing Seal Area. MODELS: 1997 - **2000** (AN) Dakota 1994 - **2000** (BR/BE) Ram Truck 1998 - **2000** (DN) Durango DISCUSSION: Front wheel bearings may be incorrectly diagnosed as faulty due to the evidence of wheel bearing grease on the bearing seal areas. This grease purge is a normal design condition. The factory fill of the bearings includes a slightly greater amount of grease than is required for the bearing lifetime lubricant. A portion of the grease purges through the self-venting seal in the initial few thousand miles to form an additional barrier in the area of the seal and the stamped slinger. This barrier aids in the prevention of contaminants passing through the seal and into the bearing. Do not remove or clean the purged grease as part of normal maintenance due to the fact that it provides additional protection and once removed, damage to the seal and bearing could result. NOTE: UNDER NORMAL CONDITIONS, THERE MAY BE A SPLATTERING OF GREASE RADIALLY OUTWARD ON THE STEERING KNUCKLE FROM THE GREASE BARRIER AREA THAT CAN BE AS THICK AS 4 MM (0.125 IN.). Front wheel bearings should be replaced only if: ^ The seal shows visible damage ^ The bearing endplay is greater than 0.13 mm (0.005 in.) ^ The bearing was operated without the proper clamping force from the spindle nut ^ The bearing has a rough, sticky feel when rotated POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Page 4811 Wheel Bearing: Specifications Lubricant Type Lubricant Type Wheel Bearing Grease NLGI GC rated automotive grease Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Page 4812 Wheel Bearing: Service and Repair REMOVAL 1. Raise and support vehicle. 2. Remove wheel and tire assembly. 3. Remove brake caliper and rotor, refer to Brakes and Traction Control. 4. Remove hub/bearing spindle nut. 5. Slide hub/bearing off spindle. INSTALLATION 1. Slide hub/bearing on spindle. 2. Install hub/bearing spindle nut and tighten to 251 Nm (185 ft. lbs.). 3. Install brake rotor and caliper, refer to Brakes and Traction Control. 4. Install wheel and tire assembly. 5. Remove support and lower vehicle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Nut ....................................................................................................................................................... ................................................. 251 Nm (185 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Specifications Center Support: Specifications Mounting Bolts ..................................................................................................................................... .................................................... 68 Nm (50 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Specifications > Page 4821 Center Support: Description and Operation Vehicles equipped with a two-piece propeller shaft uses a rubber insulated center bearing. The bearing is used to support the shafts where they are joined together. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Specifications > Page 4822 Center Support: Adjustments Drive away shudder is a vibration that occurs at first acceleration from a stop. Shudder vibration usually peaks at the engines highest torque output. Shudder is a symptom associated with vehicles using a two-piece propeller shaft. To decrease shudder, lower the center bearing in 1/8 inch increments. Use shim stock or fabricated plates. Plate stock must be used to maintain compression of the rubber insulator around the bearing. Do not use washers. Replace the original bolts with the appropriate increased length bolts. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Specifications > Page 4823 Center Support: Service and Repair REMOVAL 1. Remove rear propeller shaft. 2. Remove slip joint boot clamp and separate the two half-shafts. 3. Use hammer and punch to tap slinger away from shaft to provide room for bearing splitter. 4. Position Bearing Splitter Tool 1130, or equivalent between slinger and shaft. CAUTION: Do not damage shaft spline during removal of center bearing. 5. Set shaft in press and press bearing off the shaft. INSTALLATION 1. Install new slinger on shaft and drive into position with appropriate installer tool. 2. Install new center bearing on shaft with Bearing Installer Tool 6052, or equivalent. Drive on shaft with hammer until bearing is seated. 3. Clean shaft splines and apply a coat of multi-purpose grease. 4. Align master splines and slide front and rear half-shafts together. Reposition slip yoke boot and install new clamp. 5. Install propeller shaft in vehicle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Customer Interest: > 03-01-99A > Aug > 99 > Propeller Shaft Boot - Torn/Cut Drive/Propeller Shaft: Customer Interest Propeller Shaft Boot - Torn/Cut NUMBER: 03-01-99 Rev. A GROUP: Axle And Propshafts DATE: Aug. 13, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 03-01-99, DATED FEB. 02, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE REPLACEMENT OF THE VEHICLE CROSSMEMBER ON AUTOMATIC TRANSMISSION EQUIPPED VEHICLES. SUBJECT: Two-Piece Propeller Shaft Boot Torn OVERVIEW: ** This bulletin involves replacing of the propeller shaft assembly and, on certain applications, the replacement of the vehicle crossmember.** MODELS: 1997 - 1998 (AN) Dakota NOTE: THIS BULLETIN APPLIES TO TWO WHEEL DRIVE VEHICLES WITH THE FOLLOWING CONFIGURATIONS: ^ ALL CLUB CAB VEHICLES EQUIPPED WITH A MANUAL TRANSMISSION ^ ALL STANDARD CAB/EIGHT FOOT BOX VEHICLES EQUIPPED WITH A MANUAL TRANSMISSION ^ CLUB CAB VEHICLES EQUIPPED WITH AN AUTOMATIC TRANSMISSION BUILT BEFORE SEPTEMBER 8, 1997 (MDH 0908XX). SYMPTOM/CONDITION: Two-piece propeller shaft boot is torn. DIAGNOSIS: Raise the vehicle on a hoist and inspect the two-piece propeller shaft boot for a cut or tear in the vicinity of the crossmember. If the boot shows signs that it had been cut or torn because it may have contacted the crossmember, perform the Repair Procedure. PARTS REQUIRED: (1) 52105850AA Propshaft, Two-Piece, 2.5L/3.9L Engine, Manual Transmission, Two Wheel Drive, Standard Cab, Eight Foot Box (1) 52105851AA Propshaft, Two-Piece, 2.5L/3.9L Engine, Manual Transmission, Two Wheel Drive, Club Cab (1) 52105873AA Propshaft, Two-Piece, 5.2L Engine, Manual Transmission, Two Wheel Drive, Standard Cab, Eight Foot Box (1) 52105874AA Propshaft, Two-Piece, 5.2L Engine, Manual Transmission, Two Wheel Drive, Club Cab **(1) 521112OOAA Propshaft, One-Piece, 3.9L/5.2L Engine, Automatic Transmission, Two Wheel Drive, Club Cab** **1 52020302AA Crossmember, 3.9L/5.2L Engine, Automatic Transmission, Two Wheel Drive, Club Cab** **4 06504677 Bolt, Crossmember** **4 06502979 Nut, Crossmember** REPAIR PROCEDURE: 1. Place the vehicle on a hoist and shift the transmission to the neutral position. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Customer Interest: > 03-01-99A > Aug > 99 > Propeller Shaft Boot - Torn/Cut > Page 4832 2. Raise the vehicle. 3. Remove the bolts that attach the center bearing and heat shield to the crossmember. 4. Remove the bolts holding the universal joint clamps to the pinion yoke. 5. Slide the slip yoke off the transmission output shaft and remove the propeller shaft. For Manual Transmission Equipped Vehicles: 6. Slide the slip yoke of the new propeller shaft (see Parts Required section) onto the transmission output shaft. 7. Install the center bearing and heat shield onto the crossmember and attach the bearing with the bolts. Tighten the bolts to 68 N.m (50 ft. lbs.). 8. Position the universal joint into the axle yoke and attach the universal strap with the bolts. Tighten the bolts to 19 N.m (14 ft. lbs.). 9. Lower the vehicle. **For Automatic Transmission Equipped Vehicles: 10. Remove the crossmember attaching rivets and the crossmember. 11. Install the new crossmember (p/n 52020302AC). Attach the new crossmember to the vehicle frame with four (4) nuts and bolts (p/n 06504677 and 06052979). Tighten the bolts to 60 N.m (45 ft. lbs.). 12. Slide the slip yoke of the new propeller shaft (p/n 52111200AA) onto the transmission output shaft. 13. Position the universal joint into the axle yoke and attach the universal strap with the bolts. Tighten the bolts to 19 Nm (14 ft. lbs.). 14. Lower the vehicle.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 16-30-02-98 0.3 Hrs. Propeller Shaft - Replace Manual Transmission Equipped 16-30-02-99 0.6 Hrs. Propeller Shaft - Replace Automatic Trans. Equipped FAILURE CODE: PB - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-01-99A > Aug > 99 > Propeller Shaft Boot - Torn/Cut Drive/Propeller Shaft: All Technical Service Bulletins Propeller Shaft Boot - Torn/Cut NUMBER: 03-01-99 Rev. A GROUP: Axle And Propshafts DATE: Aug. 13, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 03-01-99, DATED FEB. 02, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE REPLACEMENT OF THE VEHICLE CROSSMEMBER ON AUTOMATIC TRANSMISSION EQUIPPED VEHICLES. SUBJECT: Two-Piece Propeller Shaft Boot Torn OVERVIEW: ** This bulletin involves replacing of the propeller shaft assembly and, on certain applications, the replacement of the vehicle crossmember.** MODELS: 1997 - 1998 (AN) Dakota NOTE: THIS BULLETIN APPLIES TO TWO WHEEL DRIVE VEHICLES WITH THE FOLLOWING CONFIGURATIONS: ^ ALL CLUB CAB VEHICLES EQUIPPED WITH A MANUAL TRANSMISSION ^ ALL STANDARD CAB/EIGHT FOOT BOX VEHICLES EQUIPPED WITH A MANUAL TRANSMISSION ^ CLUB CAB VEHICLES EQUIPPED WITH AN AUTOMATIC TRANSMISSION BUILT BEFORE SEPTEMBER 8, 1997 (MDH 0908XX). SYMPTOM/CONDITION: Two-piece propeller shaft boot is torn. DIAGNOSIS: Raise the vehicle on a hoist and inspect the two-piece propeller shaft boot for a cut or tear in the vicinity of the crossmember. If the boot shows signs that it had been cut or torn because it may have contacted the crossmember, perform the Repair Procedure. PARTS REQUIRED: (1) 52105850AA Propshaft, Two-Piece, 2.5L/3.9L Engine, Manual Transmission, Two Wheel Drive, Standard Cab, Eight Foot Box (1) 52105851AA Propshaft, Two-Piece, 2.5L/3.9L Engine, Manual Transmission, Two Wheel Drive, Club Cab (1) 52105873AA Propshaft, Two-Piece, 5.2L Engine, Manual Transmission, Two Wheel Drive, Standard Cab, Eight Foot Box (1) 52105874AA Propshaft, Two-Piece, 5.2L Engine, Manual Transmission, Two Wheel Drive, Club Cab **(1) 521112OOAA Propshaft, One-Piece, 3.9L/5.2L Engine, Automatic Transmission, Two Wheel Drive, Club Cab** **1 52020302AA Crossmember, 3.9L/5.2L Engine, Automatic Transmission, Two Wheel Drive, Club Cab** **4 06504677 Bolt, Crossmember** **4 06502979 Nut, Crossmember** REPAIR PROCEDURE: 1. Place the vehicle on a hoist and shift the transmission to the neutral position. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-01-99A > Aug > 99 > Propeller Shaft Boot - Torn/Cut > Page 4838 2. Raise the vehicle. 3. Remove the bolts that attach the center bearing and heat shield to the crossmember. 4. Remove the bolts holding the universal joint clamps to the pinion yoke. 5. Slide the slip yoke off the transmission output shaft and remove the propeller shaft. For Manual Transmission Equipped Vehicles: 6. Slide the slip yoke of the new propeller shaft (see Parts Required section) onto the transmission output shaft. 7. Install the center bearing and heat shield onto the crossmember and attach the bearing with the bolts. Tighten the bolts to 68 N.m (50 ft. lbs.). 8. Position the universal joint into the axle yoke and attach the universal strap with the bolts. Tighten the bolts to 19 N.m (14 ft. lbs.). 9. Lower the vehicle. **For Automatic Transmission Equipped Vehicles: 10. Remove the crossmember attaching rivets and the crossmember. 11. Install the new crossmember (p/n 52020302AC). Attach the new crossmember to the vehicle frame with four (4) nuts and bolts (p/n 06504677 and 06052979). Tighten the bolts to 60 N.m (45 ft. lbs.). 12. Slide the slip yoke of the new propeller shaft (p/n 52111200AA) onto the transmission output shaft. 13. Position the universal joint into the axle yoke and attach the universal strap with the bolts. Tighten the bolts to 19 Nm (14 ft. lbs.). 14. Lower the vehicle.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 16-30-02-98 0.3 Hrs. Propeller Shaft - Replace Manual Transmission Equipped 16-30-02-99 0.6 Hrs. Propeller Shaft - Replace Automatic Trans. Equipped FAILURE CODE: PB - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive/Propeller Shaft: > 08-03-97 > Feb > 97 > Instrument Cluster - Gauges Inoperative Fuse: All Technical Service Bulletins Instrument Cluster - Gauges Inoperative NO: 08-03-97 GROUP: Electrical DATE: Feb. 14, 1997 SUBJECT: Inoperative Gauges MODELS: 1997 (AN) Dakota SYMPTOM/CONDITION: Inoperative instrument cluster gauges and overhead console due to blown fuse 11 in the junction block. DIAGNOSIS: Inspect fuse 11 in the junction block to verify that the fuse is blown. If the fuse is blown, perform the following diagnostic procedure. If the instrument cluster gauges and/or overhead console is inoperative but fuse 11 is good, refer to the 1997 Dakota Service Manual (Publication No. 81-370-7110), Group 8E for instrument cluster service and Group 8V for overhead console service. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive/Propeller Shaft: > 08-03-97 > Feb > 97 > Instrument Cluster - Gauges Inoperative > Page 4844 For the above diagnosis, refer to the 1997 AN Service Manual (Publication No. 81-370- 7110), page 8W-40-2 for circuit identification. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive/Propeller Shaft: > 08-03-97 > Feb > 97 > Instrument Cluster - Gauges Inoperative > Page 4850 For the above diagnosis, refer to the 1997 AN Service Manual (Publication No. 81-370- 7110), page 8W-40-2 for circuit identification. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Page 4851 Drive/Propeller Shaft: Specifications Axle Yoke Bolts ................................................................................................................................... .................................................... 19 Nm (14 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Page 4852 Drive/Propeller Shaft: Service Precautions Use the exact replacement parts when installing the propeller shafts. The use of the correct replacement parts helps to ensure safe operation. All fasteners must be torqued to the specified values for safe operation. Also make alignment reference marks on the propeller shaft yoke and axle, or transmission, yoke prior to servicing. This helps to eliminate possible vibration. CAUTION: Do not allow the propeller shaft to drop or hang from any propeller shaft Joint during removal. Attach the propeller shaft to the vehicle underside with wire to prevent damage to the joints. CAUTION: It is very important to protect the external machined surface of the slip yoke from damage during and after propeller shaft removal. If the yoke is damaged, the transmission extension seal may be damaged and therefore cause a leak. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Page 4853 Drive/Propeller Shaft: Description and Operation The propeller shaft transmits power from one point to another in a smooth and continuous action. The shaft is designed to send torque through an angle from the transmission to the axle. The propeller shaft must operate through constantly changing relative angles between the transmission and axle. It must also be capable of changing length while transmitting torque. The axle rides suspended by springs in a floating motion. This means the propeller shaft must be able to contract, expand and change operating angles when going over various road surfaces. This is accomplished through universal joints, which permit the propeller shaft to operate at different angles. The slip joints (or yokes) permit contraction or expansion. Tubular propeller shafts are balanced by the manufacturer with weights spot welded to the tube. The propeller shaft is designed and built with the yoke lugs in line with each other. This is called phasing. This design produces the smoothest running condition. An out of phase shaft can cause a vibration. Before undercoating a vehicle, the propeller shaft and the U-joints should be covered. This will prevent the undercoating from causing an unbalanced condition. CAUTION: Use exact replacement parts for attaching the propeller shafts. This will ensure safe operation. The specified torque must always be applied when tightening the fasteners. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Vibration Drive/Propeller Shaft: Testing and Inspection Vibration Tires that are out-of-round, or wheels that are unbalanced, will cause a low frequency vibration. Refer to Steering and Suspension. Brake drums that are unbalanced will cause a harsh, low frequency vibration. Refer Brakes and Traction Control, for additional information. Driveline vibration can also result from loose or damaged engine mounts. Refer to Engine, for additional information. Propeller shaft vibration increases as the vehicle speed is increased. A vibration that occurs within a specific speed range is not usually caused by a propeller shaft being unbalanced. Defective universal joints, or an incorrect propeller shaft angle, are usually the cause of such a vibration. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Vibration > Page 4856 Drive/Propeller Shaft: Testing and Inspection Unbalance NOTE: Removing and re-indexing the propeller shaft 180° relative to the yoke may eliminate some vibrations. If propeller shaft is suspected of being unbalanced, it can be verified with the following procedure: 1. Raise the vehicle. 2. Clean all the foreign material from the propeller shaft and the universal joints. 3. Inspect the propeller shaft for missing balance weights, broken welds, and bent areas. If the propeller shaft is bent, it must be replaced. 4. Inspect the universal joints to ensure that they are not worn, are properly installed, and are correctly aligned with the shaft. 5. Check the universal joint clamp screws torque. 6. Remove the wheels and tires. Install the wheel lug nuts to retain the brake drums or rotors. 7. Mark and number the shaft six inches from the yoke end at four positions 90° apart. 8. Run and accelerate the vehicle until vibration occurs. Note the intensity and speed the vibration occurred. Stop the engine. 9. Install a screw clamp at position 1. 10. Start the engine and re-check for vibration. If there is little or no change in vibration, move the clamp to one of the other three positions. Repeat the vibration test. 11. If there is no difference in vibration at the other positions, the source of the vibration may not be propeller shaft. 12. If the vibration decreased, install a second clamp and repeat the test. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Vibration > Page 4857 13. If the additional clamp causes an additional vibration, separate the clamps (1/4 inch above and below the mark). Repeat the vibration test. 14. Increase distance between the clamp screws and repeat the test until the amount of vibration is at the lowest level. Bend the slack end of the clamps so the screws will not loosen. 15. If the vibration remains unacceptable, apply the same steps to the front end of the propeller shaft. 16. Install the wheel and tires. Lower the vehicle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Vibration > Page 4858 Drive/Propeller Shaft: Testing and Inspection Runout PROCEDURE 1. Remove dirt, rust, paint, and undercoating from the propeller shaft surface where the dial indicator will contact the shaft. 2. The dial indicator must be installed perpendicular to the shaft surface. 3. Measure runout at the center and ends of the shaft sufficiently far away from weld areas to ensure that the effects of the weld process will not enter into the measurements. 4. Refer to specifications. 5. Replace the propeller shaft if the runout exceeds the limit. SPECIFICATIONS - Front of shaft: 0.010 inch (0.25 mm) - Center of shaft: 0.015 inch (0.38 mm) - Rear of shaft: 0.010 inch (0.25 mm) NOTE: Measure front/rear runout approximately 3 inches (76 mm) from the weld seam at each end of the shaft tube for tube lengths over 30 inches. Under 30 inches the max. Runout is 0.20 inch for full length of the tube. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures Drive/Propeller Shaft: Procedures 1. Clean all universal joint bores with cleaning solvent and a wire brush. 2. Inspect the yokes for distortion, cracks, and worn bearing cap bores. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures > Page 4861 Drive/Propeller Shaft: Removal and Replacement REMOVAL 1. Raise and support vehicle on safety stands. 2. Shift the transmission to the Neutral position. 3. Using a suitable marker, mark a line across the axle pinion yoke and the propeller shaft yoke for installation reference. 4. Using a suitable marker, mark the outline of the center bearing on the frame cross member for installation reference, if equipped. 5. Remove bolts that attach the center bearing to the support bracket, if equipped. 6. Remove the bolts holding the universal joint clamps to the pinion yoke. 7. Slide the slip yoke off of the transmission, or transfer case, output shaft and remove the propeller shaft. INSTALLATION 1. Slide the slip yoke onto the transmission, or transfer case, output shaft. 2. Align the installation reference marks made on the propeller shaft and pinion yoke. 3. Align and install the center bearing to the support bracket, if necessary. 4. Install the bolts and tighten to 68 Nm (50 ft. lbs.) torque. 5. Position universal joint into pinion yoke. 6. Tighten the universal joint strap bolts to 19 Nm (14 ft. lbs.) torque. 7. Lower the vehicle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Description and Operation Universal Joint: Description and Operation Use a multi-purpose NLGI Grade 2 EP lubricant. The factory installed universal joints are lubricated for the life of the vehicle and do not need lubrication. All universal joints should be inspected for leakage and damage each time the vehicle is serviced. If seal leakage or damage exists, the universal joint should be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Description and Operation > Page 4865 Universal Joint: Service and Repair NOTE: Individual components of cardan universal joints are not serviceable. If worn or leaking, they must be replaced as an assembly. DISASSEMBLY 1. Remove the propeller shaft. 2. Using a soft drift, tap the outside of the bearing cap assembly to loosen snap ring. 3. Remove snap rings from both sides of yoke. 4. Set the yoke in an arbor press or vise with a socket whose inside diameter is large enough to receive the bearing cap positioned beneath the yoke. 5. Position the yoke with the grease fitting, if equipped, pointing up. 6. Place a socket with an outside diameter smaller than the upper bearing cap on the upper bearing cap and press the cap through the yoke to release the lower bearing cap. 7. If the bearing cap will not pull out of the yoke by hand after pressing, tap the yoke ear near the bearing cap to dislodge the cap. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Description and Operation > Page 4866 8. To remove the opposite bearing cap, turn the yoke over and straighten the cross in the open hole. Then, carefully press the end of the cross until the remaining bearing cap can be removed. CAUTION: If the cross or bearing cap are not straight during installation, the bearing cap will score the walls of the yoke bore and damage can occur. ASSEMBLY 1. Apply Extreme Pressure (EP) N.L.G.I. Grade 1 or 2 grease to inside of yoke bores to aid in installation. 2. Position the cross in the yoke with its lube fitting, if equipped, pointing up. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Description and Operation > Page 4867 3. Place a bearing cap over the trunnion and align the cap with the yoke bore. Keep the needle bearings upright in the bearing assembly. A needle bearing lying at the bottom of the cap will prevent proper assembly. 4. Press the bearing cap into the yoke bore enough to install a snap ring. 5. Install a snap ring. 6. Repeat Step 3 and Step 4 to install the opposite bearing cap. If the joint is stiff or binding, strike the yoke with a soft hammer to seat the needle bearings. 7. Add grease to lube fitting, if equipped. 8. Install the propeller shaft. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications Flex Plate: Specifications TORQUE SPECIFICATIONS FLYWHEEL BOLTS ‹›2.5 L Tighten to 68 Nm (50 ft. lbs.), then turn an additional 60 degrees. New bolts MUST be used when installing the flywheel or converter plate. ‹›3.9 L, 5.2 L ............................ .............................................................................................................................................................. .. 75 Nm (55 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications Flywheel: Specifications TORQUE SPECIFICATIONS FLYWHEEL BOLTS ‹›2.5 L Tighten to 68 Nm (50 ft. lbs.), then turn an additional 60 degrees. New bolts MUST be used when installing the flywheel or converter plate. ‹›3.9 L, 5.2 L ............................ .............................................................................................................................................................. .. 75 Nm (55 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation Overdrive Indicator Lamp: Description and Operation SYSTEM OPERATION The overdrive-off indicator lamp gives the driver an indication that the automatic transmission overdrive has been locked out. The lamp is controlled by the Powertrain Control Module (PCM) on a hard-wired circuit to instrument cluster. The PCM uses an input from the momentary overdrive lockout switch on the end of the automatic transmission gearshift selector lever to decide whether to turn the lamp on or off. The PCM then controls the lamp ground based upon the overdrive lockout switch input and its internal programming. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Page 4879 Overdrive Indicator Lamp: Testing and Inspection The diagnosis found here addresses an inoperative overdrive-off indicator lamp condition. If the overdrive-off indicator lamp comes on and stays on with the engine running, refer to the proper Diagnostic Procedures for diagnosis of the Powertrain Control Module (PCM) in Powertrain Management /Computer and Control Systems and the transmission control system circuits in Transmission and Drivetrain. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check the fuse in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Turn the ignition switch to the On position. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the ignition switch as required. 3. Disconnect and isolate the battery negative cable. Unplug the gray PCM wire harness connector. Install a jumper wire between the overdrive lamp driver circuit cavity of the gray PCM wire harness connector and a good ground. Connect the battery negative cable. Turn the ignition switch to the On position. The overdrive-off indicator lamp should light. Remove the jumper wire and the lamp should turn off. If OK, refer to the proper Diagnostic Procedures for diagnosis of the Powertrain Control Module (PCM) in Powertrain Management/Computer and Control Systems and the transmission control system circuits in Transmission and Drivetrain. If not OK, go to Step 4. 4. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Remove the instrument cluster bezel and the cluster as described. Check for continuity between the overdrive lamp driver circuit cavity of the gray PCM wire harness connector and a good ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the short circuit as required. 5. Check for continuity between the overdrive lamp driver circuit cavities of the gray PCM wire harness connector and the cluster wire harness connector. There should be continuity If OK, replace the faulty bulb. If not OK, repair the open circuit as required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Description and Operation Shift Indicator: Description and Operation SYSTEM OPERATION Vehicles equipped with a manual transmission have an upshift indicator lamp. The upshift indicator lamp gives an indication when the driver should shift to the next highest gear for the best fuel economy The lamp is turned on by the instrument cluster circuitry for about three seconds when the ignition switch is turned to the On position as a bulb test. After the bulb test, the lamp is controlled by the instrument cluster circuitry based upon a message received from the Powertrain Control Module (PCM) on the Chrysler Collision Detection (CCD) data bus. The PCM uses inputs from many sensors and its internal programming to decide whether the engine speed and load conditions are proper for a transmission upshift. The PCM then sends the proper message to the instrument cluster on the CCD data bus to turn the lamp on or off. The PCM will send a lamp-off message three to five seconds after a lamp-on message, if an upshift is not performed. The lamp will then remain off until the vehicle stops accelerating and is brought back into the range of lamp operation, or until the transmission is shifted into another gear. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Description and Operation > Page 4883 Shift Indicator: Testing and Inspection NOTE: For complete testing, refer to Powertrain Management/Computers and Control Systems/Body Control Module/Testing and Inspection. See: Body and Frame/Body Control Systems/Central Timer Module ( CTM ) High Option/Testing and Inspection The diagnosis found here addresses an inoperative upshift indicator lamp condition. If lamp accuracy is suspect, diagnosis should be performed with a DRB scan tool. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. If the upshift indicator lamp fails to light during the bulb test (about three seconds after the ignition switch is turned to the On position), replace the upshift indicator lamp bulb with a known good unit. If the indicator lamp still fails to operate, diagnosis of the Powertrain Control Module (PCM) and the Chrysler Collision Detection (CCD) data bus should be performed with a DRB scan tool. For diagnosis of the upshift indicator lamp and the instrument cluster circuitry, see Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Instrument Cluster. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four-Wheel Drive (4WD) Indicator Lamp <--> [Four Wheel Drive Indicator Lamp] > Component Information > Description and Operation Four-Wheel Drive (4WD) Indicator Lamp: Description and Operation SYSTEM OPERATION On vehicles equipped with the optional four-wheel drive system, a four-wheel drive indicator lamp is located in the transfer case shift bezel on the floor pan transmission tunnel. This lamp lights any time the transfer case is engaged in a four-wheel drive operating mode. When the ignition switch is in the On position, battery voltage is supplied to one side of the indicator lamp bulb. A normally-open, plunger-type, four-wheel drive switch in the transfer case is hard-wired in series between the other side of the indicator lamp bulb and ground. When the transfer case is shifted into the 4L or 4H positions, the plunger of the four-wheel drive switch is moved, closing the switch and providing a path to ground. This causes the four-wheel drive indicator lamp bulb to light. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four-Wheel Drive (4WD) Indicator Lamp <--> [Four Wheel Drive Indicator Lamp] > Component Information > Description and Operation > Page 4888 Four-Wheel Drive (4WD) Indicator Lamp: Testing and Inspection NOTE: For complete testing, refer to Powertrain Management/Computers and Control Systems/Body Control Module/Testing and Inspection. See: Body and Frame/Body Control Systems/Central Timer Module ( CTM ) High Option/Testing and Inspection The diagnosis found here addresses an inoperative four-wheel drive indicator lamp condition. If the problem being diagnosed is related to lamp accuracy, be certain to confirm that the problem is with the lamp or switch and not with a damaged or inoperative transfer case or transfer case linkage. If no transfer case problem is found, the following procedure will help locate a short or open in the indicator lamp circuit. 1. Check the fuse in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component and replace the faulty fuse. 2. Turn the ignition switch to the On position. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the ignition switch as required. 3. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Unplug the transfer case switch wire harness connector. Check for continuity between the ground circuit cavity of the transfer case switch wire harness connector and a good ground. There should be continuity. if OK, go to Step 4. If not OK, repair the open circuit to ground as required. 4. Connect the battery negative cable. Turn the ignition switch to the On position. Install a jumper wire between the 4WD sense circuit cavity of the transfer case switch wire harness connector and a good ground. The four-wheel drive indicator lamp should light. If OK, replace the faulty transfer case switch. If not OK, go to Step 5. 5. Turn the ignition switch to the Off position. Remove the transfer case shifter bezel, and unplug the four-wheel drive indicator lamp wire harness connector. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output circuit cavity of the four-wheel drive indicator lamp wire harness connector. If OK, go to Step 6. If not OK, repair the open circuit to the junction block as required. 6. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. With the transfer case switch wire harness connector still unplugged, check for continuity between the 4WD sense circuit cavity of the four-wheel drive indicator lamp wire harness connector and a good ground. There should be no continuity If OK, go to Step 7. If not OK, repair the short circuit as required. 7. Check for continuity between the 4WD sense circuit cavities of the four-wheel drive indicator lamp wire harness connector and the transfer case switch wire harness connector. There should be continuity If OK, replace the faulty bulb. If not OK, repair the open circuit as required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Bell Housing, M/T > Component Information > Specifications Bell Housing: Specifications Mounting Bolts ..................................................................................................................................... .................................................... 38 Nm (28 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Bell Housing, M/T > Component Information > Specifications > Page 4893 Bell Housing: Service and Repair REMOVAL 1. Raise vehicle and support vehicle. 2. Remove transmission and clutch housing as assembly. 3. Remove release bearing, release fork, and fork boot from input shaft and clutch housing. 4. Remove bolts attaching clutch housing to transmission. INSTALLATION 1. Clean mounting surfaces of transmission and clutch housing. Use a wire brush if necessary followed by a wax and grease remover, or similar solvent. Also clean engine block surface as well. 2. Position clutch housing on transmission and install housing attaching bolts. Tighten bolts to 38 Nm (28 ft. lbs.) torque. 3. Install release fork pivot ball stud to housing, if necessary. 4. Lubricate release bearing bore, release fork contact surfaces and release fork pivot stud with MOPAR high temperature bearing grease. Also lubricate transmission input shaft splines, pilot hub and bearing retainer slide surface with light coat of same grease. 5. Install release fork, bearing, and boot in housing. Be sure release fork boot is properly seated in housing. 6. Install transmission. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Drain Plug, M/T > Component Information > Specifications Drain Plug: Specifications Mounting .............................................................................................................................................. .................................................... 37 Nm (27 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fill Plug, M/T > Component Information > Specifications Fill Plug: Specifications Mounting .............................................................................................................................................. .................................................... 37 Nm (27 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications Four Wheel Drive Transmission Fluid .............................................................................................................................. .......................................................... 3.1L (6.5 Pints) The correct transmission lubricant level is to the bottom edge of the fill plug hole. Two Wheel Drive Transmission Fluid .............................................................................................................................. .......................................................... 3.1L (6.5 Pints) The correct transmission lubricant level is to the bottom edge of the fill plug hole. NV3500 Manual Transmission Transmission Fluid .............................................................................................................................. .......................................................... 2.2L (4.8 Pints) The correct transmission lubricant level is to the bottom edge of the fill plug hole. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 4904 Fluid - M/T: Fluid Type Specifications AX15 Manual Transmission Transmission Fluid Grade ................................................................................................................................................... ............................................. API GL-5 or equivalent Viscosity .............................................................................................................................................. .............................................................. SAE 75W-90 NV3500 Manual Transmission Transmission Fluid Required lubricant for the NV3500 is MOPAR Manual Transmission Lubricant, P/N 4761526. This is the only lubricant to be used in NV3500 transmissions. No other lubricants are acceptable, or recommended. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Page 4905 Fluid - M/T: Service Precautions DO NOT over fill transmission beyond normal fluid level markings. Fluid foaming and transmission damage may occur. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Output Shaft, M/T > Component Information > Diagrams Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: Customer Interest TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 4919 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 4920 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: All Technical Service Bulletins TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 4926 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 4927 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 4928 Control Module: Description and Operation This vehicle does not have a Transmission Control Module. Transmission control is accomplished through the Engine Control Module or Powertrain Control Module. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Torque Converter Clutch Relay > Component Information > Locations Torque Converter Clutch Relay: Locations Power Distribution Center Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Torque Converter Clutch Relay > Component Information > Locations > Page 4932 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Power Distribution Center Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4936 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4937 Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4938 Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4939 Transmission Control System Relay: Description and Operation CIRCUIT OPERATION Four Speed Automatic Transmission The electronic transmission relay powers the overdrive solenoid, torque convertor clutch solenoid, and governor pressure solenoid. All three solenoids are molded together. Power for the coil side of the relay is supplied on circuit T4. This circuit is controlled by the Powertrain Control Module (PCM), and is the feed for the generator. Ground for the coil side of the relay is controlled by the PCM on circuit T3. This circuit connects to cavity E30 of the PCM connector. When the PCM grounds the relay, the relay contacts connect circuit A14 to circuit T8. Circuit T8 powers the solenoids. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4940 Transmission Control System Relay: Testing and Inspection - Check the 20 Amp fuse in cavity 3 of the PDC Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm Fluid Pressure Sensor/Switch: Customer Interest A/T - Engine Bucking/Surging at 5,300 Rpm NO: 18-19-98 GROUP: Driveability DATE: Apr. 10, 1998 SUBJECT: Vehicle Bucking During Wide Open Throttle Acceleration MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE JAN 16, 1998 MDH (0116XX) EQUIPPED WITH GASOLINE ENGINES AND A 42/44/46 OR 47RE TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may experience bucking during wide open throttle (WOT) acceleration. The bucking occurs at approximately 5300 RPM. This condition may be caused by reaching the high RPM fuel shut off rev limit before the transmission can shift into the next higher gear and is most likely to occur with high electrical loads (high beams on, heated back lite, heated seats, radio, HVAC blower on MAX etc.). During high current demands, the generator may emit electrical noise that can affect the transmission governor pressure sensor output. If this occurs, the transmission may not shift properly to the next higher gear under (WOT) acceleration conditions and therefore reach the fuel shut off rev limiter. This may be seen most often between the 2-3 shift but can also be experienced between the 1-2 shift. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. NOTE: ONLY PERFORM THE FOLLOWING PROCEDURE SAFELY ON A HIGHWAY OR ROAD OBEYING ALL POSTED SPEED LIMITS AND LAWS. Attempt to duplicate the condition by switching on all accessory loads and driving the vehicle with WOT accelerations through a shift sequence to see if the engine will reach the fuel shut off rev limiter before the 2-3 or 1-2 shift is made. If the bucking condition is experienced at approximately 5300 RPM before making the appropriate upshifts, switch off all electrical loads and repeat the procedure. Repeat the procedure with the electrical loads on and off a second time. If the bucking occurs with the electrical loads on and does not occur with the loads off, perform the Repair Procedure. PARTS REQUIRED: 1 56041403AA Sensor, Governor Pressure REPAIR PROCEDURE: This bulletin involves installing a newly designed governor pressure sensor. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm > Page 4951 1. Following the procedures in the applicable service manual, replace the governor pressure sensor with p/n 56041403AA (Figure 1). 2. Check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-96-06-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm Fluid Pressure Sensor/Switch: All Technical Service Bulletins A/T - Engine Bucking/Surging at 5,300 Rpm NO: 18-19-98 GROUP: Driveability DATE: Apr. 10, 1998 SUBJECT: Vehicle Bucking During Wide Open Throttle Acceleration MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE JAN 16, 1998 MDH (0116XX) EQUIPPED WITH GASOLINE ENGINES AND A 42/44/46 OR 47RE TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may experience bucking during wide open throttle (WOT) acceleration. The bucking occurs at approximately 5300 RPM. This condition may be caused by reaching the high RPM fuel shut off rev limit before the transmission can shift into the next higher gear and is most likely to occur with high electrical loads (high beams on, heated back lite, heated seats, radio, HVAC blower on MAX etc.). During high current demands, the generator may emit electrical noise that can affect the transmission governor pressure sensor output. If this occurs, the transmission may not shift properly to the next higher gear under (WOT) acceleration conditions and therefore reach the fuel shut off rev limiter. This may be seen most often between the 2-3 shift but can also be experienced between the 1-2 shift. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. NOTE: ONLY PERFORM THE FOLLOWING PROCEDURE SAFELY ON A HIGHWAY OR ROAD OBEYING ALL POSTED SPEED LIMITS AND LAWS. Attempt to duplicate the condition by switching on all accessory loads and driving the vehicle with WOT accelerations through a shift sequence to see if the engine will reach the fuel shut off rev limiter before the 2-3 or 1-2 shift is made. If the bucking condition is experienced at approximately 5300 RPM before making the appropriate upshifts, switch off all electrical loads and repeat the procedure. Repeat the procedure with the electrical loads on and off a second time. If the bucking occurs with the electrical loads on and does not occur with the loads off, perform the Repair Procedure. PARTS REQUIRED: 1 56041403AA Sensor, Governor Pressure REPAIR PROCEDURE: This bulletin involves installing a newly designed governor pressure sensor. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm > Page 4957 1. Following the procedures in the applicable service manual, replace the governor pressure sensor with p/n 56041403AA (Figure 1). 2. Check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-96-06-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > Page 4958 Fluid Pressure Sensor/Switch: Description and Operation NOTE: This input is used with 4-speed electronic transmissions only DESCRIPTION The transmission governor pressure sensor provides a signal proportional to the transmission governor pressure. OPERATION It provides feedback for control of the variable force solenoid, which regulates transmission governor pressure. CIRCUIT OPERATION The governor pressure sensor supplies the transmission pressure input to the Powertrain Control Module on circuit T25. Circuit T25 connects to cavity B29 of the PCM. Circuit K7 from cavity B31 of the PCM supplies 5 Volts to the sensor. The PCM provides ground for the governor pressure sensor on circuit K4. Circuit K4 connects to cavity A4 of the PCM. The governor pressure sensor is part of the transmission solenoid assembly. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Description and Operation > Switch Operation Overdrive Switch: Description and Operation Switch Operation The overdrive OFF (control) switch is located on the gearshift lever. The switch is a momentary contact device that signals the Powertrain Control Module (PCM) to toggle current status of the overdrive function. 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 Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Description and Operation > Switch Operation > Page 4963 Overdrive Switch: Description and Operation Overdrive Override Switch-PCM Input PURPOSE On vehicles equipped with an automatic transmission and overdrive, the powertrain control module (PCM) regulates the 3-4 overdrive up-shift and downshift through the overdrive solenoid. OPERATION This solenoid is located in the transmission. An overdrive/override push-button switch is located at the end of transmission shift lever. This solenoid is located in the transmission. An overdrive/override push-button switch is located at the end of the transmission shift lever. The overdrive/override push-button switch is normally open (overdrive allowed) when the lamp is not illuminated. It momentarily closes (overdrive not allowed) when the operator presses the switch and the lamp is illuminated. Overdrive will revert to ON (lamp off) each time the ignition switch in turned on. The transmission downshifts if the operator presses the override switch while in overdrive. CIRCUIT OPERATION Automatic transmission equipped vehicles may have an overdrive switch. The operator disables or enables overdrive when the switch is depressed. The overdrive switch consists of a switch connected to the Powertrain Control Module (PCM), an illumination lamp and an overdrive ON/OFF indicator lamp. If overdrive is currently enabled, it is disabled when the operator depresses the overdrive switch. Conversely, if the operator already disabled over-drive, it is enabled when the switch is depressed. Circuit T6 from the overdrive switch connects to cavity C13 of the PCM and provides the overdrive signal. The PCM turns the overdrive ON/OFF indicator lamp ON or OFF by providing a ground for the lamp on circuit T18. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4967 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. 4. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 5. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 6. Test continuity of new switch with 12V test lamp. 7. Connect switch wires and lower vehicle. 8. Top off transmission fluid level. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Sensor Mounting ................................................................................................................................. ..................................................... 27 Nm (20 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 4971 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 4972 Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Shaft Speed Sensor-PCM Input Transmission Speed Sensor: Description and Operation Output Shaft Speed Sensor-PCM Input This sensor generates a signal to the PCM relating to the speed of the transmission main drive shaft. NOTE: This input is used with 4-speed electronic transmissions only. CIRCUIT OPERATION Four Speed Automatic Transmission The output shaft speed sensor generates a signal indicating the speed of the transmission output shaft. Circuits T13 and T14 connect the sensor to the Powertrain Control Module (PCM). Circuit T13 connects to cavity B25 of the PCM. Circuit T14 connects to cavity B28. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Shaft Speed Sensor-PCM Input > Page 4975 Transmission Speed Sensor: Description and Operation Sensor Operation The speed sensor is located in the overdrive gear case. The sensor is positioned over the park gear and monitors transmission output shaft rotating speed. Speed sensor signals are triggered by the park gear lugs as they rotate past the sensor pickup face. Input signals from the sensor are sent to the transmission control module for processing. The vehicle speed sensor also serves as a backup for the transmission speed sensor. Signals from this sensor are shared with the powertrain control module. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Page 4976 Transmission Speed Sensor: Service and Repair Removal Transmission Speed Sensor Removal Installation 1. Remove transmission speed sensor and O-ring seal from overdrive case. Installation 1. Install transmission speed sensor and O-ring seal in overdrive case. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations Governor Pressure Sensor, Transmission Temperature Sensor, Governor Pressure Solenoid, Governor The transmission temperature sensor is located in the transmission solenoid assembly in the valve body. The governor pressure sender and the transmission fluid temperature thermistor are separate sensors in the same component. This component is attached to the governor body in the solenoid assembly of the valve body. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission Temperature Sensor - Description and Operation Transmission Temperature Sensor/Switch: Description and Operation Transmission Temperature Sensor - Description and Operation Transmission fluid temperature readings are supplied to the transmission control module by the thermistor. The temperature readings are used to control engagement of the fourth gear overdrive clutch, the converter clutch, and governor pressure. Normal resistance value for the thermistor at room temperature is approximately 1000 ohms. The PCM prevents engagement of the converter clutch and overdrive clutch, when fluid temperature is below approximately 10 °C (50 °F). If fluid temperature exceeds 126 °C (260 °F), the PCM causes a 4-3 downshift and engage the converter clutch. Engagement is according to the third gear converter clutch engagement schedule. The overdrive OFF lamp in the instrument panel illuminates when the shift back to third occurs. The transmission will not allow fourth gear operation until fluid temperature decreases to approximately 110 °C (230 °F). The thermistor is part of the governor pressure sensor assembly and is immersed in transmission fluid at all times. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission Temperature Sensor - Description and Operation > Page 4982 Transmission Temperature Sensor/Switch: Description and Operation Transmission Temperature Sensor - PCM Input NOTE: This input is used in the shift operation for 4-speed electronic transmissions only. The temperature data is used for: torque converter clutch operation, overdrive shift, low temperature shift compensation, wide open throttle shift strategy and governor pressure transducer calibration. CIRCUIT OPERATION The transmission temperature sensor is located in the transmission solenoid assembly. The sensor is a variable resistor, as transmission temperature changes the resistance in the sensor changes. Circuit T34 connects from the Powertrain Control Module (PCM) to the sensor. Ground for the sensor is supplied on circuit K4. This circuit is the ground circuit for many of the components used in the fuel/ignition system. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications NV231 Transfer Case Transfer Case ...................................................................................................................................... ......................................................... 1.2L (2.5 Pints) Correct fill level is to the bottom edge of the fill plug hole. NV242 Transfer Case Transfer Case ...................................................................................................................................... ....................................................... 1.3L (2.8 Pints) Correct fill level is to the bottom edge of the fill plug hole. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 4988 Fluid - Transfer Case: Fluid Type Specifications Transfer Case Fluid MOPAR Dexron II, or ATF Plus type 9602 automatic transmission fluid Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Page 4989 Fluid - Transfer Case: Service Precautions DO NOT over fill transfer case beyond normal fluid level. Fluid foaming and damage may occur. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four-Wheel Drive (4WD) Indicator Lamp <--> [Four Wheel Drive Indicator Lamp] > Component Information > Description and Operation Four-Wheel Drive (4WD) Indicator Lamp: Description and Operation SYSTEM OPERATION On vehicles equipped with the optional four-wheel drive system, a four-wheel drive indicator lamp is located in the transfer case shift bezel on the floor pan transmission tunnel. This lamp lights any time the transfer case is engaged in a four-wheel drive operating mode. When the ignition switch is in the On position, battery voltage is supplied to one side of the indicator lamp bulb. A normally-open, plunger-type, four-wheel drive switch in the transfer case is hard-wired in series between the other side of the indicator lamp bulb and ground. When the transfer case is shifted into the 4L or 4H positions, the plunger of the four-wheel drive switch is moved, closing the switch and providing a path to ground. This causes the four-wheel drive indicator lamp bulb to light. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four-Wheel Drive (4WD) Indicator Lamp <--> [Four Wheel Drive Indicator Lamp] > Component Information > Description and Operation > Page 4993 Four-Wheel Drive (4WD) Indicator Lamp: Testing and Inspection NOTE: For complete testing, refer to Powertrain Management/Computers and Control Systems/Body Control Module/Testing and Inspection. See: Body and Frame/Body Control Systems/Central Timer Module ( CTM ) High Option/Testing and Inspection The diagnosis found here addresses an inoperative four-wheel drive indicator lamp condition. If the problem being diagnosed is related to lamp accuracy, be certain to confirm that the problem is with the lamp or switch and not with a damaged or inoperative transfer case or transfer case linkage. If no transfer case problem is found, the following procedure will help locate a short or open in the indicator lamp circuit. 1. Check the fuse in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component and replace the faulty fuse. 2. Turn the ignition switch to the On position. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the ignition switch as required. 3. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Unplug the transfer case switch wire harness connector. Check for continuity between the ground circuit cavity of the transfer case switch wire harness connector and a good ground. There should be continuity. if OK, go to Step 4. If not OK, repair the open circuit to ground as required. 4. Connect the battery negative cable. Turn the ignition switch to the On position. Install a jumper wire between the 4WD sense circuit cavity of the transfer case switch wire harness connector and a good ground. The four-wheel drive indicator lamp should light. If OK, replace the faulty transfer case switch. If not OK, go to Step 5. 5. Turn the ignition switch to the Off position. Remove the transfer case shifter bezel, and unplug the four-wheel drive indicator lamp wire harness connector. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output circuit cavity of the four-wheel drive indicator lamp wire harness connector. If OK, go to Step 6. If not OK, repair the open circuit to the junction block as required. 6. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. With the transfer case switch wire harness connector still unplugged, check for continuity between the 4WD sense circuit cavity of the four-wheel drive indicator lamp wire harness connector and a good ground. There should be no continuity If OK, go to Step 7. If not OK, repair the short circuit as required. 7. Check for continuity between the 4WD sense circuit cavities of the four-wheel drive indicator lamp wire harness connector and the transfer case switch wire harness connector. There should be continuity If OK, replace the faulty bulb. If not OK, repair the open circuit as required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four-Wheel Drive (4WD) Indicator Lamp <--> [Four Wheel Drive Indicator Lamp] > Component Information > Description and Operation Four-Wheel Drive (4WD) Indicator Lamp: Description and Operation SYSTEM OPERATION On vehicles equipped with the optional four-wheel drive system, a four-wheel drive indicator lamp is located in the transfer case shift bezel on the floor pan transmission tunnel. This lamp lights any time the transfer case is engaged in a four-wheel drive operating mode. When the ignition switch is in the On position, battery voltage is supplied to one side of the indicator lamp bulb. A normally-open, plunger-type, four-wheel drive switch in the transfer case is hard-wired in series between the other side of the indicator lamp bulb and ground. When the transfer case is shifted into the 4L or 4H positions, the plunger of the four-wheel drive switch is moved, closing the switch and providing a path to ground. This causes the four-wheel drive indicator lamp bulb to light. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four-Wheel Drive (4WD) Indicator Lamp <--> [Four Wheel Drive Indicator Lamp] > Component Information > Description and Operation > Page 4998 Four-Wheel Drive (4WD) Indicator Lamp: Testing and Inspection NOTE: For complete testing, refer to Powertrain Management/Computers and Control Systems/Body Control Module/Testing and Inspection. See: Body and Frame/Body Control Systems/Central Timer Module ( CTM ) High Option/Testing and Inspection The diagnosis found here addresses an inoperative four-wheel drive indicator lamp condition. If the problem being diagnosed is related to lamp accuracy, be certain to confirm that the problem is with the lamp or switch and not with a damaged or inoperative transfer case or transfer case linkage. If no transfer case problem is found, the following procedure will help locate a short or open in the indicator lamp circuit. 1. Check the fuse in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component and replace the faulty fuse. 2. Turn the ignition switch to the On position. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the ignition switch as required. 3. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Unplug the transfer case switch wire harness connector. Check for continuity between the ground circuit cavity of the transfer case switch wire harness connector and a good ground. There should be continuity. if OK, go to Step 4. If not OK, repair the open circuit to ground as required. 4. Connect the battery negative cable. Turn the ignition switch to the On position. Install a jumper wire between the 4WD sense circuit cavity of the transfer case switch wire harness connector and a good ground. The four-wheel drive indicator lamp should light. If OK, replace the faulty transfer case switch. If not OK, go to Step 5. 5. Turn the ignition switch to the Off position. Remove the transfer case shifter bezel, and unplug the four-wheel drive indicator lamp wire harness connector. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output circuit cavity of the four-wheel drive indicator lamp wire harness connector. If OK, go to Step 6. If not OK, repair the open circuit to the junction block as required. 6. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. With the transfer case switch wire harness connector still unplugged, check for continuity between the 4WD sense circuit cavity of the four-wheel drive indicator lamp wire harness connector and a good ground. There should be no continuity If OK, go to Step 7. If not OK, repair the short circuit as required. 7. Check for continuity between the 4WD sense circuit cavities of the four-wheel drive indicator lamp wire harness connector and the transfer case switch wire harness connector. There should be continuity If OK, replace the faulty bulb. If not OK, repair the open circuit as required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold Pressure Regulating Solenoid: Customer Interest A/T - Buzz/Whining in Reverse When Cold NUMBER: 21-08-99 GROUP: Transmission DATE: April 30, 1999 SUBJECT: "Buzz", "Whining", Or "Moaning" Like Noise From A Cold Transmission When Reverse Is Selected. OVERVIEW: This bulletin involves replacing the transmission regulator valve. MODELS: 1996 - 1999 (AB) Ram Van 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (TJ) Wrangler 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1999 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A RE OR RH AUTOMATIC TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may exhibit an intermittent noise from the transmission when reverse gear is selected. This noise has been described as a "buzz", whining", or "moaning" like noise. The noise is most noticeable when transmission fluid temperature is below 38 C. (100 F.). The condition is caused by a resonance of the transmission regulator valve system. Other items may cause regulator valve resonance, including air ingestion into the valve body or out of specification parts. These two items may be the result a possible cracked pump housing, a torn pump gasket, an under filled transmission, a restricted fluid filter or cooler flow, or an out of specification valve and/or valve body. You should remember these additional items / components when you perform your diagnosis. Vehicles built prior to August 1, 1995 may experience this condition if either a transmission valve body or an entire automatic transmission was replaced with components manufactured after August 1, 1995. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostics Procedure Manual, verify all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. For 1996 and 1997 model year product, review Technical Service Bulletin 21-11-97 Rev A to determine if it applies to this vehicle before attempting to complete the analysis or repairs described in this bulletin. In most instances, the sump temperature of vehicles exhibiting transmission regulator valve resonance in reverse has been less than 38 C. (100 F). If possible, allow the suspect vehicle to remain parked in a cool place overnight. Then perform the following steps: 1. Set the vehicle parking brake. 2. Start the engine (make certain windows are closed, to eliminate outside noise). 3. With brakes applied, place the transmission selector lever in reverse. 4. Listen for any buzz/moaning/whining like noises as the transmission sump temperature rises to normal operating temperature (180 - 210 degrees F). 5. If a buzz/moaning/whining like noise is present, perform the Repair Procedure. PARTS REQUIRED: 1 04130169 Valve, Steel Transmission Regulator Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > Customer Interest for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold > Page 5010 1 02464324 Gasket, Transmission Pan AR 05010124AA Fluid, ATF Plus 3, Type 7176E EQUIPMENT REQUIRED: 1 C-3763 Gauge Tool, Throttle Pressure Adjustment REPAIR PROCEDURE: 1. Following the procedures in the applicable service manual, remove the valve body from the transmission (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - REMOVAL AND INSTALLATION). 2. Remove the screws holding the adjusting screw bracket and replace the regulator valve with p/n 04130169 (Figure 1). Install the adjusting screw bracket 3. Verify and adjust, if necessary, both the line pressure and the throttle pressure settings by following the procedures in the service manual (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section ADJUSTMENTS - VALVE BODY). 4. Following the procedures in the appropriate Service Manual, re-install the valve body with the new regulator valve into the transmission. 5. After filling the transmission with the proper automatic transmission fluid, and verifying correct fill level, check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - ADJUSTMENTS - TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-90 1.2 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold Pressure Regulating Solenoid: All Technical Service Bulletins A/T - Buzz/Whining in Reverse When Cold NUMBER: 21-08-99 GROUP: Transmission DATE: April 30, 1999 SUBJECT: "Buzz", "Whining", Or "Moaning" Like Noise From A Cold Transmission When Reverse Is Selected. OVERVIEW: This bulletin involves replacing the transmission regulator valve. MODELS: 1996 - 1999 (AB) Ram Van 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (TJ) Wrangler 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1999 (WJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A RE OR RH AUTOMATIC TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may exhibit an intermittent noise from the transmission when reverse gear is selected. This noise has been described as a "buzz", whining", or "moaning" like noise. The noise is most noticeable when transmission fluid temperature is below 38 C. (100 F.). The condition is caused by a resonance of the transmission regulator valve system. Other items may cause regulator valve resonance, including air ingestion into the valve body or out of specification parts. These two items may be the result a possible cracked pump housing, a torn pump gasket, an under filled transmission, a restricted fluid filter or cooler flow, or an out of specification valve and/or valve body. You should remember these additional items / components when you perform your diagnosis. Vehicles built prior to August 1, 1995 may experience this condition if either a transmission valve body or an entire automatic transmission was replaced with components manufactured after August 1, 1995. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostics Procedure Manual, verify all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. For 1996 and 1997 model year product, review Technical Service Bulletin 21-11-97 Rev A to determine if it applies to this vehicle before attempting to complete the analysis or repairs described in this bulletin. In most instances, the sump temperature of vehicles exhibiting transmission regulator valve resonance in reverse has been less than 38 C. (100 F). If possible, allow the suspect vehicle to remain parked in a cool place overnight. Then perform the following steps: 1. Set the vehicle parking brake. 2. Start the engine (make certain windows are closed, to eliminate outside noise). 3. With brakes applied, place the transmission selector lever in reverse. 4. Listen for any buzz/moaning/whining like noises as the transmission sump temperature rises to normal operating temperature (180 - 210 degrees F). 5. If a buzz/moaning/whining like noise is present, perform the Repair Procedure. PARTS REQUIRED: 1 04130169 Valve, Steel Transmission Regulator Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Regulating Solenoid: > 21-08-99 > Apr > 99 > A/T - Buzz/Whining in Reverse When Cold > Page 5016 1 02464324 Gasket, Transmission Pan AR 05010124AA Fluid, ATF Plus 3, Type 7176E EQUIPMENT REQUIRED: 1 C-3763 Gauge Tool, Throttle Pressure Adjustment REPAIR PROCEDURE: 1. Following the procedures in the applicable service manual, remove the valve body from the transmission (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - REMOVAL AND INSTALLATION). 2. Remove the screws holding the adjusting screw bracket and replace the regulator valve with p/n 04130169 (Figure 1). Install the adjusting screw bracket 3. Verify and adjust, if necessary, both the line pressure and the throttle pressure settings by following the procedures in the service manual (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section ADJUSTMENTS - VALVE BODY). 4. Following the procedures in the appropriate Service Manual, re-install the valve body with the new regulator valve into the transmission. 5. After filling the transmission with the proper automatic transmission fluid, and verifying correct fill level, check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure (Refer to Group 21 of the appropriate Service Manual - TRANSMISSION AND TRANSFER CASE - AUTOMATIC TRANSMISSION section - ADJUSTMENTS - TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-95-01-90 1.2 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations O/D (3-4) Solenoid, TCC Solenoid, Governor Pressure Sensor, Governor Pressure Solenoid Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 5020 Shift Solenoid: Description and Operation The shift valves are moved by a combination of throttle and governor pressure. The governor pressure is generated by electrical components. The conditions under which a shift to fourth will not occur are: - Overdrive switch is Off - Transmission fluid temperature is below 10 °C (50 °F) or above 121 °C (250 °F) - Shift to third not yet completed - Vehicle speed too low for 3-4 shift to occur - Battery temperature below -5 °F Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations O/D (3-4) Solenoid, TCC Solenoid, Governor Pressure Sensor, Governor Pressure Solenoid Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation Overdrive Indicator Lamp: Description and Operation SYSTEM OPERATION The overdrive-off indicator lamp gives the driver an indication that the automatic transmission overdrive has been locked out. The lamp is controlled by the Powertrain Control Module (PCM) on a hard-wired circuit to instrument cluster. The PCM uses an input from the momentary overdrive lockout switch on the end of the automatic transmission gearshift selector lever to decide whether to turn the lamp on or off. The PCM then controls the lamp ground based upon the overdrive lockout switch input and its internal programming. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Page 5029 Overdrive Indicator Lamp: Testing and Inspection The diagnosis found here addresses an inoperative overdrive-off indicator lamp condition. If the overdrive-off indicator lamp comes on and stays on with the engine running, refer to the proper Diagnostic Procedures for diagnosis of the Powertrain Control Module (PCM) in Powertrain Management /Computer and Control Systems and the transmission control system circuits in Transmission and Drivetrain. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check the fuse in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Turn the ignition switch to the On position. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the ignition switch as required. 3. Disconnect and isolate the battery negative cable. Unplug the gray PCM wire harness connector. Install a jumper wire between the overdrive lamp driver circuit cavity of the gray PCM wire harness connector and a good ground. Connect the battery negative cable. Turn the ignition switch to the On position. The overdrive-off indicator lamp should light. Remove the jumper wire and the lamp should turn off. If OK, refer to the proper Diagnostic Procedures for diagnosis of the Powertrain Control Module (PCM) in Powertrain Management/Computer and Control Systems and the transmission control system circuits in Transmission and Drivetrain. If not OK, go to Step 4. 4. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Remove the instrument cluster bezel and the cluster as described. Check for continuity between the overdrive lamp driver circuit cavity of the gray PCM wire harness connector and a good ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the short circuit as required. 5. Check for continuity between the overdrive lamp driver circuit cavities of the gray PCM wire harness connector and the cluster wire harness connector. There should be continuity If OK, replace the faulty bulb. If not OK, repair the open circuit as required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Description and Operation Shift Indicator: Description and Operation SYSTEM OPERATION Vehicles equipped with a manual transmission have an upshift indicator lamp. The upshift indicator lamp gives an indication when the driver should shift to the next highest gear for the best fuel economy The lamp is turned on by the instrument cluster circuitry for about three seconds when the ignition switch is turned to the On position as a bulb test. After the bulb test, the lamp is controlled by the instrument cluster circuitry based upon a message received from the Powertrain Control Module (PCM) on the Chrysler Collision Detection (CCD) data bus. The PCM uses inputs from many sensors and its internal programming to decide whether the engine speed and load conditions are proper for a transmission upshift. The PCM then sends the proper message to the instrument cluster on the CCD data bus to turn the lamp on or off. The PCM will send a lamp-off message three to five seconds after a lamp-on message, if an upshift is not performed. The lamp will then remain off until the vehicle stops accelerating and is brought back into the range of lamp operation, or until the transmission is shifted into another gear. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Description and Operation > Page 5033 Shift Indicator: Testing and Inspection NOTE: For complete testing, refer to Powertrain Management/Computers and Control Systems/Body Control Module/Testing and Inspection. See: Body and Frame/Body Control Systems/Central Timer Module ( CTM ) High Option/Testing and Inspection The diagnosis found here addresses an inoperative upshift indicator lamp condition. If lamp accuracy is suspect, diagnosis should be performed with a DRB scan tool. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. If the upshift indicator lamp fails to light during the bulb test (about three seconds after the ignition switch is turned to the On position), replace the upshift indicator lamp bulb with a known good unit. If the indicator lamp still fails to operate, diagnosis of the Powertrain Control Module (PCM) and the Chrysler Collision Detection (CCD) data bus should be performed with a DRB scan tool. For diagnosis of the upshift indicator lamp and the instrument cluster circuitry, see Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Instrument Cluster. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four-Wheel Drive (4WD) Indicator Lamp <--> [Four Wheel Drive Indicator Lamp] > Component Information > Description and Operation Four-Wheel Drive (4WD) Indicator Lamp: Description and Operation SYSTEM OPERATION On vehicles equipped with the optional four-wheel drive system, a four-wheel drive indicator lamp is located in the transfer case shift bezel on the floor pan transmission tunnel. This lamp lights any time the transfer case is engaged in a four-wheel drive operating mode. When the ignition switch is in the On position, battery voltage is supplied to one side of the indicator lamp bulb. A normally-open, plunger-type, four-wheel drive switch in the transfer case is hard-wired in series between the other side of the indicator lamp bulb and ground. When the transfer case is shifted into the 4L or 4H positions, the plunger of the four-wheel drive switch is moved, closing the switch and providing a path to ground. This causes the four-wheel drive indicator lamp bulb to light. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four-Wheel Drive (4WD) Indicator Lamp <--> [Four Wheel Drive Indicator Lamp] > Component Information > Description and Operation > Page 5038 Four-Wheel Drive (4WD) Indicator Lamp: Testing and Inspection NOTE: For complete testing, refer to Powertrain Management/Computers and Control Systems/Body Control Module/Testing and Inspection. See: Body and Frame/Body Control Systems/Central Timer Module ( CTM ) High Option/Testing and Inspection The diagnosis found here addresses an inoperative four-wheel drive indicator lamp condition. If the problem being diagnosed is related to lamp accuracy, be certain to confirm that the problem is with the lamp or switch and not with a damaged or inoperative transfer case or transfer case linkage. If no transfer case problem is found, the following procedure will help locate a short or open in the indicator lamp circuit. 1. Check the fuse in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component and replace the faulty fuse. 2. Turn the ignition switch to the On position. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the ignition switch as required. 3. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Unplug the transfer case switch wire harness connector. Check for continuity between the ground circuit cavity of the transfer case switch wire harness connector and a good ground. There should be continuity. if OK, go to Step 4. If not OK, repair the open circuit to ground as required. 4. Connect the battery negative cable. Turn the ignition switch to the On position. Install a jumper wire between the 4WD sense circuit cavity of the transfer case switch wire harness connector and a good ground. The four-wheel drive indicator lamp should light. If OK, replace the faulty transfer case switch. If not OK, go to Step 5. 5. Turn the ignition switch to the Off position. Remove the transfer case shifter bezel, and unplug the four-wheel drive indicator lamp wire harness connector. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output circuit cavity of the four-wheel drive indicator lamp wire harness connector. If OK, go to Step 6. If not OK, repair the open circuit to the junction block as required. 6. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. With the transfer case switch wire harness connector still unplugged, check for continuity between the 4WD sense circuit cavity of the four-wheel drive indicator lamp wire harness connector and a good ground. There should be no continuity If OK, go to Step 7. If not OK, repair the short circuit as required. 7. Check for continuity between the 4WD sense circuit cavities of the four-wheel drive indicator lamp wire harness connector and the transfer case switch wire harness connector. There should be continuity If OK, replace the faulty bulb. If not OK, repair the open circuit as required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: Customer Interest TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 5049 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 5050 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: All Technical Service Bulletins TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 5056 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 5057 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 5058 Control Module: Description and Operation This vehicle does not have a Transmission Control Module. Transmission control is accomplished through the Engine Control Module or Powertrain Control Module. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Torque Converter Clutch Relay > Component Information > Locations Torque Converter Clutch Relay: Locations Power Distribution Center Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Torque Converter Clutch Relay > Component Information > Locations > Page 5062 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Power Distribution Center Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 5066 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 5067 Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 5068 Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 5069 Transmission Control System Relay: Description and Operation CIRCUIT OPERATION Four Speed Automatic Transmission The electronic transmission relay powers the overdrive solenoid, torque convertor clutch solenoid, and governor pressure solenoid. All three solenoids are molded together. Power for the coil side of the relay is supplied on circuit T4. This circuit is controlled by the Powertrain Control Module (PCM), and is the feed for the generator. Ground for the coil side of the relay is controlled by the PCM on circuit T3. This circuit connects to cavity E30 of the PCM connector. When the PCM grounds the relay, the relay contacts connect circuit A14 to circuit T8. Circuit T8 powers the solenoids. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 5070 Transmission Control System Relay: Testing and Inspection - Check the 20 Amp fuse in cavity 3 of the PDC Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm Fluid Pressure Sensor/Switch: Customer Interest A/T - Engine Bucking/Surging at 5,300 Rpm NO: 18-19-98 GROUP: Driveability DATE: Apr. 10, 1998 SUBJECT: Vehicle Bucking During Wide Open Throttle Acceleration MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE JAN 16, 1998 MDH (0116XX) EQUIPPED WITH GASOLINE ENGINES AND A 42/44/46 OR 47RE TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may experience bucking during wide open throttle (WOT) acceleration. The bucking occurs at approximately 5300 RPM. This condition may be caused by reaching the high RPM fuel shut off rev limit before the transmission can shift into the next higher gear and is most likely to occur with high electrical loads (high beams on, heated back lite, heated seats, radio, HVAC blower on MAX etc.). During high current demands, the generator may emit electrical noise that can affect the transmission governor pressure sensor output. If this occurs, the transmission may not shift properly to the next higher gear under (WOT) acceleration conditions and therefore reach the fuel shut off rev limiter. This may be seen most often between the 2-3 shift but can also be experienced between the 1-2 shift. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. NOTE: ONLY PERFORM THE FOLLOWING PROCEDURE SAFELY ON A HIGHWAY OR ROAD OBEYING ALL POSTED SPEED LIMITS AND LAWS. Attempt to duplicate the condition by switching on all accessory loads and driving the vehicle with WOT accelerations through a shift sequence to see if the engine will reach the fuel shut off rev limiter before the 2-3 or 1-2 shift is made. If the bucking condition is experienced at approximately 5300 RPM before making the appropriate upshifts, switch off all electrical loads and repeat the procedure. Repeat the procedure with the electrical loads on and off a second time. If the bucking occurs with the electrical loads on and does not occur with the loads off, perform the Repair Procedure. PARTS REQUIRED: 1 56041403AA Sensor, Governor Pressure REPAIR PROCEDURE: This bulletin involves installing a newly designed governor pressure sensor. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm > Page 5081 1. Following the procedures in the applicable service manual, replace the governor pressure sensor with p/n 56041403AA (Figure 1). 2. Check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-96-06-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm Fluid Pressure Sensor/Switch: All Technical Service Bulletins A/T - Engine Bucking/Surging at 5,300 Rpm NO: 18-19-98 GROUP: Driveability DATE: Apr. 10, 1998 SUBJECT: Vehicle Bucking During Wide Open Throttle Acceleration MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT BEFORE JAN 16, 1998 MDH (0116XX) EQUIPPED WITH GASOLINE ENGINES AND A 42/44/46 OR 47RE TRANSMISSION. SYMPTOM/CONDITION: Some vehicles may experience bucking during wide open throttle (WOT) acceleration. The bucking occurs at approximately 5300 RPM. This condition may be caused by reaching the high RPM fuel shut off rev limit before the transmission can shift into the next higher gear and is most likely to occur with high electrical loads (high beams on, heated back lite, heated seats, radio, HVAC blower on MAX etc.). During high current demands, the generator may emit electrical noise that can affect the transmission governor pressure sensor output. If this occurs, the transmission may not shift properly to the next higher gear under (WOT) acceleration conditions and therefore reach the fuel shut off rev limiter. This may be seen most often between the 2-3 shift but can also be experienced between the 1-2 shift. DIAGNOSIS: Using the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. NOTE: ONLY PERFORM THE FOLLOWING PROCEDURE SAFELY ON A HIGHWAY OR ROAD OBEYING ALL POSTED SPEED LIMITS AND LAWS. Attempt to duplicate the condition by switching on all accessory loads and driving the vehicle with WOT accelerations through a shift sequence to see if the engine will reach the fuel shut off rev limiter before the 2-3 or 1-2 shift is made. If the bucking condition is experienced at approximately 5300 RPM before making the appropriate upshifts, switch off all electrical loads and repeat the procedure. Repeat the procedure with the electrical loads on and off a second time. If the bucking occurs with the electrical loads on and does not occur with the loads off, perform the Repair Procedure. PARTS REQUIRED: 1 56041403AA Sensor, Governor Pressure REPAIR PROCEDURE: This bulletin involves installing a newly designed governor pressure sensor. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pressure Sensor/Switch: > 18-19-98 > Apr > 98 > A/T - Engine Bucking/Surging at 5,300 Rpm > Page 5087 1. Following the procedures in the applicable service manual, replace the governor pressure sensor with p/n 56041403AA (Figure 1). 2. Check the throttle valve cable adjustment. Make appropriate adjustments, if necessary, following the applicable service manual procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 21-96-06-90 1.1 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Technical Service Bulletins > Page 5088 Fluid Pressure Sensor/Switch: Description and Operation NOTE: This input is used with 4-speed electronic transmissions only DESCRIPTION The transmission governor pressure sensor provides a signal proportional to the transmission governor pressure. OPERATION It provides feedback for control of the variable force solenoid, which regulates transmission governor pressure. CIRCUIT OPERATION The governor pressure sensor supplies the transmission pressure input to the Powertrain Control Module on circuit T25. Circuit T25 connects to cavity B29 of the PCM. Circuit K7 from cavity B31 of the PCM supplies 5 Volts to the sensor. The PCM provides ground for the governor pressure sensor on circuit K4. Circuit K4 connects to cavity A4 of the PCM. The governor pressure sensor is part of the transmission solenoid assembly. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Description and Operation > Switch Operation Overdrive Switch: Description and Operation Switch Operation The overdrive OFF (control) switch is located on the gearshift lever. The switch is a momentary contact device that signals the Powertrain Control Module (PCM) to toggle current status of the overdrive function. 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 Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Description and Operation > Switch Operation > Page 5093 Overdrive Switch: Description and Operation Overdrive Override Switch-PCM Input PURPOSE On vehicles equipped with an automatic transmission and overdrive, the powertrain control module (PCM) regulates the 3-4 overdrive up-shift and downshift through the overdrive solenoid. OPERATION This solenoid is located in the transmission. An overdrive/override push-button switch is located at the end of transmission shift lever. This solenoid is located in the transmission. An overdrive/override push-button switch is located at the end of the transmission shift lever. The overdrive/override push-button switch is normally open (overdrive allowed) when the lamp is not illuminated. It momentarily closes (overdrive not allowed) when the operator presses the switch and the lamp is illuminated. Overdrive will revert to ON (lamp off) each time the ignition switch in turned on. The transmission downshifts if the operator presses the override switch while in overdrive. CIRCUIT OPERATION Automatic transmission equipped vehicles may have an overdrive switch. The operator disables or enables overdrive when the switch is depressed. The overdrive switch consists of a switch connected to the Powertrain Control Module (PCM), an illumination lamp and an overdrive ON/OFF indicator lamp. If overdrive is currently enabled, it is disabled when the operator depresses the overdrive switch. Conversely, if the operator already disabled over-drive, it is enabled when the switch is depressed. Circuit T6 from the overdrive switch connects to cavity C13 of the PCM and provides the overdrive signal. The PCM turns the overdrive ON/OFF indicator lamp ON or OFF by providing a ground for the lamp on circuit T18. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5097 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. 4. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 5. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 6. Test continuity of new switch with 12V test lamp. 7. Connect switch wires and lower vehicle. 8. Top off transmission fluid level. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Sensor Mounting ................................................................................................................................. ..................................................... 27 Nm (20 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 5101 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 5102 Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Shaft Speed Sensor-PCM Input Transmission Speed Sensor: Description and Operation Output Shaft Speed Sensor-PCM Input This sensor generates a signal to the PCM relating to the speed of the transmission main drive shaft. NOTE: This input is used with 4-speed electronic transmissions only. CIRCUIT OPERATION Four Speed Automatic Transmission The output shaft speed sensor generates a signal indicating the speed of the transmission output shaft. Circuits T13 and T14 connect the sensor to the Powertrain Control Module (PCM). Circuit T13 connects to cavity B25 of the PCM. Circuit T14 connects to cavity B28. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Output Shaft Speed Sensor-PCM Input > Page 5105 Transmission Speed Sensor: Description and Operation Sensor Operation The speed sensor is located in the overdrive gear case. The sensor is positioned over the park gear and monitors transmission output shaft rotating speed. Speed sensor signals are triggered by the park gear lugs as they rotate past the sensor pickup face. Input signals from the sensor are sent to the transmission control module for processing. The vehicle speed sensor also serves as a backup for the transmission speed sensor. Signals from this sensor are shared with the powertrain control module. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > Page 5106 Transmission Speed Sensor: Service and Repair Removal Transmission Speed Sensor Removal Installation 1. Remove transmission speed sensor and O-ring seal from overdrive case. Installation 1. Install transmission speed sensor and O-ring seal in overdrive case. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations Governor Pressure Sensor, Transmission Temperature Sensor, Governor Pressure Solenoid, Governor The transmission temperature sensor is located in the transmission solenoid assembly in the valve body. The governor pressure sender and the transmission fluid temperature thermistor are separate sensors in the same component. This component is attached to the governor body in the solenoid assembly of the valve body. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission Temperature Sensor - Description and Operation Transmission Temperature Sensor/Switch: Description and Operation Transmission Temperature Sensor - Description and Operation Transmission fluid temperature readings are supplied to the transmission control module by the thermistor. The temperature readings are used to control engagement of the fourth gear overdrive clutch, the converter clutch, and governor pressure. Normal resistance value for the thermistor at room temperature is approximately 1000 ohms. The PCM prevents engagement of the converter clutch and overdrive clutch, when fluid temperature is below approximately 10 °C (50 °F). If fluid temperature exceeds 126 °C (260 °F), the PCM causes a 4-3 downshift and engage the converter clutch. Engagement is according to the third gear converter clutch engagement schedule. The overdrive OFF lamp in the instrument panel illuminates when the shift back to third occurs. The transmission will not allow fourth gear operation until fluid temperature decreases to approximately 110 °C (230 °F). The thermistor is part of the governor pressure sensor assembly and is immersed in transmission fluid at all times. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission Temperature Sensor - Description and Operation > Page 5112 Transmission Temperature Sensor/Switch: Description and Operation Transmission Temperature Sensor - PCM Input NOTE: This input is used in the shift operation for 4-speed electronic transmissions only. The temperature data is used for: torque converter clutch operation, overdrive shift, low temperature shift compensation, wide open throttle shift strategy and governor pressure transducer calibration. CIRCUIT OPERATION The transmission temperature sensor is located in the transmission solenoid assembly. The sensor is a variable resistor, as transmission temperature changes the resistance in the sensor changes. Circuit T34 connects from the Powertrain Control Module (PCM) to the sensor. Ground for the sensor is supplied on circuit K4. This circuit is the ground circuit for many of the components used in the fuel/ignition system. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > 4WD Switch > Component Information > Description and Operation 4WD Switch: Description and Operation CIRCUIT OPERATION Circuit F12 from fuse 11 in the junction block supplies voltage for the four-wheel drive indicator lamp. The ground path for the lamp is provided when the switch closes. Circuit G107 connects the lamp to the four-wheel drive switch. The switch connects to ground circuit Z1. From circuit G107, the Controller Antilock Brakes (CAB) senses when the four-wheel drive switch closes. Circuit Gl07 connects to the CAB, for wheel drive switch and the four-wheel drive indicator lamp. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Description and Operation ABS Light: Description and Operation The amber anti-lock warning lamp is controlled by the vehicle's "smart" instrument cluster. This cluster has direct control over the Anti-Lock Brake System (ABS) warning lamp. The cluster will periodically transmit a message over the Chrysler Collision Detection (CCD) bus relating to diagnostics and current lamp status for the ABS lamp. If the Controller Anti-Lock Brake (CAB) does not receive this message for a period of three seconds, it will assume that either the CCD bus or the instrument cluster is not operational and will turn on the red brake lamp in the event a fault is set. Likewise, the cluster will expect a periodic message from the CAB indicating whether the lamp should be turned on or off. In the event that no signal is received from the CAB for a certain number of ignition cycles, the cluster will turn on the ABS warning lamp. The lamp detects system related problems and indicates the start of diagnostic action. SYSTEM OPERATION The Anti-Lock Brake System (ABS) lamp gives an indication when the ABS system is faulty or inoperative. The lamp is controlled by the instrument cluster circuitry based upon messages received from the Controller Anti-lock Brake (CAB) on the Chrysler Collision Detection (CCD) data bus. The lamp is turned on by the CAB for about two seconds when the ignition switch is turned to the On position as a bulb test. After the bulb test, the CAB turns the lamp on or off based upon the results of the ABS self-tests. The CAB continually monitors the ABS circuits and sensors to decide whether the system is in good operating condition. The CAB then sends the proper message to the instrument cluster on the CCD data bus to turn the lamp on or off. If the CAB turns the lamp on after the bulb test, it indicates that the CAB has detected a system malfunction and/or that the ABS system has become inoperative. If only the amber ABS lamp is illuminated, and the red brake warning lamp remains off, the base brake system will operate normally Each time the instrument cluster circuitry receives a lamp-on message from the CAB, it will light the lamp for the duration of the ABS malfunction. The CAB will also flash this lamp during the diagnostic mode, unless a hard fault is present. If a hard fault is present, the ABS lamp will illuminate without flashing. Rear Wheel Anti-Lock Brake System Lamp The Rear Wheel Anti-Lock (RWAL) brake system lamp gives an indication when the RWAL system is faulty or inoperative. The lamp is controlled by a hard-wired input to the instrument cluster from the RWAL Controller Anti-lock Brake (CAB). The lamp is turned on by the CAB for about four seconds when the ignition switch is turned to the On position as a bulb test. After the bulb test, the CAB turns the lamp on or off based upon the results of the RWAL system self-tests. The CAB continually monitors the RWAL system circuits and sensors to decide whether the system is in good operating condition. The CAB then switches the ground circuit to the lamp in the instrument cluster to turn the lamp on or off. If the CAB turns the lamp on after the bulb test, it indicates that the CAB has detected an RWAL system malfunction and/or that the RWAL system has become inoperative. If only the amber RWAL lamp is illuminated, and the red brake warning lamp remains off, the base brake system will operate normally. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Description and Operation > Page 5121 ABS Light: Testing and Inspection The diagnosis found here addresses an inoperative Anti-lock Brake System (ABS) lamp condition. If the ABS lamp stays on with the ignition switch in the On position, or comes on and stays on while driving, refer to Brakes and Traction Control/Brakes/Anti-Lock Brakes for diagnosis. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. If the ABS lamp fails to light when the ignition switch is turned to the On position, replace the ABS lamp bulb with a known good unit. If the ABS lamp still fails to operate, diagnosis of the ABS system and the Chrysler Collision Detection (CCD) data bus should be performed with a DRB scan tool as described in the proper Diagnostic Procedures. For diagnosis of the ABS lamp and the instrument cluster circuitry, see Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Instrument Cluster. Rear Wheel Anti-Lock Brake System Lamp The diagnosis found here addresses an inoperative Rear Wheel Anti-Lock (RWAL) brake system lamp condition. If the RWAL lamp stays on with the ignition switch in the On position, or comes on and stays on while driving, refer to Brakes and Traction Control/Brakes/Anti-Lock Brakes for diagnosis. If no RWAL system problem is found, the following procedure will help locate a short or open in the RWAL lamp circuit. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check the fuse in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Turn the ignition switch to the On position. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the ignition switch as required. 3. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Remove the instrument cluster bezel and the cluster as described. Unplug the wire harness connector from the RWAL Controller Anti-lock Brake (CAB). Check for continuity between the RWAL indicator control circuit cavity of the CAB wire harness connector and a good ground. There should be no continuity. If OK, go to Step 4. If not OK, repair the short circuit as required. 4. Check for continuity between the HWAL indicator control circuit cavities of the CAB wire harness connector and the cluster wire harness connector. There should be continuity. If OK, replace the faulty bulb. If not OK, repair the open circuit as required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Main Relay > Component Information > Locations ABS Main Relay: Locations Anti-Lock Brake System (ABS) relays are located in the power distribution box in the engine compartment. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Main Relay > Component Information > Locations > Page 5125 ABS Main Relay: Description and Operation The Anti-Lock Brake System (ABS) has two relays, one for the system and one for the pump motor. The system relay is used for the solenoid valves and Controller Anti-Lock Brake (CAB). The system relay is connected to the CAB at the power control relay terminal. The pump motor relay is used for the pump motor only. The pump motor relay starts/stops the pump motor when signaled by the CAB. The relays are located in the power distribution box in the engine compartment. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid Accumulator > Component Information > Description and Operation Brake Fluid Accumulator: Description and Operation The accumulator is part of the Hydraulic Control Unit (HCU), which also consists of a valve body, pump body and pump motor. The pump, motor and accumulators are combined into an assembly attached to the valve body. The accumulators store the extra fluid released to the system for anti-lock mode operation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic Connector - ABS > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic Connector - ABS > Component Information > Locations > Page 5132 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic Connector - ABS > Component Information > Locations > Page 5133 Diagnostic Connector - ABS: Description and Operation CIRCUIT OPERATION Rear Wheel Circuit B112 from the Controller Antilock Brakes (CAB) and circuit B113 from the rear wheel speed sensor connect to the data link connector. All Wheel The DRB scan tool connects to the data link connector. Circuits D11 and D12 from the Controller, Antilock Brakes (CAB) connect to the data link connector. Circuit D12 connects to cavity 10 of the CAB. The CAB transmits data to the DRB scan tool on circuit D12. The DRB scan tool receives data from the CAB on circuit D11. Circuit D11 connects to cavity 11 of the CAB. Circuit A4 from fuse F in the Power Distribution Center (PDC) powers circuit M1 through PDC fuse 2. Circuit M1 supplies battery voltage to the data link connector. Circuit Z12 provides ground for the data link connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 5137 CAB Connectors Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Description and Operation > With Four Wheel Antilock Brakes Electronic Brake Control Module: Description and Operation With Four Wheel Antilock Brakes GENERAL INFORMATION The Controller Anti-Lock Brake (CAB) module is mounted on the top of the Hydraulic Control Unit (HCU). It operates the Anti-Lock Brake System (ABS) and is separate from other vehicle electrical circuits. CAB voltage comes through the ignition switch in the RUN position. The CAB contains dual microprocessors. A logic block in each microprocessor receives identical sensor signals. These signals are processed and compared simultaneously. OPERATION The module is used to monitor wheel speeds and modulate (control) hydraulic pressure in each brake channel. The modulated hydraulic pressure is used to prevent wheel lockup during braking. Brake switch input is monitored to determine whether or not to prepare for possible anti-lock braking. Wheel speed sensors are monitored to determine when a wheel is beginning to lock up. The CAB will operate the valves in the HCU to control braking pressure during anti-lock braking. SELF-DIAGNOSTIC FEATURES 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 Diagnostic Readout Box (DRB) scan tool. ABS faults remain in memory until cleared, or until after the vehicle is started approximately 50 times. Stored faults are not erased if the battery is disconnected. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Description and Operation > With Four Wheel Antilock Brakes > Page 5140 Electronic Brake Control Module: Description and Operation With Rear Wheel Antilock Brakes GENERAL INFORMATION The Controller Anti-Lock Brake (CAB) is a microprocessor which monitors and controls the Anti-Lock Brake System (ABS) operation. It has a 14 terminal connector to deliver power and ground and to connect all inputs and outputs associated with the system. The CAB primary functions are: ^ Detect wheel locking tendencies. ^ Control the application of brake fluid pressure to the rear brakes during ABS braking. ^ Monitor the Rear Wheel Anti-Lock (RWAL) brake system for proper operation. ^ Perform self-check diagnostics. The CAB continuously monitors the speed of the differential ring gear by monitoring signals generated by the rear wheel speed sensor. The CAB determines a wheel locking tendency when it recognizes the ring gear decelerating too rapidly. When a wheel-locking tendency is detected, the CAB energizes the isolation solenoid in the RWAL valve. When the isolation solenoid is energized, hydraulic pressure cannot be increased to the rear wheel cylinders. If the rear wheel speed sensor still indicate that the ring gear is decelerating too rapidly, the CAB then energizes the dump solenoid to reduce pressure at the rear wheel cylinders. The CAB continues this action until the wheel-locking tendency no longer exists. ON-BOARD DIAGNOSTICS When a fault is detected, the CAB will generate and store diagnostic trouble codes. Only one code can be stored at any one time. If the CAB senses a fault in any one of its monitored circuits, it will illuminate the red brake warning and ABS warning lamps. It will then generate a Diagnostic Trouble Code (DTC) and store it in memory. In general, the diagnostic trouble code will remain in memory when the ignition key has been turned Off. The exception to this is Diagnostic Trouble Codes 9 and 11, which are erased any time the key has been turned to the Off position. Also, Diagnostic Trouble Code 11 will be removed from memory when the ignition switch is in the Run or Accessory positions if the malfunction has been eliminated. If the malfunction remains, Diagnostic Trouble Codes 9 and 11 will be reset on the next ignition key cycle to On. INPUTS The CAB monitors the following inputs to determine when a wheel locking tendency may exist: ^ Rear Wheel Speed Sensor ^ Brake Lamp Switch ^ Brake Warning Lamp Switch ^ Reset Switch ^ 4WD Switch (If equipped) OUTPUTS The CAB controls the following outputs for anti-lock braking and brake warning information: ^ RWAL Valve ^ ABS Warning Lamp ^ Brake Warning Lamp POWER SUPPLY & GROUND Ignition voltage is provided to the CAB through connector pin 3 and is protected by a 20 amp fuse. Ignition voltage is supplied when the ignition switch is in the Run or Accessory positions. The CAB requires ignition voltage to be able to operate the anti-lock brakes. Battery voltage is provided to the CAB through pin 9 and is protected by a 20 amp fuse. This circuit supplies power to the memory cells so that the CAB can retain diagnostic information. Except for Diagnostic Trouble Codes 9 and 11, the CAB stores DTCs in the battery fed volatile memory. Volatile memories only retain information as long as power is supplied to the memory. If a DTC is stored in the battery fed volatile memory, the DTC can Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Description and Operation > With Four Wheel Antilock Brakes > Page 5141 be cleared from the memory by disconnecting the battery supply to the CAB. Diagnostic Trouble Codes 9 and 11 are also in a volatile memory but their memories are fed with ignition voltage. A ground is provided to the CAB through pin 12 of the 14-way connector. It is required by the CAB to be able to operate any of its circuits. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Four Wheel Antilock Brake System Electronic Brake Control Module: Service and Repair Four Wheel Antilock Brake System Pump Motor Connector REMOVAL 1. Disconnect harness connector from the Controller Anti-Lock Brake (CAB). 2. Remove screws attaching CAB to the Hydraulic Control Unit (HCU). 3. Lift the CAB up off the HCU and disconnect the pump motor connector. 4. Remove the CAB. INSTALLATION 1. Position controller over the HCU and connect the pump motor harness. NOTE: Ensure the CAB seal is in position before installation. 2. Place the CAB onto the HCU and install the mounting screws. 3. Connect the harness to the CAB. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Four Wheel Antilock Brake System > Page 5144 Electronic Brake Control Module: Service and Repair Rear Wheel Antilock Brake System Trim Panel RWAL Controller REMOVAL 1. Remove the trim panel, Data Link Connector (DLC) and knee blocker. 2. Remove bolts attaching module to the left side of the steering column support. 3. Disconnect wiring and remove module from vehicle. INSTALLATION 1. Connect wiring to control module. 2. Position module on steering column support. 3. Install control module mounting bolts. 4. Install the knee blocker, DLC and trim panel. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Specifications Hydraulic Control Unit: Specifications TIGHTENING SPECIFICATIONS Brake Line Fittings ............................................................................................................................................................. 16-23 Nm (140-200 inch lbs.) Mounting Nuts ...................................................................................... ........................................................................................... 12 Nm (102 inch lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Description and Operation > Hydraulic Control Unit (HCU) Hydraulic Control Unit: Description and Operation Hydraulic Control Unit (HCU) GENERAL INFORMATION The Hydraulic Control Unit (HCU) consists of a valve body, pump body, accumulator and pump motor. The pump, motor, and accumulators are combined into an assembly attached to the valve body. The accumulators store the extra fluid released to the system for Anti-Lock Brake System (ABS) mode operation. The pump provides the fluid volume needed and is operated by a DC type motor. The motor is controlled by the Controller Anti-Lock Brake (CAB). The valve body contains the solenoid valves. The valves modulate brake pressure during anti-lock braking and are controlled by the CAB. The HCU provides three channel pressure control to the front and rear brakes. One channel controls the rear wheel brakes in tandem. The two remaining channels control the front wheel brakes individually. During anti-lock braking, the solenoid valves are opened and closed as needed. The valves are not static. They are cycled rapidly and continuously to modulate pressure and control wheel slip and deceleration. During normal braking, the HCU solenoid valves and pump are not activated. The master cylinder and power booster operate the same as a vehicle without ABS. OPERATION When the brakes are applied, fluid is forced from the master cylinder outlet ports to the HCU inlet ports. This pressure is transmitted through three normally open isolation valves inside the HCU, then through the outlet ports of the HCU to the wheels. If the CAB senses that a wheel is about to lock, based on wheel speed sensor data, it pulls the normally open isolation valve closed for that circuit. This prevents any more fluid from entering that circuit. The CAB continues to look at the sensor signal to determine if the wheel is still decelerating. If deceleration is still taking place, the normally closed dump valve for that circuit is opened. This dumps any pressure that is trapped between the normally open valve and the brake back into an accumulator. Once the affected circuit comes back up to speed, the CAB returns the valves to their normal condition allowing the affected brake to be reapplied. The pump and accumulators are used to provide rapid response during the reapply sequence and to minimize pedal feedback. During anti-lock braking, solenoid valve pressure modulation occurs in three stages: pressure increase, pressure hold, and pressure decrease. The valves are all contained in the valve body portion of the HCU. PRESSURE MODULATION STAGES Pressure Decrease The outlet valve is opened and the inlet valve is closed during the pressure decrease cycle. A pressure decrease cycle is initiated when speed sensor signals indicate high wheel slip at one or more wheels. At this point, the CAB opens the outlet valve, which also opens the return circuit to the accumulators. Fluid pressure is allowed to bleed off (decrease) as needed to prevent wheel lock. Once the period of high wheel slip has ended, the CAB closes the outlet valve and begins a pressure increase or hold cycle as needed. Pressure Hold Both solenoid valves are closed in the pressure hold cycle. Fluid apply pressure in the control channel is maintained at a constant rate. The CAB maintains the hold cycle until sensor inputs indicate a pressure change is necessary. Pressure Increase The inlet valve is open and the outlet valve is closed during the pressure increase cycle. The pressure increase cycle is used to counteract unequal wheel speeds. This cycle controls re-application of fluid apply pressure due to changing road surfaces or wheel speed. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Description and Operation > Hydraulic Control Unit (HCU) > Page 5150 Hydraulic Control Unit: Description and Operation Rear Antilock Valve Circuit Operation NORMAL OPERATION CYCLE If the Controller Anti-Lock Brake (CAB) senses that rear wheel speed deceleration is excessive, it will energize an isolation solenoid by providing battery voltage to the solenoid. This prevents a further increase of driver induced brake pressure to the rear wheels. If this initial action is not enough to prevent rear wheel lock-up, the CAB will momentarily energize a dump solenoid (the CAB energizes the dump solenoid by providing battery voltage to the solenoid). This opens the dump valve to vent a small amount of isolated rear brake pressure to an accumulator. The action of fluid moving to the accumulator reduces the isolated brake pressure at the wheel cylinders. The dump (pressure venting) cycle is limited to very short time periods (milliseconds). The CAB will pulse the dump valve until rear wheel deceleration matches the vehicle deceleration rate or the desired slip rate programmed into the CAB. The system will switch to normal braking once wheel locking tendencies are no longer present. A predetermined maximum number of consecutive dump cycles can be performed during any one anti-lock stop. ABNORMAL ACTIVITY If excessive dump cycles occur, a Diagnostic Trouble Code (DTC) will be set and stored in the CAB memory. If, during an anti-lock stop, the driver releases the brake pedal, the reset switch contacts will open. This signal to the CAB is an indication that pressure has equalized across the Rear Wheel Anti-Lock (RWAL) valve. The CAB will then reset the dump cycle counter in anticipation of the next anti-lock stop. Additionally, any fluid stored in the accumulator will force its way past the dump valve, back into the hydraulic circuit and return to the master cylinder. A fuse inside the CAB provides a fail-safe device which prevents unwanted control over the isolation and dump solenoids. The fuse is in series with the isolation and dump solenoids output circuits. If the internal fuse is open, the CAB cannot provide voltage to energize either solenoid and anti-lock stops are prevented. If the fuse is open, the braking system will operate normally but without anti-lock control over rear brake pressure. CIRCUIT OPERATION The rear wheel anti-lock valve (RWAL) contains an isolation solenoid, a dump solenoid and a reset switch. Each is powered by the Controller, Antilock Brakes (CAB) on separate circuits. Circuit B108 from the CAB feeds the dump solenoid. The isolation solenoid is powered on circuit B101 from the CAB. Circuit Z6 provides ground for both solenoids. Circuit B111 from the CAB connects to the reset switch. The case grounded RWAL valve provides ground for the reset switch. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Description and Operation > Page 5151 Hydraulic Control Unit: Service and Repair HCU Brake Lines Hydraulic Control Unit (HCU) Mounting NOTE: The Hydraulic Control Unit (HCU) is serviced as an assembly. Neither the valve body or pump/motor are repairable components. The complete assembly must be replaced if diagnosis indicates a fault. REMOVAL 1. Disconnect battery negative cable. 2. Disconnect brake lines at front anti-lock valve. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Description and Operation > Page 5152 3. Disconnect harness from the Controller Anti-Lock Brake (CAB). 4. Remove mounting nuts attaching the assembly to bracket. 5. Lift the assembly upward off studs and remove assembly. 6. Remove the bracket from the HCU. 7. Remove the CAB mounting screws and disconnect the pump motor connector 8. Lift the CAB off the HCU. INSTALLATION 1. Install the CAB on the HCU. 2. Install the bracket on the HCU. 3. Install the assembly on the mounting studs. 4. Install and tighten the mounting nuts to 12 Nm (102 inch lbs.). 5. Connect the CAB harness. 6. Connect the brake lines to the HCU. Tighten brake line fittings to 16-23 Nm (140-200 inch lbs.). 7. Connect battery. 8. Bleed brake system as outlined in ABS Service and Repair. See: Brake Bleeding/Service and Repair/Antilock Brake System Bleeding Procedures/W/ Four Wheel Antilock Brakes Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions Wheel Speed Sensor: Technical Service Bulletins ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions NUMBER: 26-10-99I GROUP: Miscellaneous DATE: October, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1993-1997 Kelsey Hayes EBC-5H, EBC 310 ABS Diagnostic Manual - Publication Number 81-699-96026 DESCRIPTION OF CHANGES Revisions to the ABS test procedures for wheel speed sensors Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5157 39 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5158 43 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5159 45 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5160 47 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5161 51 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5162 55 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5163 57 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5164 59 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5165 63 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5166 67 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5167 69 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5168 71 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5169 173 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5170 177 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5171 179 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5172 181 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5173 187 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5174 191 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5175 193 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5176 195 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5177 201 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5178 205 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5179 207 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5180 209 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5181 256 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications > Electrical Specifications Wheel Speed Sensor: Electrical Specifications Sensor Coil Resistance 1000 to 2500 ohms Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications > Electrical Specifications > Page 5184 Wheel Speed Sensor: Mechanical Specifications Front Sensor Mounting Bolt 160-220 in.lb Rear Sensor Mounting Bolt 170-230 in.lb Wheel Speed Sensor (WSS) Clearance 0.005-0.050 in WSS Attaching Bolt 170-230 in.lb Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Component Locations Wheel Speed Sensor: Component Locations Tone Wheels Toothed Tone Wheel Ring For Front Wheel Speed Sensor Rear Tone Wheel Location FRONT The toothed tone wheel ring for the front speed sensor is located on the hub/bearing. It is not a serviceable component. To replace the ring, the hub/bearing assembly must be replaced. Refer Steering and Suspension for the service procedure. REAR The toothed exciter (tone wheel) ring is press-fitted onto the differential carrier next to the final drive ring gear in the differential case. If the ring is damaged, the differential assembly must be serviced as outlined in Transmission and Drivetrain. Front Wheel Speed Sensor (WSS) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 5187 RWAL Wheel Speed Sensor Rear Wheel Speed Sensor (WSS) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 5188 Wheel Speed Sensor: Connector Locations Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Page 5189 Wheel Speed Sensor: Diagrams Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Description and Operation > Circuit Operation Wheel Speed Sensor: Description and Operation Circuit Operation CIRCUIT OPERATION The all wheel Antilock Brake System (ABS) uses three wheel speed sensors; a single sensor for both rear wheels and individual sensors for the front wheels. The single sensor used for the rear wheels mounts on the top of the rear axle differential housing. Each sensor converts wheel speed into an electrical signal that is transmitted to the Controller Antilock Brakes (CAB). A pair of twisted wires connect to each sensor and provide signals to the CAB. Circuits B6 and B7 provide signals to the CAB from the right front wheel speed sensor. Circuit B6, which provides the LOW signal, connects to cavity 4 of the CAB. Circuit B7 connects to cavity 9 of the CAB and provides the HIGH signal. Circuits B8 and B9 provide signals to the CAB from the left front wheel speed sensor. Circuit B8, which provides the LOW signal, connects to cavity 3 of the CAB. Circuit B9 connects to cavity 8 and provides the HIGH signal. Circuit B114 connects to cavity 10 of the CAB and provides the rear wheel speed sensor LOW input. While circuit B113 provides the HIGH input to cavity 5 of the CAB. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Description and Operation > Circuit Operation > Page 5192 Wheel Speed Sensor: Description and Operation Four Wheel Antilock Brakes Front Wheel Speed Sensor (WSS) Rear Wheel Speed Sensor (WSS) The Anti-Lock Brake System (ABS) uses three wheel speed sensors. A sensor is mounted to each front steering knuckles. The third sensor is mounted on top of the rear axle differential housing. The sensor is a magnet coil that is mounted over a tone wheel front/exciter ring rear with an air gap between them. The sensors measure the wheel speed by monitoring the rotation of the front tone wheels and rear exciter ring. As the teeth of the wheels and ring move through the magnetic field of the sensor, an AC voltage signal is generated. This signal frequency increases or decreases proportionally to the speed of the wheel. The Controller Anti-Lock Brake (CAB) monitors these signals for changes in wheel deceleration. If the CAB detects that a wheel or wheels are suddenly decelerating at a predetermined rate, the CAB will activate the ABS. Each wheel speed sensor's coil will have approximately 1000 to 2500 ohms of resistance. The CAB will disable anti-lock control, complete the anti-lock warning light circuit, and store trouble codes if it detects one of the following problems 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 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Description and Operation > Circuit Operation > Page 5193 Wheel Speed Sensor: Description and Operation Rear Wheel Antilock Brakes RWAL Wheel Speed Sensor The rear Wheel Speed Sensor (WSS) is mounted in the rear differential housing. The WSS consists of a magnet surrounded by windings from a single strand of wire. The sensor sends a small AC signal to the Controller Anti-Lock Brake (CAB). This signal is generated by magnetic induction. The magnetic induction is created when a toothed ring (exciter ring or tone wheel) passes the stationary magnetic WSS. Toothed Exciter Ring The toothed ring is press-fitted onto the differential carrier next to the final drive ring gear. When the ring gear is rotated, the exciter ring passes the tip of the WSS. As the exciter ring passes the tip of the WSS, the magnetic lines of force of the sensor are cut, causing the magnetic field to be moved across the sensor's windings. This, in turn causes current to flow through the WSS circuit. Wheel Speed Sensor (WSS) Operation 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 sine wave) is Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Description and Operation > Circuit Operation > Page 5194 interpreted by the CAB. It then compares the frequency of the sine wave 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 rotates, the stronger the signal will be. - Distance between the exciter ring teeth and WSS; the closer the WSS is to the exciter ring, the stronger the signal will be. The 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 to 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 left of the steering column and attached to the lower portion of the instrument panel. Data Link Connector (DLC) The rolls test terminal is spliced to the WSS circuit. The vehicle is then driven on a set of rollers and the WSS output is monitored for proper operation. CIRCUIT OPERATION The rear wheel speed sensor is mounted on the top of the rear axle differential. The sensor converts wheel speed into an electrical signal that is transmitted to the Controller, Antilock Brakes (CAB). Circuits B113 and B114, a pair of twisted wires, connect to the sensor and provide signals to the CAB. Circuit B113 connects to cavity 14 of the CAB. Circuit B114 connects to cavity 13 of the CAB. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Description and Operation > Circuit Operation > Page 5195 Wheel Speed Sensor: Description and Operation Tone Wheels Toothed Tone Wheel Ring For Front Wheel Speed Sensor Rear Tone Wheel Location FRONT The toothed tone wheel ring for the front speed sensor is located on the hub/bearing. It is not a serviceable component. To replace the ring, the hub/bearing assembly must be replaced. Refer Steering and Suspension for the service procedure. REAR The toothed exciter (tone wheel) ring is press-fitted onto the differential carrier next to the final drive ring gear in the differential case. If the ring is damaged, the differential assembly must be serviced as outlined in Transmission and Drivetrain. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Description and Operation > Page 5196 Wheel Speed Sensor: Testing and Inspection RWAL Speed Sensor Air Gap 1. Remove sensor from differential. 2. Measure and record the distance from the underside of the sensor flange to the end of the sensor pole piece. This distance represents dimension B. 3. Measure and record the distance between the sensor mounting surface of differential case and teeth at top of the exciter ring. This distance represents dimension A. 4. Subtract dimension B from dimension A to determine the Rear Wheel Anti-Lock (RWAL) speed sensor air gap. The gap should be a minimum of 0.127 mm (0.005 inch) and a maximum of 1.27 mm (0.050 inch). 5. If air gap is not within stated limits, proceed as follows: a. Dimension B distance should be 27.18-27.43 mm (1.070-1.080 inch). If the RWAL speed sensor is not within these limits, replace the RWAL speed sensor. b. Dimension A distance should be 27.56-28.45 mm (1.085-1.120 inch). If dimension A is not within the specification, replace the exciter ring or repair the differential. c. If dimension A and dimension B exceeds their specifications, replace both the RWAL speed sensor and exciter ring. Also, repair the differential if necessary. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Description and Operation > Page 5197 Wheel Speed Sensor: Adjustments The Wheel Speed Sensor (WSS) is not adjustable. A clearance specification of 0.005 to 0.050 inch has been established for manufacturing tolerances. If the clearance is not within these specifications, the WSS or other components may be damaged. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement Front Front Wheel Speed Sensor Mounting CAUTION: Special bolts are used to attach the front sensor. The bolts have a special shoulder, thread length and surface treatment. If the original bolts must be replaced, use only a factory replacement part. Do not use substitute bolts under any circumstances. REMOVAL 1. Raise and support vehicle. 2. Remove bolt attaching sensor to the steering knuckle. 3. Remove clamps securing sensor wire to control arm and inner fender panel. 4. In engine compartment, disconnect sensor wire from harness and remove sensor. INSTALLATION 1. Position sensor in the knuckle and install sensor attaching bolts. Tighten bolts to 18-25 Nm (160-220 inch lbs.). 2. Secure sensor wire retaining clamps to control arm and fender panel. 3. In engine compartment, connect sensor wire to harness connector. Make sure wire is routed away from hot or rotating underhood components. 4. Turn steering wheel back and forth to verify that wire is clear of steering and suspension components. 5. Remove supports and lower vehicle. Rear Rear Speed Sensor Mounting REMOVAL Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 5200 1. Raise vehicle on hoist. 2. Remove bolt securing sensor and shield to differential housing. 3. Remove sensor and shield from differential housing. 4. Disconnect sensor wire harness and remove sensor. INSTALLATION 1. Connect harness to sensor. Be sure seal is securely in place between sensor and wiring connector. 2. Install O-ring on sensor (if removed). 3. Insert sensor in differential housing. 4. Install sensor shield. 5. Install and torque sensor attaching bolt to 19-29 N.m (170-230 in. lbs.). 6. Lower vehicle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 5201 Wheel Speed Sensor: Service and Repair Tone Wheel Replacement Rear Tone Wheel The toothed exciter ring is press-fitted onto the differential carrier next to the final drive ring gear in the differential case. If the ring is damaged, refer to Transmission and Drivetrain for service procedures. With Four Wheel Antilock Brakes Toothed Tone Wheel Ring For Front Wheel Speed Sensor Rear Tone Wheel Location FRONT The toothed tone wheel ring for the front speed sensor is located on the hub/bearing. It is not a serviceable component. To replace the ring, the hub/bearing assembly must be replaced. Refer Steering and Suspension for the service procedure. REAR The toothed exciter (tone wheel) ring is press-fitted onto the differential carrier next to the final drive ring gear in the differential case. If the ring is damaged, the differential assembly must be serviced as outlined in Transmission and Drivetrain. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Bleeding Procedures Brake Bleeding: Service and Repair Antilock Brake System Bleeding Procedures W/ Four Wheel Antilock Brakes Anti-Lock Brake System (ABS) bleeding requires conventional bleeding methods plus use of the Diagnostic Readout Box (DRB) scan tool. The procedure involves performing a base brake bleeding, followed by use of the scan tool to cycle and bleed the Hydraulic Control Unit (HCU) pump and solenoids. A second base brake bleeding procedure is then required to remove any air remaining in the system. 1. Perform base brake bleeding procedure. See: 2. Connect scan tool to the Data Link Connector (DLC). 3. Select ANTILOCK BRAKES, followed by MISCELLANEOUS, then ABS BRAKES. Follow the instructions displayed. When scan tool displays TEST COMPLETE, disconnect scan tool and proceed. 4. Perform base brake bleeding a second time. 5. Top off master cylinder fluid level and verify proper brake operation before moving vehicle. W/ Rear Wheel Antilock Brakes Rear Wheel Anti-Lock (RWAL) brake bleeding can be performed manually, or with vacuum/pressure equipment. Bleed only one brake component at a time. Recommended bleed sequence is: 1. Master Cylinder 2. Combination Valve 3. Rear Anti-Lock Valve 4. Left Rear Wheel 5. Right Rear Wheel 6. Right Front Wheel 7. Left Front Wheel Use Mopar DOT 3 brake fluid, or an equivalent meeting SAE J1703-F and DOT 3 standards, to fill and bleed the system. Use a bleed hose at each caliper/cylinder bleed screw. Attach one end of the hose to the bleed screw and insert the opposite end in glass container partially filled with brake fluid. A glass container makes it easier to see air bubbles as they exit the bleed hose. Be sure the end of the bleed hose remains immersed in fluid. This prevents air from being drawn back into the system. Do not allow the master cylinder to run out of fluid when bleeding the brakes. An empty cylinder will allow air to be drawn back into the system. Check fluid level frequently during bleeding operations. Be sure to tighten each brake line fitting, or bleed screw once bleeding is completed. Loose fittings and bleed screws allow air to enter the system. Vacuum Bleeding If vacuum bleeding equipment is being used, it is not necessary to hold the front brake metering valve open. Simply bleed the brakes following the bleed equipment manufacturer's instructions. Pressure Bleeding If pressure bleeding equipment will be used, the front brake metering valve will have to be held open to bleed the front brakes. The valve stem is located in the forward end of the combination valve. The stem must either be pressed inward, or held outward slightly. a spring clip tool or helper is needed to hold the valve stem in position. Follow the manufacturer's instructions carefully when using pressure equipment. Do not exceed the tank manufacturer's pressure recommendations. Generally, a tank pressure of 15-20 psi is more than sufficient for bleeding purposes. Fill the bleeder tank with recommended fluid and purge air from the tank lines before bleeding. NOTE: ^ Do not pressure bleed without a proper master cylinder adapter. The wrong adapter can lead to leakage, or drawing air back into the system. ^ Make sure the front brake metering valve in the combination valve is held open. A spring clip tool is best for securing the valve stem in an open position. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Bleeding Procedures > Page 5206 Brake Bleeding: Service and Repair Base Brake System Bleeding BASE BRAKE SYSTEM BLEEDING NOTE: The following procedure describes a manual bleed of the base brake system. Additional steps may be required for Anti-Lock Brake System (ABS) components. CAUTION: - Use Mopar brake fluid or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. - Do not pump the brake pedal at any time while bleeding. Air in the system will be compressed into small bubbles that are distributed throughout the hydraulic system. This will make additional bleeding operations necessary. - Do not allow the master cylinder to run out of fluid during bleed operations. An empty cylinder will allow additional air to be drawn into the system. Check the cylinder fluid level frequently and add fluid as needed. NOTE: The brakes should be bled in sequence: First, bleed the right rear wheel, then the left rear wheel. Next, move to the front brakes and bleed the right front wheel and, finally, the left front wheel. 1. Remove reservoir filler caps and fill reservoir with brake fluid. 2. If calipers or wheel cylinders were overhauled, open all caliper and wheel cylinder bleed screws. Then close each bleed screw as fluid starts to drip from it. Top off master cylinder reservoir once more before proceeding. 3. Attach one end of bleed hose to bleed screw and insert opposite end in glass container partially filled with brake fluid. Be sure end of bleed hose is immersed in fluid. 4. Open up bleeder, then have a helper press down the brake pedal. Once the pedal is down close the bleeder. Repeat bleeding until fluid stream is clear and free of bubbles, then move to the next wheel. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications Brake Pedal Assy: Specifications TIGHTENING SPECIFICATIONS Brake Pedal Shaft Nut ......................................................................................................................... .......................................................... 30 ft. lbs. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications > Page 5210 Brake Pedal Assy: Description and Operation Pedal Mounting A suspended type brake pedal is used. The pedal is attached to the pedal support bracket with a pivot bolt and bushings. The booster push rod is attached to the pedal with a clip. The pedal, bushings, pivot pin and support bracket are all serviceable components. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications > Page 5211 Brake Pedal Assy: Service and Repair Pedal Mounting REMOVAL 1. Remove stop lamp switch as follows: a. Disconnect switch harness. b. Press and hold brake pedal in applied position. c. Rotate switch counterclockwise about 30 degrees to align switch lock tab with notch in bracket. d. Pull switch rearward out of mounting bracket and release brake pedal. 2. Remove clip securing booster push rod to brake pedal. 3. Remove pedal pivot pin C-clip and slide pin out of support bracket and pedal. 4. Remove pedal and bushings. INSTALLATION 1. Replace bushings if worn or damaged. 2. Lubricate pedal bushings and pivot pin with Mopar multi mileage grease, Lubriplate or a silicone grease. 3. Install bushings in pedal and position pedal in support. 4. Insert pivot pin through support and pedal bushings and install C-clip. 5. Install booster push rod on brake pedal and install push rod retainer clip. 6. Install stop lamp switch as follows: a. Pull switch plunger all the way out to fully extended position. b. Push switch plunger inward 4 detent positions (or clicks). This is required preset position for switch installation. Plunger will extend approximately 0.55 inch out of housing at this setting. c. Connect harness wires to switch. d. Press and hold brake pedal down. e. Install switch. Align tab on switch with notch in switch bracket. Then insert switch in bracket and turn it clockwise about 30 degrees to lock it in place. f. Release brake pedal, then lightly pull pedal fully rearward. Pedal will adjust switch plunger to correct position as pedal is moved to rear. CAUTION: Do not use excessive force to move the pedal rearward for switch adjustment. Excessive force will damage the switch. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Technical Service Bulletins > Brakes - Teves Mark IV/Teves Mark 20 ABS Revisions Brake Warning Indicator: Technical Service Bulletins Brakes - Teves Mark IV/Teves Mark 20 ABS Revisions NUMBER: 26-12-97F GROUP: Miscellaneous DATE: December, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997-1998 Teves Mark IV, Teves Mark 20 ABS Diagnostic Manual - Publication Number 81-699-97012 DESCRIPTION OF CHANGES Revisions to the ABS warning light procedure Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Technical Service Bulletins > Brakes - Teves Mark IV/Teves Mark 20 ABS Revisions > Page 5216 244 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Technical Service Bulletins > Brakes - Teves Mark IV/Teves Mark 20 ABS Revisions > Page 5217 245 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Technical Service Bulletins > Page 5218 Brake Warning Indicator: Description and Operation ANTI-LOCK BRAKE SYSTEM (ABS) WARNING INDICATORS Rear Wheel Anti-Lock (RWAL) Brake System In the RWAL brake system, as in other brake systems, the brake warning lamp (red) is used to alert the driver of a hydraulic fault or that the parking brake is applied. However, in the RWAL system, the brake warning lamp is also used to alert the driver that there is a problem with the RWAL system. There is also an ABS warning lamp (amber). The ABS warning lamp is only used to alert the driver of RWAL malfunctions and to identify Diagnostic Trouble Codes (DTCs) stored in the Controller Anti-Lock Brake (CAB) memory. The ABS warning lamp illuminates when ignition voltage is supplied to the bulb and a ground is provided for the bulb. The bulb has ignition voltage supplied to it any time the ignition switch is in the Run or Start positions. A ground for the bulb is provided by the CAB only. A circuit in the CAB monitors the brake warning lamp switch and the ignition switch bulb check circuit (grounds the brake warning lamp bulb while in the Start position). When the CAB identifies a ground on this circuit, the CAB illuminates the ABS warning lamp. Four Wheel Anti-Lock Brake System The amber ABS warning lamp is located in the instrument cluster. The lamp illuminates at start-up to perform a self check. The lamp goes out when the self check program determines the system is operating normal. If an ABS component exhibits a fault, the CAB will illuminate the lamp and register a trouble code in the microprocessor. The lamp is controlled by the vehicle's "smart" instrument cluster and by the CAB. The CAB activates the lamp by directly grounding the circuit. The CAB checks the brake warning light circuit at the beginning of each ignition cycle. If the CAB detects high voltage when it attempts to ground the light circuit, it determines that a short exists. Diagnostic action for this detected condition includes setting an (88) Indicator Lamp (Red) Circuit diagnostic trouble code. ABS operation will not be inhibited. BASE BRAKE WARNING INDICATOR Purpose A red warning lamp is used for the service brake portion of the hydraulic system. The lamp is located in the instrument cluster. The lamp alerts the driver when a pressure differential exists between the front and rear hydraulic systems or when the parking brakes are applied. Operation The red brake warning lamp is connected to the parking brake switch and to the pressure differential warning switch in the combination valve. The red light illuminates for approximately 2-4 seconds at engine start up. This is a self test feature designed to check bulb operation. The lamp also illuminates when the parking brake is applied. It also illuminates if a fluid pressure drop occurs in either the front or rear brake hydraulic circuit. A pressure drop moves the valve in the combination valve toward the low pressure side. When the valve moves, it pushes the pressure differential switch contact plunger upward. This closes the contacts and completes the circuit to the lamp. The lamp will remain on until repairs are made and normal fluid pressure is restored. CIRCUIT OPERATION Brake Warning Lamp The Controller Antilock Brakes (CAB) provides ground for the instrument cluster. Check Antilock warning lamp on circuit G19. ABS Warning Lamp Operation of the Anti-Lock Brake System (ABS) warning lamp is controller by the DPA switch. If a pressure problem is detected in the system the DPA switch CLOSES connecting circuits B9 and Z1. The B9 circuit connects from the instrument cluster and the Controller Anti-Lock Brake (CAB) to the DPA switch. Circuit Z1 provides the ground path for the switch. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Technical Service Bulletins > Page 5219 Brake Warning Indicator: Testing and Inspection Brake Warning Lamp The diagnosis found here addresses an inoperative brake warning lamp condition. If the brake warning lamp stays on with the ignition switch in the On position and the parking brake released, or comes on while driving, refer to Brakes and Traction Control/Brakes/Anti-Lock Brakes for diagnosis. If no service brake or parking brake problem is found, the following procedure will help locate a faulty hard-wired circuit or switch. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check the fuse in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component and replace the faulty fuse. 2. Turn the ignition switch to the On position. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the ignition switch as required. 3. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Unplug the wire harness connector at the park brake switch. With the park brake released, check for continuity between the park brake switch terminal and a good ground. There should be no continuity If OK, go to Step 4. If not OK, adjust or replace the faulty park brake switch. 4. Unplug the wire harness connector at the brake warning switch. Check for continuity between the two terminals of the brake warning switch. There should be no continuity If OK, go to Step 5. If not OK, replace the faulty brake warning switch. 5. Check for continuity between the ground circuit cavity of the brake warning switch wire harness connector and a good ground. There should be continuity If OK, go to Step 6. If not OK, repair the circuit to ground as required. 6. Remove the instrument cluster bezel and the cluster as described. With both the park brake switch and the brake warning switch wire harness connectors are still unplugged, check for continuity between the park brake switch wire harness connector cavity and a good ground. There should be no continuity If OK, go to Step 7. If not OK, repair the short circuit as required. 7. With the ignition switch held in the Start position, check for continuity between the brake warning switch sense cavity of the brake warning switch wire harness connector and a good ground. There should be continuity If OK, go to Step 8. If not OK, refer to Starting and Charging/Starting System for diagnosis of the ignition switch. 8. Turn the ignition switch to the Off position. Check for continuity between the brake warning switch sense circuit cavity of the cluster wire harness connector and a good ground. There should be no continuity If OK, go to Step 9. If not OK, repair the short circuit as required. 9. Check for continuity between the brake warning switch sense circuit cavities of the cluster wire harness connector and the brake warning switch wire harness connector. There should be continuity If OK, go to Step 10. If not OK, repair the open circuit as required. 10. With the park brake switch wire harness connector still unplugged, check for continuity between the park brake switch sense circuit cavity of the cluster wire harness connector and a good ground. There should be no continuity If OK, go to Step 11. If not OK, repair the short circuit as required. 11. Check for continuity between the park brake switch sense circuit cavities of the cluster wire harness connector and the park brake switch wire harness connector. There should be continuity If OK, see Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Instrument Cluster to test the brake warning lamp and the instrument cluster circuitry If not OK, repair the open circuit as required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Front Caliper Mounting/Steering Knuckle - Thread Repair Brake Caliper: Technical Service Bulletins Front Caliper Mounting/Steering Knuckle - Thread Repair NUMBER: 05-03-99 GROUP: Brakes EFFECTIVE DATE: Apr. 23, 1999 SUBJECT: Front Brake Caliper Mounting To Steering Knuckle Thread Repair OVERVIEW: This bulletin involves repair of the threads on the steering knuckle or brake caliper mounting adapter that are used to install and retain the front brake caliper housing in its correct operating location. MODELS: 1986 - 1999 (AN) Dakota 1998 - 1999 (DN) Durango DISCUSSION: A Brake Knuckle Thread Repair Kit has been developed to repair stripped threads on the front brake caliper mounting attachment making it no longer necessary to replace the front steering knuckle/brake caliper mounting adapter when encountering stripped threads. The following information provides the repair procedure for using the Brake Knuckle Thread Repair Kit. DIAGNOSIS: 1. Place the vehicle on an appropriate hoist. 2. Remove the front tire/wheel assembly. 3. Remove the brake caliper housing assembly by loosening the mounting bolts. NOTE: IF HIGH TORQUE IS ENCOUNTERED DURING THE MOUNTING BOLT REMOVAL, IT IS LIKELY THAT THREAD DAMAGE WILL OCCUR OR HAS OCCURRED. 4. Remove the caliper housing assembly and hang the housing on the frame of the vehicle using an appropriate wire hanger. NOTE: DO NOT ALLOW THE CALIPER HOUSING TO HANG BY ITSELF FROM THE BRAKE HOSE AS DAMAGE TO THE HOSE MAY RESULT. 5. If the vehicle has a bolt-on brake caliper mounting adapter, remove the adapter. If the brake caliper mounts directly to the steering knuckle, remove retainers on the wheel studs and remove the rotor. 6. Inspect the mounting bolts and knuckle threads for damage. If either is damaged, it is likely that damage to the other has occurred as well. If damage has occurred to the threads in the form of knicks, thread pulling, or cross-threading, perform the Repair Procedure. PARTS REQUIRED: AR (1) 05016156AA Insert, Heli-Coil, M9 X 1.25 AR (1) 04886075AA Bolts, Caliper Housing Mounting EQUIPMENT REQUIRED: AR (1) 05016155AA Kit, Brake Knuckle Thread Repair Includes: 23/64 Drill Bit M9 X 1.25 Tap Heli-Coil Installation Tool Heli-Coil Tang Break-Off Rod (25) M9 X 1.25 Stainless Steel Heli-Coils REPAIR PROCEDURE: Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Front Caliper Mounting/Steering Knuckle - Thread Repair > Page 5225 1. Using the 23/64 in. drill, drill through the brake caliper mounting attachment hole keeping the drill perpendicular to the knuckle. 2. Using the M9 X 1.25 tap, tap the drilled hole ensuring to tap the hole entirely through. 3. Install a Heli-Coil insert onto the installation tool (tool number 3747-9). Be sure the tang is properly engaged into the driving contour of the tool. 4. Install the Heli-Coil into the drilled/tapped hole by rotating the tool and exerting slight pressure onto the tool/Heli-Coil and into the drilled/tapped hole. Continue to rotate the tool until the insert is located 1/4 to 1/2 turn below the steering knuckle surface. 5. Back the Heli-Coil installation tool out of the installed Heli-Coil. Then, remove the tang from the Heli-Coil by breaking the tang off using the tang break-off tool. Place the break-off tool into the assembled insert until it rests on the Heli-Coil tang. Holding the tool squarely, strike the tool sharply with a hammer. 6. If the vehicle has a bolt-on brake caliper mounting adapter, install the adapter. Refer to the appropriate Service Manual for information regarding proper brake caliper adapter mounting information. If the brake caliper mounts directly to the steering knuckle, install the rotor. 7. Install the caliper using new mounting bolts p/n 04886075AA in any location that had a Heli-Coil installed. Tighten the bolts to 30 - 35 N.m (22-26 ft. lbs.). 8. Install the tire/wheel assembly. 9. Lower the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-80-20-93 Brake Caliper Mounting Support Thread Repair, Left Side 0.4 Hrs. 05-80-20-94 Brake Caliper Mounting Support Thread Repair, Right Side 0.4 Hrs. 05-80-20-50 Brake Caliper Mounting Support Thread Repair, Each Additional Same Side 0.1 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Page 5226 Brake Caliper: Specifications Type Sliding Caliper Slide Pins 18-26 ft.lb Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Page 5227 Disc Brake Caliper Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Page 5228 Brake Caliper: Service Precautions CAUTION: Do not allow brake fluid to contact painted surfaces. Use suitable cloths or covers to protect components from fluid spillage or spray. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Page 5229 Brake Caliper: Description and Operation Disc Brake Caliper The calipers are a single piston type. The calipers are free to slide laterally; this allows continuous compensation for lining wear. When the brakes are applied fluid pressure is exerted against the caliper piston. The fluid pressure is exerted equally and in all directions. This means pressure exerted against the caliper piston and within the caliper bore will be equal. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Page 5230 Brake Caliper: Testing and Inspection Fig 14 Honing Piston Bore PISTON INSPECTION The piston is made from a phenolic resin (plastic material) and should be smooth and clean. Replace the piston if cracked or scored. Do not attempt to restore a scored piston surface by sanding or polishing. The piston must be replaced if damaged. CAUTION: If the caliper piston must be replaced, install the same type of piston in the caliper. Never interchange phenolic resin and steel caliper pistons. The pistons, seals, seal grooves, caliper bore and piston tolerances are different for resin and steel pistons. Do not intermix these components at any time. BORE INSPECTION The bore can be lightly polished with a brake hone to remove very minor surface imperfections. The caliper should be replaced if the bore is severely corroded, rusted, scored, or if polishing would increase bore diameter more than 0.001 inch. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation Brake Caliper: Service and Repair Removal and Installation NOTE: Use Mopar multi-mileage or high temperature grease to lubricate caliper slide surfaces. Use multi-mileage grease, GE 661 or Dow 111 silicone grease on caliper bushings and slide pins to ensure proper operation. REMOVAL 1. Raise and support vehicle. 2. Remove front wheel and tire assemblies. 3. Disconnect brake hose at caliper. Discard hose fitting washers if worn or damaged. Caliper Brake Hose Connection 4. Remove caliper slide pins. 5. Remove caliper and separate brake shoes from caliper. INSTALLATION 1. Install brake shoes in caliper. 2. Install caliper and shoes over rotor and into ledges in steering knuckle. Be sure ends of brake shoes are properly seated on slide surfaces of ledges. 3. Align caliper in adapter and install caliper slide pins. Torque caliper slide pins to 18-26 ft. lbs. 4. Connect brake hose to caliper. Use new washers to attach hose fitting if original washers are scored, worn, or damaged. 5. Fill and bleed brake system. See: Brake Bleeding/Service and Repair 6. Install wheel and tire assemblies. 7. Remove supports and lower vehicle. 8. Pump brake pedal to seat shoes and verify firm pedal before moving vehicle. 9. Check master cylinder fluid level again and top off if necessary. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5233 Brake Caliper: Service and Repair Disassembly and Assembly DISASSEMBLY 1. Drain old brake fluid out of caliper into drain pan. 2. Remove piston dust boot. Use screwdriver to push boot out of groove. Piston Dust Boot 3. Pad outboard shoe side of caliper interior with a minimum one inch thickness of shop towels. Towels will prevent piston damage when piston comes out of bore. Caliper Piston Removal 4. Remove caliper piston with short bursts of compressed air. Apply air pressure through fluid inlet port of caliper. CAUTION: Do not blow the piston out of the caliper. Use only enough air pressure to ease the piston out of the bore. Never attempt to catch the piston as it leaves the caliper bore. This practice will result in personal injury. 5. Remove caliper piston seal with wood pencil or plastic tool. Do not use metal tools as they will scratch piston bore. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5234 Caliper Piston Seal CAUTION: If the caliper piston must be replaced, install the same type of piston in the caliper. Never interchange phenolic resin and steel caliper pistons. The pistons, seals, seal grooves, caliper bore and piston tolerances are different for resin and steel pistons. Do not intermix these components at any time. NOTE: The bore can be lightly polished with a brake hone to remove very minor surface imperfections. The caliper should be replaced if the bore is severely corroded, rusted, scored, or if polishing would increase bore diameter more than 0.001 inch. Fig 14 Honing Piston Bore 6. Remove caliper slide pin bushings and boots. 7. Remove caliper bleed screw and cap. CLEANING Clean the caliper components with clean brake fluid or brake clean only. Do not use gasoline, kerosene, thinner, or similar solvents. These products may leave a residue that could damage the piston and seal. Wipe the caliper and piston dry with lint free towels or use low pressure compressed air. ASSEMBLY 1. Lubricate slide pin boots and bushings with GE or Dow silicone grease, then install the boots and bushings in caliper. 2. Coat caliper piston bore, piston and new piston seal with clean brake fluid. 3. Install new piston seal in caliper bore. Press seal into groove with finger. Lubricate seal and caliper bore with additional, fresh brake fluid after seal installation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5235 Fig 19 Installing Caliper Piston Seal 4. Apply light coat of GE 661, Dow 111 or similar silicone grease to edge and groove of piston and dust seal. Grease acts as corrosion protection for these areas. 5. Slide new seal boot over piston until boot lip seats in piston groove. Sliding Boot Onto Piston 6. Push retainer part of boot forward until folds in boot snap into place. Snapping Boot Folds Into Place 7. Start caliper piston in bore with a twisting motion. When piston is started in seal, push piston only part way into bore. Maintain uniform pressure on piston to avoid cocking it in bore. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5236 Fig 22 Installing Caliper Piston And Boot 8. Press caliper piston to bottom of bore. 9. Seat piston dust boot with Installer Tool 7868 or C-4842 and Tool Handle C-4171, or equivalents. Fig 23 Seating Piston Dust Boot 10. Install caliper bleed screw and bleed screw cap, if removed. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5237 Caliper Bleed Screw & Cap Installation Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Page 5238 Brake Caliper: Tools and Equipment Caliper Dust Seal Installer Tool No. 7868 Special Tools C-4689 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications Brake Pad: Specifications As a general rule, riveted brake shoes should be replaced when worn to within 0.78 mm (1/32 inch) of the rivet heads. Bonded lining should be replaced when worn to a thickness of 1.6 mm (1/16 inch). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Page 5242 Brake Pad: Service Precautions ASBESTOS HAZARD Factory installed brake linings do not contain asbestos fibers. Dust and dirt accumulating on brake parts during normal use may contain asbestos fibers from after market brake linings. Breathing excessive concentrations of asbestos fibers can cause serious bodily harm. Exercise care when servicing brake parts. Do not clean brake parts with compressed air or by dry brushing. Use a vacuum cleaner specifically designed for the removal of asbestos fibers from brake components. If a suitable vacuum cleaner is not available, cleaning should be done with a water dampened cloth. Do not sand or grind brake lining unless the equipment used is designed to contain the dust residue. Dispose of all residue containing asbestos fibers in sealed bags or containers to minimize exposure to yourself and others. Follow practices prescribed by the Occupational Safety and Health Administration (OSHA) and the Environmental Protection Agency (EPA) for the handling, processing, and disposal of dust or debris that may contain asbestos fibers. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Page 5243 Brake Pad: Service and Repair REMOVAL 1. Clean master cylinder reservoir and filler caps. 2. Remove reservoir filler cap and drain approximately 1/4 of fluid from reservoir. Use clean suction gun or similar device to drain fluid. 3. Raise and support vehicle. 4. Remove front wheel and tire assemblies. 5. Bottom caliper pistons in bores with large C-clamp. Position clamp frame on rear of caliper and clamp screw on outboard brake pad. 6. Remove caliper slide pins. 7. Remove caliper and brake pads. Fig 3 Removing Caliper And Brake Shoes 8. Remove outboard brake pad. Pry one end of pad retainer spring away from caliper, then tilt pad upward and rotate it out of caliper. Fig. 6 Outboard Brake Pad Removal 9. Remove inboard pad by tilting pad outward until retainer spring is clear of caliper piston. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Page 5244 Fig 5 Removing/installing Inboard Brake Shoes 10. Support caliper with wire from suspension component. Do not allow brake hose to support caliper weight. INSTALLATION 1. Clean slide surfaces of adapter ledges with a wire brush. Then lubricate surfaces with a thin coat of high temperature grease. 2. Install new slide pin boots and sleeves if necessary. 3. Install inboard pad. Be sure retainer spring is firmly seated in caliper piston. 4. Insert outboard brake pad in caliper. Fig. 10 Outboard Brake Pad Installation 5. Seat ends of outboard pad retainer spring in caliper. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Page 5245 Fig 10 Seating Outboard Shoe Retainer Spring 6. Install caliper and brake pads over rotor and into adapter. Be sure pad tangs are properly seated on adapter ledges. 7. Install caliper slide pins and torque to 18-26 ft. lbs. Start the slide pins by hand before tightening. Do not cross thread the pins. 8. Install wheel and tire assembly. 9. Lower vehicle. 10. Apply brakes several times to seat pads and caliper pistons. Do not move vehicle until firm brake pedal is obtained. 11. Top off master cylinder fluid. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications Brake Rotor/Disc: Specifications Front Rotor Specifications: Nominal Thickness .............................................................................................................................. .............................................................. 0.949" Minimum Machine Thickness .............................................................................................................. ...................................................................... * Discard Thickness ............................................................................................................................... .............................................................. 0.890" Runout Limit ........................................................................................................................................ ............................................................. 0.004" Maximum Parallel Variation ................................................................................................................. .......................................................... 0.0005" * - Information not supplied by the manufacturer. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Runout Check Brake Rotor/Disc: Testing and Inspection Runout Check Rotor Runout & Thickness Variation Inspection Check rotor lateral runout with dial indicator tool No. C-3339, or equivalent. Excessive lateral runout will cause brake pedal pulsation and rapid, uneven wear of the brake shoes. Position the dial indicator plunger approximately 1 inch inward from the rotor edge. NOTE: Be sure wheel bearing has zero end play before checking rotor runout. Maximum allowable rotor runout is 0.004 inch. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Runout Check > Page 5251 Brake Rotor/Disc: Testing and Inspection Thickness Variation Check Rotor Thickness Measurement Variations in rotor thickness will cause pedal pulsation, noise and shudder. Measure rotor thickness at 6 to 12 points around the rotor face. Position the micrometer approximately 1 inch from the rotor outer circumference for each measurement. Thickness should not vary by more than 0.0005 inch from point to point on the rotor. Machine or replace the rotor if necessary. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Page 5252 Brake Rotor/Disc: Service and Repair REMOVAL 1. Raise and support vehicle. 2. Remove wheel and tire assembly. 3. Remove brake caliper. 4. Remove retainers on wheel studs and remove rotor. Disc Brake Rotor REFINISHING NOTE: The rotor braking surfaces should not be refinished unless necessary. Light surface rust and scale can be removed with a lathe equipped with dual sanding discs. The rotor surfaces can be restored by machining in a disc brake lathe if surface scoring and wear are light. Replace the rotor if any of the following conditions exist: ^ Severe scoring ^ Tapering ^ Hard spots ^ Cracks ^ Below minimum thickness CAUTION: Do not machine the rotor if it will cause the rotor to fall below minimum allowable thickness. NOTE: Rotor minimum thickness is usually specified on the rotor hub. The specification is either stamped or cast into the hub surface. Rotor braking surfaces can be sanded or machined in a disc brake lathe. The lathe must machine both sides of the rotor simultaneously with dual (two) cutter heads. Equipment capable of machining only one side at a time will produce a tapered rotor. The lathe should also be equipped with a grinder attachment or dual sanding discs for final cleanup or light refinishing. If the rotor surfaces only need minor cleanup of rust, scale, or minor scoring, use abrasive discs to clean up the rotor surfaces. However, when a rotor is scored or worn, machining with cutting tools will be required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Page 5253 Fig 3 Rotor Refinishing Equipment INSTALLATION 1. Install rotor hub and install retainers. 2. Install brake caliper. 3. Install wheel and tire assembly. 4. Remove support and lower vehicle. 5. Depress brake pedal several times to seat brake shoes. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Support Plate <--> [Backing Plate] > Component Information > Specifications Support Plate: Specifications TIGHTENING SPECIFICATIONS Backing Plate To Axle Flange Bolts ........................................................................................................................................................ 35-60 ft. lbs. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Support Plate <--> [Backing Plate] > Component Information > Specifications > Page 5258 Support Plate: Testing and Inspection Inspect the brake shoe contact pads on the support plate. Replace the support plate if any of the pads are worn or rusted through. Also replace the plate if it is bent or distorted. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Support Plate <--> [Backing Plate] > Component Information > Specifications > Page 5259 Support Plate: Service and Repair REMOVAL 1. Remove wheel and tire assembly and brake drum. 2. Remove brake shoe assembly. 3. Remove parking brake cable from parking brake lever. 4. Compress parking brake cable retainer tabs with a hose clamp, then push retainer and cable through and out of backing plate. Fig 4 Compressing Cable Retainer Tabs 5. Disconnect brake line at wheel cylinder. 6. Remove wheel cylinder from backing plate. 7. Remove axle shaft. 8. Remove bolts attaching backing plate to axle and remove backing plate. INSTALLATION 1. Apply bead of silicone sealer around axle mounting surface of backing plate. 2. Install backing plate on axle flange. Tighten attaching bolts to 35-60 ft. lbs. 3. Apply bead of silicone sealer around wheel cylinder mounting surface and install wheel cylinder. 4. Install brake line in wheel cylinder. 5. Install parking brake cable in backing plate. 6. Install axle shaft. 7. Connect parking brake cable to lever on secondary shoe and install brake shoes on backing plate. 8. Adjust brake shoes to drum with brake gauge. 9. Install brake drum and wheel and tire assembly. 10. Bleed brake system. See: Brake Bleeding/Service and Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications Brake Drum: Specifications Rear Drum Specifications 9" Rear Drum Nominal Diameter ................................................................................................................................ ............................................................... 9.00" Maximum Machine Limit ...................................................................................................................... ............................................................ 9.060" Discard Diameter ................................................................................................................................. .............................................................. 9.090" Runout Limit ........................................................................................................................................ ............................................................. 0.008" 10" Rear Drum Nominal Diameter ................................................................................................................................ ............................................................. 10.00" Maximum Machine Limit ...................................................................................................................... .......................................................... 10.060" Discard Diameter ................................................................................................................................. ............................................................ 10.090" Runout Limit ........................................................................................................................................ ............................................................. 0.008" 11" Rear Drum Nominal Diameter ................................................................................................................................ ............................................................. 11.00" Maximum Machine Limit ...................................................................................................................... .......................................................... 11.060" Discard Diameter ................................................................................................................................. ............................................................ 11.090" Runout Limit ........................................................................................................................................ ............................................................. 0.008" Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Testing and Inspection > Braking Surface Diameter Brake Drum: Testing and Inspection Braking Surface Diameter The maximum allowable diameter of the drum braking surface is stamped or cast into the drum outer edge. Generally, a drum can be machined to a maximum of 0.060 inch oversize. Always replace the drum if machining would cause drum diameter to exceed the size limit indicated on the drum. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Testing and Inspection > Braking Surface Diameter > Page 5265 Brake Drum: Testing and Inspection Brake Drum Runout Measure drum diameter and runout with an accurate gauge. The most accurate method of measurement involves mounting the drum in a brake lathe and checking variation and runout with a dial indicator. Variations in drum diameter should not exceed 0.003 inch. Drum runout should not exceed 0.008 inch out of round. Machine the drum if runout or variation exceed these values. Replace the drum if machining causes the drum to exceed the maximum allowable diameter. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Brake Drum Removal and Installation Brake Drum: Service and Repair Brake Drum Removal and Installation 1. Raise and support vehicle. 2. Remove wheel and tire assembly. 3. Remove clip nuts securing brake drum to wheel studs. 4. Remove drum. If drum is difficult to remove, proceed as follows: a. Remove rear plug from access hole in support plate. b. Insert a thin screwdriver into access hole and push lever away from adjuster screw star wheel. c. Insert an adjuster tool into brake adjusting hole and rotate adjuster star wheel to retract brake shoes. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Brake Drum Removal and Installation > Page 5268 Brake Drum: Service and Repair Brake Drum Refinishing CAUTION: Be sure the drum is securely mounted in the lathe before machining operations. A damper strap should always be used around the drum to reduce vibration and avoid chatter marks. The brake drums can be machined on a drum lathe when necessary. Initial machining cuts should be limited to 0.0050 to 0.0080 inch at a time as heavier feed rates can produce taper and surface variation. Final finish cuts of 0.0010 to 0.0015 inch are recommended and will generally provide the best surface finish. The maximum allowable diameter of the drum braking surface is stamped or cast into the drum outer edge. CAUTION: Always replace the drum if machining would cause drum diameter to exceed the size limit indicated on the drum. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications Brake Shoe: Specifications As a general rule, riveted brake shoes should be replaced when worn to within 0.78 mm (1/32 inch) of the rivet heads. Bonded linings should be replaced when worn to a thickness of 1.6 mm (1/16 inch). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 5272 Brake Shoe: Service Precautions ASBESTOS HAZARD Factory installed brake linings do not contain asbestos fibers. Dust and dirt accumulating on brake parts during normal use may contain asbestos fibers from after market brake linings. Breathing excessive concentrations of asbestos fibers can cause serious bodily harm. Exercise care when servicing brake parts. Do not clean brake parts with compressed air or by dry brushing. Use a vacuum cleaner specifically designed for the removal of asbestos fibers from brake components. If a suitable vacuum cleaner is not available, cleaning should be done with a water dampened cloth. Do not sand or grind brake lining unless the equipment used is designed to contain the dust residue. Dispose of all residue containing asbestos fibers in sealed bags or containers to minimize exposure to yourself and others. Follow practices prescribed by the Occupational Safety and Health Administration (OSHA) and the Environmental Protection Agency (EPA) for the handling, processing, and disposal of dust or debris that may contain asbestos fibers. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation Brake Shoe: Service and Repair Brake Shoe Removal and Installation REMOVAL 1. Raise and support vehicle. 2. Remove wheel and tire assembly. 3. Remove clip nuts securing brake drum to wheel studs. 4. Remove drum. If drum is difficult to remove, proceed as follows: a. Remove rear plug from access hole in support plate. b. BInsert a thin screwdriver into access hole and push lever away from adjuster screw star wheel. c. Insert an adjuster tool into brake adjusting hole and rotate adjuster star wheel to retract brake shoes. 5. Vacuum brake components to remove brake lining dust. If vacuum is not available, use water dampened cloths to remove dust. 6. Remove shoe return springs with brake spring plier tool. 7. Remove adjuster cable. Slide cable eye off anchor pin, then unhook and remove cable from adjuster lever. 8. Remove cable guide from secondary shoe and anchor plate from anchor pin. 9. Remove adjuster lever. Disengage lever from spring by sliding lever forward to clear pivot and work lever out from under spring. 10. Remove adjuster lever spring from pivot. 11. Disengage and remove shoe spring from brake shoes. 12. Disengage and remove adjuster screw assembly from brake shoes. 13. Remove brake shoe retainers and springs. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 5275 14. Remove secondary brake shoe from support plate. 15. Remove strut and spring. 16. Remove parking brake lever from secondary shoe. 17. Remove primary shoe from support plate. 18. Disengage parking brake lever from parking brake cable. INSTALLATION 1. Clean and inspect individual brake components. 2. Lubricate anchor pin and brake shoe contact pads on support plate with high temperature grease or Lubriplate. 3. Lubricate adjuster screw socket, nut, button and screw thread surfaces with grease or Lubriplate. 4. Attach parking brake cable to lever, then connect lever to secondary shoe. 5. Install primary shoe on support plate. Secure shoe with new spring retainers and pin. 6. Install spring on parking brake strut and engage strut in primary. 7. Install secondary shoe on support plate. Insert strut in shoe and guide shoe onto anchor pin. Temporarily secure shoe with retaining pin. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 5276 Fig 7 Installing Brake Shoes 8. Install anchor plate and adjuster cable eyelet on support plate anchor pin. 9. Install cable guide in secondary shoe and position cable in guide. 10. Assemble adjuster screw, then install between the brake shoes. NOTE: Be sure the adjuster screws are installed on the correct brake unit. The adjuster screws are marked L (left) and R (right) for identification. 11. Install adjuster lever and spring and connect adjuster cable to lever. 12. Install secondary shoe retainers and spring. 13. Install shoe spring. Connect spring to secondary shoe first, then to primary shoe. 14. Verity adjuster operation. Pull adjuster cable upward, cable should lift lever and rotate star wheel. Be sure adjuster lever properly engages star wheel teeth. 15. Adjust brake shoes to drum with brake gauge. See: Adjustments 16. Install wheel and tire assembly. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 5277 Brake Shoe: Service and Repair Cleaning and Inspection As a general rule, riveted brake shoes should be replaced when worn to within 1/32 inch of the rivet heads. Bonded lining should be replaced when worn to a thickness of 1/16 inch. Examine the lining contact pattern to determine if the shoes are bent or the drum is tapered. The lining should exhibit contact across its entire width. Shoes exhibiting contact only on one side should be replaced and the drum checked for runout or taper. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Page 5278 Brake Shoe: Tools and Equipment Adjusting Brake Shoes With Gauge Brake Shoe Adjuster Tool No. C-3784 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Specifications Wheel Cylinder: Specifications Wheel Cylinder Bolts 1/4-20 11 ft.lb 5/16-18 16 ft.lb Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation Wheel Cylinder: Service and Repair Wheel Cylinder Removal and Installation REMOVAL 1. Raise and support vehicle, then remove wheel and tire assembly. 2. Remove brake drum. 3. Disconnect wheel cylinder brake line. 4. Remove brake shoe return springs and move shoes out of engagement with cylinder push rods. 5. Remove cylinder attaching bolts and remove cylinder from support plate. INSTALLATION 1. Apply bead of silicone sealer around cylinder mounting surface of support plate. 2. Install cylinder mounting bolts and proceed as follows: a. Torque 1/4-20 bolts to 11 ft. lbs. b. Torque 5/16-18 bolts to 16 ft. lbs. 3. Connect brake line to cylinder. 4. Install brake shoe return spring. 5. Install brake drum. 6. Install wheel and tire assembly. 7. Bleed brake system. See: Brake Bleeding/Service and Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation > Page 5284 Wheel Cylinder: Service and Repair Cleaning and Inspection CLEANING Clean the cylinder and pistons with clean brake fluid or brake cleaner only. Do not use any other cleaning agents. Dry the cylinder and pistons with compressed air. Do not use rags or shop towels to dry the cylinder components. Lint from cloth material will adhere to the cylinder bores and pistons. INSPECTION Inspect the cylinder bore. Light discoloration and dark stains in the bore are normal and will not impair cylinder operation. The cylinder bore can be lightly polished but only with crocus cloth. Replace the cylinder if the bore is scored, pitted or heavily corroded. Honing the bore to restore the surface is not recommended. Inspect the cylinder pistons. The piston surfaces should be smooth and free of scratches, scoring and corrosion. Replace the pistons if worn, scored, or corroded. Do attempt to restore the surface by sanding or polishing. Discard the old piston cups and the spring and expander. These parts are not reusable. The original dust boots may be reused but only if they are in good condition. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation > Page 5285 Wheel Cylinder: Service and Repair Wheel Cylinder Overhaul DISASSEMBLY 1. Remove push rods and boots. 2. Press pistons, cups and spring and expander out of cylinder bore. 3. Remove bleed screw. CLEANING Clean the cylinder and pistons with clean brake fluid or brake cleaner only. Do not use any other cleaning agents. Dry the cylinder and pistons with compressed air. Do not use rags or shop towels to dry the cylinder components. Lint from cloth material will adhere to the cylinder bores and pistons. NOTE: The cylinder bore can be lightly polished but only with crocus cloth. Replace the cylinder if the bore is scored, pitted or heavily corroded. Honing the bore to restore the surface is not recommended. ASSEMBLY 1. Lubricate wheel cylinder bore, pistons, piston cups and spring and expander with clean brake fluid. 2. Install first piston in cylinder bore. Then install first cup in bore and against piston. Be sure lip of piston cup is facing inward (toward spring and expander) and flat side is against piston. 3. Install spring and expander followed by remaining piston cup and piston. 4. Install boots on each end of cylinder and insert push rods in boots. 5. Install cylinder bleed screw. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Bleeding Procedures Brake Bleeding: Service and Repair Antilock Brake System Bleeding Procedures W/ Four Wheel Antilock Brakes Anti-Lock Brake System (ABS) bleeding requires conventional bleeding methods plus use of the Diagnostic Readout Box (DRB) scan tool. The procedure involves performing a base brake bleeding, followed by use of the scan tool to cycle and bleed the Hydraulic Control Unit (HCU) pump and solenoids. A second base brake bleeding procedure is then required to remove any air remaining in the system. 1. Perform base brake bleeding procedure. See: 2. Connect scan tool to the Data Link Connector (DLC). 3. Select ANTILOCK BRAKES, followed by MISCELLANEOUS, then ABS BRAKES. Follow the instructions displayed. When scan tool displays TEST COMPLETE, disconnect scan tool and proceed. 4. Perform base brake bleeding a second time. 5. Top off master cylinder fluid level and verify proper brake operation before moving vehicle. W/ Rear Wheel Antilock Brakes Rear Wheel Anti-Lock (RWAL) brake bleeding can be performed manually, or with vacuum/pressure equipment. Bleed only one brake component at a time. Recommended bleed sequence is: 1. Master Cylinder 2. Combination Valve 3. Rear Anti-Lock Valve 4. Left Rear Wheel 5. Right Rear Wheel 6. Right Front Wheel 7. Left Front Wheel Use Mopar DOT 3 brake fluid, or an equivalent meeting SAE J1703-F and DOT 3 standards, to fill and bleed the system. Use a bleed hose at each caliper/cylinder bleed screw. Attach one end of the hose to the bleed screw and insert the opposite end in glass container partially filled with brake fluid. A glass container makes it easier to see air bubbles as they exit the bleed hose. Be sure the end of the bleed hose remains immersed in fluid. This prevents air from being drawn back into the system. Do not allow the master cylinder to run out of fluid when bleeding the brakes. An empty cylinder will allow air to be drawn back into the system. Check fluid level frequently during bleeding operations. Be sure to tighten each brake line fitting, or bleed screw once bleeding is completed. Loose fittings and bleed screws allow air to enter the system. Vacuum Bleeding If vacuum bleeding equipment is being used, it is not necessary to hold the front brake metering valve open. Simply bleed the brakes following the bleed equipment manufacturer's instructions. Pressure Bleeding If pressure bleeding equipment will be used, the front brake metering valve will have to be held open to bleed the front brakes. The valve stem is located in the forward end of the combination valve. The stem must either be pressed inward, or held outward slightly. a spring clip tool or helper is needed to hold the valve stem in position. Follow the manufacturer's instructions carefully when using pressure equipment. Do not exceed the tank manufacturer's pressure recommendations. Generally, a tank pressure of 15-20 psi is more than sufficient for bleeding purposes. Fill the bleeder tank with recommended fluid and purge air from the tank lines before bleeding. NOTE: ^ Do not pressure bleed without a proper master cylinder adapter. The wrong adapter can lead to leakage, or drawing air back into the system. ^ Make sure the front brake metering valve in the combination valve is held open. A spring clip tool is best for securing the valve stem in an open position. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Antilock Brake System Bleeding Procedures > Page 5291 Brake Bleeding: Service and Repair Base Brake System Bleeding BASE BRAKE SYSTEM BLEEDING NOTE: The following procedure describes a manual bleed of the base brake system. Additional steps may be required for Anti-Lock Brake System (ABS) components. CAUTION: - Use Mopar brake fluid or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. - Do not pump the brake pedal at any time while bleeding. Air in the system will be compressed into small bubbles that are distributed throughout the hydraulic system. This will make additional bleeding operations necessary. - Do not allow the master cylinder to run out of fluid during bleed operations. An empty cylinder will allow additional air to be drawn into the system. Check the cylinder fluid level frequently and add fluid as needed. NOTE: The brakes should be bled in sequence: First, bleed the right rear wheel, then the left rear wheel. Next, move to the front brakes and bleed the right front wheel and, finally, the left front wheel. 1. Remove reservoir filler caps and fill reservoir with brake fluid. 2. If calipers or wheel cylinders were overhauled, open all caliper and wheel cylinder bleed screws. Then close each bleed screw as fluid starts to drip from it. Top off master cylinder reservoir once more before proceeding. 3. Attach one end of bleed hose to bleed screw and insert opposite end in glass container partially filled with brake fluid. Be sure end of bleed hose is immersed in fluid. 4. Open up bleeder, then have a helper press down the brake pedal. Once the pedal is down close the bleeder. Repeat bleeding until fluid stream is clear and free of bubbles, then move to the next wheel. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Front Caliper Mounting/Steering Knuckle - Thread Repair Brake Caliper: Technical Service Bulletins Front Caliper Mounting/Steering Knuckle - Thread Repair NUMBER: 05-03-99 GROUP: Brakes EFFECTIVE DATE: Apr. 23, 1999 SUBJECT: Front Brake Caliper Mounting To Steering Knuckle Thread Repair OVERVIEW: This bulletin involves repair of the threads on the steering knuckle or brake caliper mounting adapter that are used to install and retain the front brake caliper housing in its correct operating location. MODELS: 1986 - 1999 (AN) Dakota 1998 - 1999 (DN) Durango DISCUSSION: A Brake Knuckle Thread Repair Kit has been developed to repair stripped threads on the front brake caliper mounting attachment making it no longer necessary to replace the front steering knuckle/brake caliper mounting adapter when encountering stripped threads. The following information provides the repair procedure for using the Brake Knuckle Thread Repair Kit. DIAGNOSIS: 1. Place the vehicle on an appropriate hoist. 2. Remove the front tire/wheel assembly. 3. Remove the brake caliper housing assembly by loosening the mounting bolts. NOTE: IF HIGH TORQUE IS ENCOUNTERED DURING THE MOUNTING BOLT REMOVAL, IT IS LIKELY THAT THREAD DAMAGE WILL OCCUR OR HAS OCCURRED. 4. Remove the caliper housing assembly and hang the housing on the frame of the vehicle using an appropriate wire hanger. NOTE: DO NOT ALLOW THE CALIPER HOUSING TO HANG BY ITSELF FROM THE BRAKE HOSE AS DAMAGE TO THE HOSE MAY RESULT. 5. If the vehicle has a bolt-on brake caliper mounting adapter, remove the adapter. If the brake caliper mounts directly to the steering knuckle, remove retainers on the wheel studs and remove the rotor. 6. Inspect the mounting bolts and knuckle threads for damage. If either is damaged, it is likely that damage to the other has occurred as well. If damage has occurred to the threads in the form of knicks, thread pulling, or cross-threading, perform the Repair Procedure. PARTS REQUIRED: AR (1) 05016156AA Insert, Heli-Coil, M9 X 1.25 AR (1) 04886075AA Bolts, Caliper Housing Mounting EQUIPMENT REQUIRED: AR (1) 05016155AA Kit, Brake Knuckle Thread Repair Includes: 23/64 Drill Bit M9 X 1.25 Tap Heli-Coil Installation Tool Heli-Coil Tang Break-Off Rod (25) M9 X 1.25 Stainless Steel Heli-Coils REPAIR PROCEDURE: Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Front Caliper Mounting/Steering Knuckle - Thread Repair > Page 5296 1. Using the 23/64 in. drill, drill through the brake caliper mounting attachment hole keeping the drill perpendicular to the knuckle. 2. Using the M9 X 1.25 tap, tap the drilled hole ensuring to tap the hole entirely through. 3. Install a Heli-Coil insert onto the installation tool (tool number 3747-9). Be sure the tang is properly engaged into the driving contour of the tool. 4. Install the Heli-Coil into the drilled/tapped hole by rotating the tool and exerting slight pressure onto the tool/Heli-Coil and into the drilled/tapped hole. Continue to rotate the tool until the insert is located 1/4 to 1/2 turn below the steering knuckle surface. 5. Back the Heli-Coil installation tool out of the installed Heli-Coil. Then, remove the tang from the Heli-Coil by breaking the tang off using the tang break-off tool. Place the break-off tool into the assembled insert until it rests on the Heli-Coil tang. Holding the tool squarely, strike the tool sharply with a hammer. 6. If the vehicle has a bolt-on brake caliper mounting adapter, install the adapter. Refer to the appropriate Service Manual for information regarding proper brake caliper adapter mounting information. If the brake caliper mounts directly to the steering knuckle, install the rotor. 7. Install the caliper using new mounting bolts p/n 04886075AA in any location that had a Heli-Coil installed. Tighten the bolts to 30 - 35 N.m (22-26 ft. lbs.). 8. Install the tire/wheel assembly. 9. Lower the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-80-20-93 Brake Caliper Mounting Support Thread Repair, Left Side 0.4 Hrs. 05-80-20-94 Brake Caliper Mounting Support Thread Repair, Right Side 0.4 Hrs. 05-80-20-50 Brake Caliper Mounting Support Thread Repair, Each Additional Same Side 0.1 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Page 5297 Brake Caliper: Specifications Type Sliding Caliper Slide Pins 18-26 ft.lb Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Page 5298 Disc Brake Caliper Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Page 5299 Brake Caliper: Service Precautions CAUTION: Do not allow brake fluid to contact painted surfaces. Use suitable cloths or covers to protect components from fluid spillage or spray. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Page 5300 Brake Caliper: Description and Operation Disc Brake Caliper The calipers are a single piston type. The calipers are free to slide laterally; this allows continuous compensation for lining wear. When the brakes are applied fluid pressure is exerted against the caliper piston. The fluid pressure is exerted equally and in all directions. This means pressure exerted against the caliper piston and within the caliper bore will be equal. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Page 5301 Brake Caliper: Testing and Inspection Fig 14 Honing Piston Bore PISTON INSPECTION The piston is made from a phenolic resin (plastic material) and should be smooth and clean. Replace the piston if cracked or scored. Do not attempt to restore a scored piston surface by sanding or polishing. The piston must be replaced if damaged. CAUTION: If the caliper piston must be replaced, install the same type of piston in the caliper. Never interchange phenolic resin and steel caliper pistons. The pistons, seals, seal grooves, caliper bore and piston tolerances are different for resin and steel pistons. Do not intermix these components at any time. BORE INSPECTION The bore can be lightly polished with a brake hone to remove very minor surface imperfections. The caliper should be replaced if the bore is severely corroded, rusted, scored, or if polishing would increase bore diameter more than 0.001 inch. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation Brake Caliper: Service and Repair Removal and Installation NOTE: Use Mopar multi-mileage or high temperature grease to lubricate caliper slide surfaces. Use multi-mileage grease, GE 661 or Dow 111 silicone grease on caliper bushings and slide pins to ensure proper operation. REMOVAL 1. Raise and support vehicle. 2. Remove front wheel and tire assemblies. 3. Disconnect brake hose at caliper. Discard hose fitting washers if worn or damaged. Caliper Brake Hose Connection 4. Remove caliper slide pins. 5. Remove caliper and separate brake shoes from caliper. INSTALLATION 1. Install brake shoes in caliper. 2. Install caliper and shoes over rotor and into ledges in steering knuckle. Be sure ends of brake shoes are properly seated on slide surfaces of ledges. 3. Align caliper in adapter and install caliper slide pins. Torque caliper slide pins to 18-26 ft. lbs. 4. Connect brake hose to caliper. Use new washers to attach hose fitting if original washers are scored, worn, or damaged. 5. Fill and bleed brake system. See: Brake Bleeding/Service and Repair 6. Install wheel and tire assemblies. 7. Remove supports and lower vehicle. 8. Pump brake pedal to seat shoes and verify firm pedal before moving vehicle. 9. Check master cylinder fluid level again and top off if necessary. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5304 Brake Caliper: Service and Repair Disassembly and Assembly DISASSEMBLY 1. Drain old brake fluid out of caliper into drain pan. 2. Remove piston dust boot. Use screwdriver to push boot out of groove. Piston Dust Boot 3. Pad outboard shoe side of caliper interior with a minimum one inch thickness of shop towels. Towels will prevent piston damage when piston comes out of bore. Caliper Piston Removal 4. Remove caliper piston with short bursts of compressed air. Apply air pressure through fluid inlet port of caliper. CAUTION: Do not blow the piston out of the caliper. Use only enough air pressure to ease the piston out of the bore. Never attempt to catch the piston as it leaves the caliper bore. This practice will result in personal injury. 5. Remove caliper piston seal with wood pencil or plastic tool. Do not use metal tools as they will scratch piston bore. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5305 Caliper Piston Seal CAUTION: If the caliper piston must be replaced, install the same type of piston in the caliper. Never interchange phenolic resin and steel caliper pistons. The pistons, seals, seal grooves, caliper bore and piston tolerances are different for resin and steel pistons. Do not intermix these components at any time. NOTE: The bore can be lightly polished with a brake hone to remove very minor surface imperfections. The caliper should be replaced if the bore is severely corroded, rusted, scored, or if polishing would increase bore diameter more than 0.001 inch. Fig 14 Honing Piston Bore 6. Remove caliper slide pin bushings and boots. 7. Remove caliper bleed screw and cap. CLEANING Clean the caliper components with clean brake fluid or brake clean only. Do not use gasoline, kerosene, thinner, or similar solvents. These products may leave a residue that could damage the piston and seal. Wipe the caliper and piston dry with lint free towels or use low pressure compressed air. ASSEMBLY 1. Lubricate slide pin boots and bushings with GE or Dow silicone grease, then install the boots and bushings in caliper. 2. Coat caliper piston bore, piston and new piston seal with clean brake fluid. 3. Install new piston seal in caliper bore. Press seal into groove with finger. Lubricate seal and caliper bore with additional, fresh brake fluid after seal installation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5306 Fig 19 Installing Caliper Piston Seal 4. Apply light coat of GE 661, Dow 111 or similar silicone grease to edge and groove of piston and dust seal. Grease acts as corrosion protection for these areas. 5. Slide new seal boot over piston until boot lip seats in piston groove. Sliding Boot Onto Piston 6. Push retainer part of boot forward until folds in boot snap into place. Snapping Boot Folds Into Place 7. Start caliper piston in bore with a twisting motion. When piston is started in seal, push piston only part way into bore. Maintain uniform pressure on piston to avoid cocking it in bore. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5307 Fig 22 Installing Caliper Piston And Boot 8. Press caliper piston to bottom of bore. 9. Seat piston dust boot with Installer Tool 7868 or C-4842 and Tool Handle C-4171, or equivalents. Fig 23 Seating Piston Dust Boot 10. Install caliper bleed screw and bleed screw cap, if removed. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5308 Caliper Bleed Screw & Cap Installation Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Page 5309 Brake Caliper: Tools and Equipment Caliper Dust Seal Installer Tool No. 7868 Special Tools C-4689 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications BRAKE FLUID Specification ........................................................................................................................................ .................................................................. DOT 3 Standard .............................................................................................................................................. ........................................................... SAE J1703 NOTE: The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar brake fluid or an equivalent from a tightly sealed container. CAUTION: Never use reclaimed brake fluid or fluid from a container which has been left open. An open container of brake fluid will absorb moisture from the air and contaminate the fluid. CAUTION: Never use any type of a petroleum based fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid, etc. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Page 5313 Brake Fluid: Testing and Inspection 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, Anti-Lock Brake System (ABS) hydraulic unit and all hydraulic fluid hoses. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Page 5314 Brake Fluid: Service and Repair FLUID SPECIFICATIONS 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 an container which has been left open. An open container 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. FLUID LEVEL INSPECTION CAUTION: Always clean the master cylinder reservoir and caps before checking fluid level. If not cleaned, dirt could enter the fluid. Brake Fluid Level Inspection The fluid fill level is indicated on the side of the master cylinder reservoir. The correct fluid level is to the FULL indicator on the side of the reservoir. If necessary, add fluid to the proper level. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Accumulator > Component Information > Description and Operation Brake Fluid Accumulator: Description and Operation The accumulator is part of the Hydraulic Control Unit (HCU), which also consists of a valve body, pump body and pump motor. The pump, motor and accumulators are combined into an assembly attached to the valve body. The accumulators store the extra fluid released to the system for anti-lock mode operation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Description and Operation Brake Fluid Pressure Sensor/Switch: Description and Operation CIRCUIT OPERATION Circuit G9 from the Controller, Antilock Brakes (CAB) supplies ground for the brake warning lamp. The lamp can also be grounded when either the ignition switch is in the START position, the park brake switch closes or the brake warning lamp switch in the hydraulic combination valve closes. Circuit G14 connects the brake warning lamp switch to the lamp. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Recalls for Brake Hose/Line: > 892 > Sep > 00 > Recall - Fuel Tube/Brake Hose Wear Through Technical Service Bulletin # 892 Date: 000901 Recall - Fuel Tube/Brake Hose Wear Through September 2000 Safety Recall No. 892 Fuel Tube Isolator and Axle Vent Hose Clip Models 1997 (AN) Dodge Dakota Club Cab (131" Wheel Base) NOTE: Safety Recall No.870 and 891 also involve the axle vent hose clip repair. Dakotas involved in Recall No. 892 are NOT included in either Recall No.870 or 891. Dealers must verify which recall the truck is involved in prior to completing the service procedure. ^ Safety Recall No.870 applies to 1997-2000 model year trucks equipped with a 2.5L engine and involves the axle vent hose clip and a power steering hose bracket. ^ Safety Recall No.891 applies to 1997-2000 model year trucks that only require the axle vent hose clip. IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The chassis fuel tube on about 90,000 of the above vehicles may contact the cab underbody. Prolonged fuel tube contact may cause the tube to rub through and leak. Fuel leakage in the presence of an ignition source can result in an underbody fire. In addition, the rear brake hose may contact the rear axle vent hose. Prolonged brake hose contact may cause the hose to rub through and leak, resulting in a partial brake system loss and increased stopping distance. The increased stopping distance can cause an accident without warning. Repair The chassis fuel tube must be inspected for evidence of contact and/or wear. All fuel tubes must have an isolator installed and fuel tubes that show signs of wear from contact with the underbody must be replaced. In addition, the rear brake hose must be inspected for evidence of contact and/or wear. The rear axle vent hose must also be shortened and repositioned. Rear brake hoses that have ribs worn smooth from contact with the vent hose must be replaced. Alternate Transportation If inspection determines that fuel tube and/or brake hose replacement is required and the vehicle must be held overnight, dealers should attempt to minimize customer inconvenience by placing the owner in a loaner vehicle. Parts Information A. Fuel Tube and Axle Vent Hose Isolator Package Part Number Description CBK48920 Fuel Tube and Axle Vent Hose Isolator Package Each package contains a fuel tube isolator and a vent hose isolator clip. Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Isolator Packages to service about 25% of those vehicles. B. Chassis Fuel Tube Part Number Description 52127884AC Chassis Fuel Tube Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Fuel Tubes to service about 10% of those vehicles. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Recalls for Brake Hose/Line: > 892 > Sep > 00 > Recall - Fuel Tube/Brake Hose Wear Through > Page 5329 C. Rear Brake Hose Part Number Description 52008984AE Rear Brake Hose Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Brake Hoses to service about 10% of those vehicles. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown: Add the cost of the part(s) plus applicable dealer allowance to your claim. NOTE: Vehicles involved in Recall No.892 are NOT included in either Recall No.870 or 891. Accordingly, claims submitted for Recall No.870 or 891 on vehicles involved in Recall No.892 will be rejected. See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return Not required Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD892". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner letter is shown. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Recalls for Brake Hose/Line: > 892 > Sep > 00 > Recall - Fuel Tube/Brake Hose Wear Through > Page 5330 Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. A. Inspect Chassis Fuel Tube 1. Raise the vehicle on an appropriate hoist. 2. Inspect the chassis fuel tube for evidence of wear from contact with the vehicle underbody where it is routed over the frame crossmember just behind the evaporative canister mounting bracket (Figure 1). ^ If there is evidence of wear from contact with the underbody, the chassis fuel tube must be replaced and a rubber isolator must be installed on the new fuel tube. Continue with Section B Replace Chassis Fuel Tube. ^ If there is NO evidence of contact, install a rubber isolator on the fuel tube as follows: a. Clean the fuel tube with brake clean (Mopar PN 04897150AA or equivalent). b. Fill the cavity of the provided rubber isolator with RTV Sealant (Mopar PN 82300234 or equivalent). c. Snap the isolator over the area of the tube that is closest to the underbody (Figure 1). Position the isolator with the slit toward the ground. d. Continue with Section C--Inspect Rear Brake Hose. NOTE: It is acceptable, and likely, that the rubber isolator will be in contact with the vehicle underbody. Do NOT bend the fuel tube to avoid contact with the underbody. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Recalls for Brake Hose/Line: > 892 > Sep > 00 > Recall - Fuel Tube/Brake Hose Wear Through > Page 5331 B. Replace Chassis Fuel Tube 1. Lower the vehicle. 2. Remove the Power Distribution Center (PDC) cover. 3. Remove the fuel pump relay from the PDC. 4. Start the engine and let it run until it runs out of fuel. Then attempt to start the engine two more times. 5. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 6. Install the fuel pump relay into the PDC and install the PDC cover. 7. Raise the vehicle on the hoist. 8. Position two (2) tall jack stands under the left (driver) side of the cab (Figure 2). 9. Remove the two (2) left side cab mounting bolts (Figure 2). 10. Loosen, but do not remove, the two (2) right passenger) side cab mounting bolts. 11. Carefully lower the vehicle on the hoist until the left side of the cab is supported by the jack stands and the cab has been raised 2-3 inches above the frame. CAUTION: Do NOT raise the cab of the vehicle more than 3 inches or damage to cab may result. 12. Disconnect the vapor hoses from the evaporative canister. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Recalls for Brake Hose/Line: > 892 > Sep > 00 > Recall - Fuel Tube/Brake Hose Wear Through > Page 5332 13. Remove the three (3) bolts that attach the evaporative canister bracket to the frame rail (Figure 3). Set the evaporative canister and bracket assembly aside. 14. Remove the two (2) chassis fuel tube P-clip bolts along the top of the frame rail and one P-clip on the transmission crossmember. 15. Disconnect the chassis fuel tube from the fuel pump module. 16. Disconnect the fuel vent hose from the vent tube near the fuel tank. 17. Disconnect the chassis fuel tube from the engine compartment fuel line. 18. Disconnect the three (3) electrical harness clips from the top of the frame rail near the fuel tank. 19. Remove the fuel tube from the frame rail clip near the transmission crossmember. 20. Remove the chassis fuel tube by pulling it forward and out from under the vehicle. 21. Transfer the vapor tube and P-clips from the old fuel tube to the new fuel tube. 22. With a helper to assist you, install the new chassis fuel tube. CAUTION: Be careful not to kink the plastic tubing at the rear of the fuel tube assembly. 23. Secure the fuel tube into the frame rail clip. 24. Connect the fuel tube to the engine compartment fuel line. Pull back on the quick connect fitting to ensure that it is fully connected. 25. Connect the fuel tube to the fuel pump module. Pull back on the quick connect fitting to ensure that it is fully connected. 26. Connect the vapor hose to the vapor tube. 27. Secure the electrical harness to the frame rail with the three (3) harness clips. 28. Install the three (3) fuel tube P-clip bolts. Tighten the bolts securely. 29. Install the evaporative canister and bracket assembly (Figure 3). Tighten the canister bracket bolts to 90 in-lbs (10 Nm). 30. Connect the vapor hoses to the canister. 31. Fill the cavity of the provided rubber isolator with RTV Sealant (Mopar PN 82300234 or equivalent). 32. Snap the isolator over the area of the new fuel tube near the canister that is closest to the underbody. Position the isolator with the slit toward the ground. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Recalls for Brake Hose/Line: > 892 > Sep > 00 > Recall - Fuel Tube/Brake Hose Wear Through > Page 5333 31. Raise the vehicle on the hoist and remove the jack stands. 32. Install the two left side cab bolts (Figure 3). Tighten the cab bolts to 60 ft-lbs (81 Nm). 33. Tighten the two right cab bolts to 60 ft-lbs (81 Nm). 34. Lower the vehicle. 35. Connect the negative battery cable. 36. Start the vehicle and check for any fuel leaks. 37. Continue with Section C - Inspect Rear Brake Hose. C. Inspect Rear Brake Hose 1. Raise the vehicle on an appropriate hoist. 2. Inspect the rear brake hose for evidence of contact with the rear axle vent hose (Figure 4). ^ If the ribs on the brake hose surface are worn smooth from contact with the vent hose, the brake hose must be replaced and the rear axle vent hose must be shortened and repositioned.Continue with Section D - Replace Rear Brake Hose. ^ If the ribs on the brake hose surface are NOT worn smooth, the rear axle vent hose must be shortened and repositioned. Continue with Section E - Reposition and Clip the Rear Axle Vent Hose. D. Replace Rear Brake Hose NOTE: Only those vehicles that have a worn brake hose, as determined by the inspection in Section C, require replacement. Very few vehicles are expected to require brake hose replacement. 1. Lower the vehicle. 2. Depress and hold the brake pedal using a brake pedal prop rod. NOTE: Keeping the brake pedal in the "applied" position makes bleeding the brakes faster and easier since only the rear brakes will require bleeding. 3. Raise the vehicle on the hoist. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Recalls for Brake Hose/Line: > 892 > Sep > 00 > Recall - Fuel Tube/Brake Hose Wear Through > Page 5334 4. Disconnect the rear chassis brake tube from the rear brake hose and cap the brake tube (Figure 5). NOTE: DO NOT allow brake fluid to drip or spill on painted surfaces as this may damage the paint. If brake fluid contacts a painted surface, flush with water immediately. 5. Remove the retaining clip and disconnect the rear brake hose from the mounting bracket. 6. Disconnect the left and right rear brake tubes from the rear brake hose (Figure 6). 7. Remove the brake hose bracket nut from the RWAL/ABS speed sensor bracket (Figure 6). 8. Remove the rear brake hose from the clips and discard the brake hose. 9. Install the new brake hose into the clips. 10. Install the brake hose bracket onto the RWAL/ABS speed sensor bracket (Figure 6). Tighten the bracket nut to 195 in-lbs (24 Nm). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Recalls for Brake Hose/Line: > 892 > Sep > 00 > Recall - Fuel Tube/Brake Hose Wear Through > Page 5335 11. Connect the left and right brake tubes to the new brake hose (Figure 6). Tighten the brake tube fittings to 145 in-lbs (16 Nm). 12. Install the other end of the brake hose into the mounting bracket and install the retaining clip (Figure 5). 13. Connect the rear chassis brake tube to the rear brake hose (Figure 5). Tighten the brake tube fitting to 145 in-lbs (16 Nm). 14. Bleed the left and right rear brake circuits as follows: a. Attach a clear plastic hose to the right rear bleeder screw and feed the hose into a clear jar containing enough fresh brake fluid to submerge the end of the hose. b. Have a helper pump the brake pedal three or four times and then hold it in the down position. c. With the pedal in the down position, open the bleeder screw at least one full turn. d. Once the brake pedal has dropped, close the bleeder screw. After the bleeder screw is closed, release the brake pedal. e. Repeat steps b through d until all trapped air is removed from the right rear brake circuit (usually four or five times). f. Repeat steps a through e for the left rear brake circuit. 15. Top off the master cylinder with brake fluid and inspect brake hose connections to insure that there are no leaks. 16. Continue with Section E - Reposition and Clip the Rear Axle Vent Hose. E. Reposition and Clip the Rear Axle Vent Hose 1. Disconnect the vent hose from the nipple on the rear axle housing (Figure 7). 2. Mark the vent hose 3" (75 mm) from the end of the hose that was disconnected from the axle (Figure 7). Cut the vent hose at the mark and discard the cut-off piece. 3. Mark the vent hose 4" (100 mm) from the new cut end. 4. Connect the vent hose to the axle nipple. IMPORTANT: Make sure that the vent hose is NOT routed between the rear brake hose and the wiring harness as shown in Figure 7. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Recalls for Brake Hose/Line: > 892 > Sep > 00 > Recall - Fuel Tube/Brake Hose Wear Through > Page 5336 5. Install the provided isolator clip on the vent hose at the mark made in Step 3 (Figure 8). 6. Attach the other end of the isolator clip to the parking brake cable so that the vent hose is routed away from the brake hose and perpendicular to the axle (Figure 8). 7. Lower the vehicle. 8. Verify proper brake operation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Recalls for Brake Hose/Line: > 892 > Sep > 00 > Recall - Fuel Tube/Brake Hose Wear Through > Page 5337 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Recalls for Brake Hose/Line: > 891 > Aug > 00 > Recall - Axle Vent Rubs Through Brake Hose Technical Service Bulletin # 891 Date: 000801 Recall - Axle Vent Rubs Through Brake Hose August 2000 Safety Recall No.891-Axle Vent Hose Clip Models 1997-2000 (AN) Dodge Dakota NOTE: This recall applies to most of the above vehicles built through August 20, 1999 (MDH082007). NOTE: Safety Recall No.870 and 892 combine the axle vent hose clip with another repair. Dealers should verify which recall the vehicle is involved in prior to completing the service procedure. ^ Safety Recall No.870 applies to 1997-2000 model year trucks equipped with a 2.5L engine and involves the axle vent hose clip and a power steering hose bracket. ^ Safety Recall No.892 applies to 1997 model year club cab (131" W.B.) trucks and involves the axle vent hose clip and a rear fuel tube isolator. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to stop sale and complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The rear brake hose on about 309,000 of the above vehicles may contact the rear axle vent hose. Prolonged brake hose contact may cause the hose to rub through and leak, resulting in a partial brake system loss and increased stopping distance. The increased stopping distance can cause an accident without warning. Repair The rear brake hose must be inspected for evidence of contact and/or wear. The rear axle vent hose must also be shortened and repositioned. Brake hoses that have ribs worn smooth from contact with the vent hose must be replaced. Alternate Transportation If inspection determines that brake hose replacement is required and the vehicle must be held overnight, dealers should attempt to minimize customer inconvenience by placing the owner in a loaner vehicle. Parts Information A. Axle Vent Hose Isolator Clip Part Number Description 56021260 Axle Vent Hose Isolator Clip Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Isolator Clips to service about 25% of those vehicles. B. Rear Brake Hose Part Number Description 52008984AE Rear Brake Hose Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Brake Hoses to service about 10% of those vehicles. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Recalls for Brake Hose/Line: > 891 > Aug > 00 > Recall - Axle Vent Rubs Through Brake Hose > Page 5342 service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown: Add the cost of the part(s) plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD891". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner letter is shown. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. A. Inspect Rear Brake Hose 1. Raise the vehicle on an appropriate hoist. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Recalls for Brake Hose/Line: > 891 > Aug > 00 > Recall - Axle Vent Rubs Through Brake Hose > Page 5343 2. Inspect the rear brake hose for evidence of contact with the rear axle vent hose (Figure 1). ^ If the ribs on the brake hose surface are worn smooth from contact with the vent hose, the brake hose must be replaced and the rear axle vent hose must be shortened and repositioned. Continue with Section "B" - Replace Rear Brake Hose. ^ If the ribs on the brake hose surface are NOT worn smooth, the rear axle vent hose must be shortened and repositioned. Continue with Section "C" - Reposition and Clip Rear Axle Vent Hose. B. Replace Rear Brake Hose NOTE: Only those vehicles that have a worn brake hose, as determined by the inspection in Section "A", require replacement. Very few vehicles are expected to require brake hose replacement. 1. Lower the vehicle. 2. Depress and hold the brake pedal using a brake pedal prop rod. NOTE: Keeping the brake pedal in the "applied" position makes bleeding the brakes faster and easier since only the rear brakes will require bleeding. 3. Raise the vehicle on the hoist. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Recalls for Brake Hose/Line: > 891 > Aug > 00 > Recall - Axle Vent Rubs Through Brake Hose > Page 5344 4. Disconnect the rear chassis brake tube from the rear brake hose and cap the brake tube (Figure 2). NOTE: DO NOT allow brake fluid to drip or spill on painted surfaces as this may damage the paint. If brake fluid contacts a painted surface, flush with water immediately. 5. Remove the retaining clip and disconnect the rear brake hose from the mounting bracket. 6. Disconnect the left and right rear brake tubes from the rear brake hose (Figure 3). 7. Remove the brake hose bracket nut from the RWAL/ABS speed sensor bracket (Figure 3). 8. Remove the rear brake hose from the clips and discard the brake hose. 9. Install the new brake hose into the clips. 10. Install the brake hose bracket onto the RWAL/ABS speed sensor bracket (Figure 3). Tighten the bracket nut to 195 in-lbs (24 Nm). 11. Connect the left and right brake tubes to the new brake hose (Figure 3). Tighten the brake tube fittings to 145 in-lbs (16 Nm). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Recalls for Brake Hose/Line: > 891 > Aug > 00 > Recall - Axle Vent Rubs Through Brake Hose > Page 5345 12. Install the other end of the brake hose into the mounting bracket and install the retaining clip (Figure 2). 13. Connect the rear chassis brake tube to the rear brake hose (Figure 2). Tighten the brake tube fining to 145 in-lbs (16 Nm). 14. Bleed the left and right rear brake circuits as follows: a. Attach a clear plastic hose to the right rear bleeder screw and feed the hose into a clear jar containing enough fresh brake fluid to submerge the end of the hose. b. Have a helper pump the brake pedal three or four times and then hold it in the down position. c. With the pedal in the down position, open the bleeder screw at least one full turn. d. Once the brake pedal has dropped, close the bleeder screw. After the bleeder screw is closed, release the brake pedal. e. Repeat steps b through d until all trapped air is removed from the right rear brake circuit (usually four or five times). f. Repeat steps a through e for the left rear brake circuit. 15. Inspect brake hose connections to insure that there are no leaks. 16. Continue with Section "C - Reposition and Clip the Rear Axle Vent Hose." C. Reposition and Clip the Rear Axle Vent Hose 1. Disconnect the vent hose from the nipple on the rear axle housing (Figure 4). 2. Mark the vent hose about 3" (75 mm) from the end of the hose that was disconnected from the axle (Figure 4). Cut the vent hose at the mark and discard the cut-off piece. 3. Mark the vent hose about 4" (100 mm) from the new cut end. 4. Connect the vent hose to the axle nipple. IMPORTANT: Make sure that the vent hose is NOT routed between the rear brake hose and the wiring harness as shown in Figure 4. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Recalls for Brake Hose/Line: > 891 > Aug > 00 > Recall - Axle Vent Rubs Through Brake Hose > Page 5346 5. Install the provided isolator clip on the vent hose at the mark made in Step 3 (Figure 5). 6. Attach the other end of the isolator clip to the parking brake cable so that the vent hose is routed away from the brake hose and perpendicular to the axle (Figure 5). 7. Lower the vehicle. 8. Verify proper brake operation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Recalls for Brake Hose/Line: > 891 > Aug > 00 > Recall - Axle Vent Rubs Through Brake Hose > Page 5347 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Recalls for Brake Hose/Line: > NHTSA00V198000 > Jul > 00 > Recall 00V198000: Brake Hose Puncture Brake Hose/Line: Recalls Recall 00V198000: Brake Hose Puncture Vehicle Description: Pickup trucks. Some vehicles may have been built with inadequate clearance between the rear axle vent hose and the brake hose. A puncture in the rear brake hose will result in a loss of braking force at the rear wheels. Dealers will inspect the rear brake hose for evidence of wear. Worn brake hoses will be replaced. The rear vent hose will be shortened by 3 inches and a clip will be installed to assure clearance between the axle vent line and brake hose is maintained. Owner notification is divided into phases based on vehicle build configuration. Notification to owners of vehicles contained in the first phase of the recall began August 21, 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact DaimlerChrysler at 1-800-992-1997. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Hose/Line: > 892 > Sep > 00 > Recall Fuel Tube/Brake Hose Wear Through Technical Service Bulletin # 892 Date: 000901 Recall - Fuel Tube/Brake Hose Wear Through September 2000 Safety Recall No. 892 Fuel Tube Isolator and Axle Vent Hose Clip Models 1997 (AN) Dodge Dakota Club Cab (131" Wheel Base) NOTE: Safety Recall No.870 and 891 also involve the axle vent hose clip repair. Dakotas involved in Recall No. 892 are NOT included in either Recall No.870 or 891. Dealers must verify which recall the truck is involved in prior to completing the service procedure. ^ Safety Recall No.870 applies to 1997-2000 model year trucks equipped with a 2.5L engine and involves the axle vent hose clip and a power steering hose bracket. ^ Safety Recall No.891 applies to 1997-2000 model year trucks that only require the axle vent hose clip. IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The chassis fuel tube on about 90,000 of the above vehicles may contact the cab underbody. Prolonged fuel tube contact may cause the tube to rub through and leak. Fuel leakage in the presence of an ignition source can result in an underbody fire. In addition, the rear brake hose may contact the rear axle vent hose. Prolonged brake hose contact may cause the hose to rub through and leak, resulting in a partial brake system loss and increased stopping distance. The increased stopping distance can cause an accident without warning. Repair The chassis fuel tube must be inspected for evidence of contact and/or wear. All fuel tubes must have an isolator installed and fuel tubes that show signs of wear from contact with the underbody must be replaced. In addition, the rear brake hose must be inspected for evidence of contact and/or wear. The rear axle vent hose must also be shortened and repositioned. Rear brake hoses that have ribs worn smooth from contact with the vent hose must be replaced. Alternate Transportation If inspection determines that fuel tube and/or brake hose replacement is required and the vehicle must be held overnight, dealers should attempt to minimize customer inconvenience by placing the owner in a loaner vehicle. Parts Information A. Fuel Tube and Axle Vent Hose Isolator Package Part Number Description CBK48920 Fuel Tube and Axle Vent Hose Isolator Package Each package contains a fuel tube isolator and a vent hose isolator clip. Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Isolator Packages to service about 25% of those vehicles. B. Chassis Fuel Tube Part Number Description 52127884AC Chassis Fuel Tube Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Fuel Tubes to service about 10% of those vehicles. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Hose/Line: > 892 > Sep > 00 > Recall Fuel Tube/Brake Hose Wear Through > Page 5357 C. Rear Brake Hose Part Number Description 52008984AE Rear Brake Hose Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Brake Hoses to service about 10% of those vehicles. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown: Add the cost of the part(s) plus applicable dealer allowance to your claim. NOTE: Vehicles involved in Recall No.892 are NOT included in either Recall No.870 or 891. Accordingly, claims submitted for Recall No.870 or 891 on vehicles involved in Recall No.892 will be rejected. See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return Not required Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD892". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner letter is shown. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Hose/Line: > 892 > Sep > 00 > Recall Fuel Tube/Brake Hose Wear Through > Page 5358 Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. A. Inspect Chassis Fuel Tube 1. Raise the vehicle on an appropriate hoist. 2. Inspect the chassis fuel tube for evidence of wear from contact with the vehicle underbody where it is routed over the frame crossmember just behind the evaporative canister mounting bracket (Figure 1). ^ If there is evidence of wear from contact with the underbody, the chassis fuel tube must be replaced and a rubber isolator must be installed on the new fuel tube. Continue with Section B Replace Chassis Fuel Tube. ^ If there is NO evidence of contact, install a rubber isolator on the fuel tube as follows: a. Clean the fuel tube with brake clean (Mopar PN 04897150AA or equivalent). b. Fill the cavity of the provided rubber isolator with RTV Sealant (Mopar PN 82300234 or equivalent). c. Snap the isolator over the area of the tube that is closest to the underbody (Figure 1). Position the isolator with the slit toward the ground. d. Continue with Section C--Inspect Rear Brake Hose. NOTE: It is acceptable, and likely, that the rubber isolator will be in contact with the vehicle underbody. Do NOT bend the fuel tube to avoid contact with the underbody. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Hose/Line: > 892 > Sep > 00 > Recall Fuel Tube/Brake Hose Wear Through > Page 5359 B. Replace Chassis Fuel Tube 1. Lower the vehicle. 2. Remove the Power Distribution Center (PDC) cover. 3. Remove the fuel pump relay from the PDC. 4. Start the engine and let it run until it runs out of fuel. Then attempt to start the engine two more times. 5. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 6. Install the fuel pump relay into the PDC and install the PDC cover. 7. Raise the vehicle on the hoist. 8. Position two (2) tall jack stands under the left (driver) side of the cab (Figure 2). 9. Remove the two (2) left side cab mounting bolts (Figure 2). 10. Loosen, but do not remove, the two (2) right passenger) side cab mounting bolts. 11. Carefully lower the vehicle on the hoist until the left side of the cab is supported by the jack stands and the cab has been raised 2-3 inches above the frame. CAUTION: Do NOT raise the cab of the vehicle more than 3 inches or damage to cab may result. 12. Disconnect the vapor hoses from the evaporative canister. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Hose/Line: > 892 > Sep > 00 > Recall Fuel Tube/Brake Hose Wear Through > Page 5360 13. Remove the three (3) bolts that attach the evaporative canister bracket to the frame rail (Figure 3). Set the evaporative canister and bracket assembly aside. 14. Remove the two (2) chassis fuel tube P-clip bolts along the top of the frame rail and one P-clip on the transmission crossmember. 15. Disconnect the chassis fuel tube from the fuel pump module. 16. Disconnect the fuel vent hose from the vent tube near the fuel tank. 17. Disconnect the chassis fuel tube from the engine compartment fuel line. 18. Disconnect the three (3) electrical harness clips from the top of the frame rail near the fuel tank. 19. Remove the fuel tube from the frame rail clip near the transmission crossmember. 20. Remove the chassis fuel tube by pulling it forward and out from under the vehicle. 21. Transfer the vapor tube and P-clips from the old fuel tube to the new fuel tube. 22. With a helper to assist you, install the new chassis fuel tube. CAUTION: Be careful not to kink the plastic tubing at the rear of the fuel tube assembly. 23. Secure the fuel tube into the frame rail clip. 24. Connect the fuel tube to the engine compartment fuel line. Pull back on the quick connect fitting to ensure that it is fully connected. 25. Connect the fuel tube to the fuel pump module. Pull back on the quick connect fitting to ensure that it is fully connected. 26. Connect the vapor hose to the vapor tube. 27. Secure the electrical harness to the frame rail with the three (3) harness clips. 28. Install the three (3) fuel tube P-clip bolts. Tighten the bolts securely. 29. Install the evaporative canister and bracket assembly (Figure 3). Tighten the canister bracket bolts to 90 in-lbs (10 Nm). 30. Connect the vapor hoses to the canister. 31. Fill the cavity of the provided rubber isolator with RTV Sealant (Mopar PN 82300234 or equivalent). 32. Snap the isolator over the area of the new fuel tube near the canister that is closest to the underbody. Position the isolator with the slit toward the ground. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Hose/Line: > 892 > Sep > 00 > Recall Fuel Tube/Brake Hose Wear Through > Page 5361 31. Raise the vehicle on the hoist and remove the jack stands. 32. Install the two left side cab bolts (Figure 3). Tighten the cab bolts to 60 ft-lbs (81 Nm). 33. Tighten the two right cab bolts to 60 ft-lbs (81 Nm). 34. Lower the vehicle. 35. Connect the negative battery cable. 36. Start the vehicle and check for any fuel leaks. 37. Continue with Section C - Inspect Rear Brake Hose. C. Inspect Rear Brake Hose 1. Raise the vehicle on an appropriate hoist. 2. Inspect the rear brake hose for evidence of contact with the rear axle vent hose (Figure 4). ^ If the ribs on the brake hose surface are worn smooth from contact with the vent hose, the brake hose must be replaced and the rear axle vent hose must be shortened and repositioned.Continue with Section D - Replace Rear Brake Hose. ^ If the ribs on the brake hose surface are NOT worn smooth, the rear axle vent hose must be shortened and repositioned. Continue with Section E - Reposition and Clip the Rear Axle Vent Hose. D. Replace Rear Brake Hose NOTE: Only those vehicles that have a worn brake hose, as determined by the inspection in Section C, require replacement. Very few vehicles are expected to require brake hose replacement. 1. Lower the vehicle. 2. Depress and hold the brake pedal using a brake pedal prop rod. NOTE: Keeping the brake pedal in the "applied" position makes bleeding the brakes faster and easier since only the rear brakes will require bleeding. 3. Raise the vehicle on the hoist. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Hose/Line: > 892 > Sep > 00 > Recall Fuel Tube/Brake Hose Wear Through > Page 5362 4. Disconnect the rear chassis brake tube from the rear brake hose and cap the brake tube (Figure 5). NOTE: DO NOT allow brake fluid to drip or spill on painted surfaces as this may damage the paint. If brake fluid contacts a painted surface, flush with water immediately. 5. Remove the retaining clip and disconnect the rear brake hose from the mounting bracket. 6. Disconnect the left and right rear brake tubes from the rear brake hose (Figure 6). 7. Remove the brake hose bracket nut from the RWAL/ABS speed sensor bracket (Figure 6). 8. Remove the rear brake hose from the clips and discard the brake hose. 9. Install the new brake hose into the clips. 10. Install the brake hose bracket onto the RWAL/ABS speed sensor bracket (Figure 6). Tighten the bracket nut to 195 in-lbs (24 Nm). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Hose/Line: > 892 > Sep > 00 > Recall Fuel Tube/Brake Hose Wear Through > Page 5363 11. Connect the left and right brake tubes to the new brake hose (Figure 6). Tighten the brake tube fittings to 145 in-lbs (16 Nm). 12. Install the other end of the brake hose into the mounting bracket and install the retaining clip (Figure 5). 13. Connect the rear chassis brake tube to the rear brake hose (Figure 5). Tighten the brake tube fitting to 145 in-lbs (16 Nm). 14. Bleed the left and right rear brake circuits as follows: a. Attach a clear plastic hose to the right rear bleeder screw and feed the hose into a clear jar containing enough fresh brake fluid to submerge the end of the hose. b. Have a helper pump the brake pedal three or four times and then hold it in the down position. c. With the pedal in the down position, open the bleeder screw at least one full turn. d. Once the brake pedal has dropped, close the bleeder screw. After the bleeder screw is closed, release the brake pedal. e. Repeat steps b through d until all trapped air is removed from the right rear brake circuit (usually four or five times). f. Repeat steps a through e for the left rear brake circuit. 15. Top off the master cylinder with brake fluid and inspect brake hose connections to insure that there are no leaks. 16. Continue with Section E - Reposition and Clip the Rear Axle Vent Hose. E. Reposition and Clip the Rear Axle Vent Hose 1. Disconnect the vent hose from the nipple on the rear axle housing (Figure 7). 2. Mark the vent hose 3" (75 mm) from the end of the hose that was disconnected from the axle (Figure 7). Cut the vent hose at the mark and discard the cut-off piece. 3. Mark the vent hose 4" (100 mm) from the new cut end. 4. Connect the vent hose to the axle nipple. IMPORTANT: Make sure that the vent hose is NOT routed between the rear brake hose and the wiring harness as shown in Figure 7. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Hose/Line: > 892 > Sep > 00 > Recall Fuel Tube/Brake Hose Wear Through > Page 5364 5. Install the provided isolator clip on the vent hose at the mark made in Step 3 (Figure 8). 6. Attach the other end of the isolator clip to the parking brake cable so that the vent hose is routed away from the brake hose and perpendicular to the axle (Figure 8). 7. Lower the vehicle. 8. Verify proper brake operation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Hose/Line: > 892 > Sep > 00 > Recall Fuel Tube/Brake Hose Wear Through > Page 5365 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Hose/Line: > 891 > Aug > 00 > Recall Axle Vent Rubs Through Brake Hose Technical Service Bulletin # 891 Date: 000801 Recall - Axle Vent Rubs Through Brake Hose August 2000 Safety Recall No.891-Axle Vent Hose Clip Models 1997-2000 (AN) Dodge Dakota NOTE: This recall applies to most of the above vehicles built through August 20, 1999 (MDH082007). NOTE: Safety Recall No.870 and 892 combine the axle vent hose clip with another repair. Dealers should verify which recall the vehicle is involved in prior to completing the service procedure. ^ Safety Recall No.870 applies to 1997-2000 model year trucks equipped with a 2.5L engine and involves the axle vent hose clip and a power steering hose bracket. ^ Safety Recall No.892 applies to 1997 model year club cab (131" W.B.) trucks and involves the axle vent hose clip and a rear fuel tube isolator. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to stop sale and complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject The rear brake hose on about 309,000 of the above vehicles may contact the rear axle vent hose. Prolonged brake hose contact may cause the hose to rub through and leak, resulting in a partial brake system loss and increased stopping distance. The increased stopping distance can cause an accident without warning. Repair The rear brake hose must be inspected for evidence of contact and/or wear. The rear axle vent hose must also be shortened and repositioned. Brake hoses that have ribs worn smooth from contact with the vent hose must be replaced. Alternate Transportation If inspection determines that brake hose replacement is required and the vehicle must be held overnight, dealers should attempt to minimize customer inconvenience by placing the owner in a loaner vehicle. Parts Information A. Axle Vent Hose Isolator Clip Part Number Description 56021260 Axle Vent Hose Isolator Clip Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Isolator Clips to service about 25% of those vehicles. B. Rear Brake Hose Part Number Description 52008984AE Rear Brake Hose Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Brake Hoses to service about 10% of those vehicles. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Hose/Line: > 891 > Aug > 00 > Recall Axle Vent Rubs Through Brake Hose > Page 5370 service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown: Add the cost of the part(s) plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD891". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner letter is shown. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. A. Inspect Rear Brake Hose 1. Raise the vehicle on an appropriate hoist. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Hose/Line: > 891 > Aug > 00 > Recall Axle Vent Rubs Through Brake Hose > Page 5371 2. Inspect the rear brake hose for evidence of contact with the rear axle vent hose (Figure 1). ^ If the ribs on the brake hose surface are worn smooth from contact with the vent hose, the brake hose must be replaced and the rear axle vent hose must be shortened and repositioned. Continue with Section "B" - Replace Rear Brake Hose. ^ If the ribs on the brake hose surface are NOT worn smooth, the rear axle vent hose must be shortened and repositioned. Continue with Section "C" - Reposition and Clip Rear Axle Vent Hose. B. Replace Rear Brake Hose NOTE: Only those vehicles that have a worn brake hose, as determined by the inspection in Section "A", require replacement. Very few vehicles are expected to require brake hose replacement. 1. Lower the vehicle. 2. Depress and hold the brake pedal using a brake pedal prop rod. NOTE: Keeping the brake pedal in the "applied" position makes bleeding the brakes faster and easier since only the rear brakes will require bleeding. 3. Raise the vehicle on the hoist. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Hose/Line: > 891 > Aug > 00 > Recall Axle Vent Rubs Through Brake Hose > Page 5372 4. Disconnect the rear chassis brake tube from the rear brake hose and cap the brake tube (Figure 2). NOTE: DO NOT allow brake fluid to drip or spill on painted surfaces as this may damage the paint. If brake fluid contacts a painted surface, flush with water immediately. 5. Remove the retaining clip and disconnect the rear brake hose from the mounting bracket. 6. Disconnect the left and right rear brake tubes from the rear brake hose (Figure 3). 7. Remove the brake hose bracket nut from the RWAL/ABS speed sensor bracket (Figure 3). 8. Remove the rear brake hose from the clips and discard the brake hose. 9. Install the new brake hose into the clips. 10. Install the brake hose bracket onto the RWAL/ABS speed sensor bracket (Figure 3). Tighten the bracket nut to 195 in-lbs (24 Nm). 11. Connect the left and right brake tubes to the new brake hose (Figure 3). Tighten the brake tube fittings to 145 in-lbs (16 Nm). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Hose/Line: > 891 > Aug > 00 > Recall Axle Vent Rubs Through Brake Hose > Page 5373 12. Install the other end of the brake hose into the mounting bracket and install the retaining clip (Figure 2). 13. Connect the rear chassis brake tube to the rear brake hose (Figure 2). Tighten the brake tube fining to 145 in-lbs (16 Nm). 14. Bleed the left and right rear brake circuits as follows: a. Attach a clear plastic hose to the right rear bleeder screw and feed the hose into a clear jar containing enough fresh brake fluid to submerge the end of the hose. b. Have a helper pump the brake pedal three or four times and then hold it in the down position. c. With the pedal in the down position, open the bleeder screw at least one full turn. d. Once the brake pedal has dropped, close the bleeder screw. After the bleeder screw is closed, release the brake pedal. e. Repeat steps b through d until all trapped air is removed from the right rear brake circuit (usually four or five times). f. Repeat steps a through e for the left rear brake circuit. 15. Inspect brake hose connections to insure that there are no leaks. 16. Continue with Section "C - Reposition and Clip the Rear Axle Vent Hose." C. Reposition and Clip the Rear Axle Vent Hose 1. Disconnect the vent hose from the nipple on the rear axle housing (Figure 4). 2. Mark the vent hose about 3" (75 mm) from the end of the hose that was disconnected from the axle (Figure 4). Cut the vent hose at the mark and discard the cut-off piece. 3. Mark the vent hose about 4" (100 mm) from the new cut end. 4. Connect the vent hose to the axle nipple. IMPORTANT: Make sure that the vent hose is NOT routed between the rear brake hose and the wiring harness as shown in Figure 4. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Hose/Line: > 891 > Aug > 00 > Recall Axle Vent Rubs Through Brake Hose > Page 5374 5. Install the provided isolator clip on the vent hose at the mark made in Step 3 (Figure 5). 6. Attach the other end of the isolator clip to the parking brake cable so that the vent hose is routed away from the brake hose and perpendicular to the axle (Figure 5). 7. Lower the vehicle. 8. Verify proper brake operation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Hose/Line: > 891 > Aug > 00 > Recall Axle Vent Rubs Through Brake Hose > Page 5375 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Hose/Line: > NHTSA00V198000 > Jul > 00 > Recall 00V198000: Brake Hose Puncture Brake Hose/Line: All Technical Service Bulletins Recall 00V198000: Brake Hose Puncture Vehicle Description: Pickup trucks. Some vehicles may have been built with inadequate clearance between the rear axle vent hose and the brake hose. A puncture in the rear brake hose will result in a loss of braking force at the rear wheels. Dealers will inspect the rear brake hose for evidence of wear. Worn brake hoses will be replaced. The rear vent hose will be shortened by 3 inches and a clip will be installed to assure clearance between the axle vent line and brake hose is maintained. Owner notification is divided into phases based on vehicle build configuration. Notification to owners of vehicles contained in the first phase of the recall began August 21, 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact DaimlerChrysler at 1-800-992-1997. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Page 5380 Brake Hose/Line: Specifications TIGHTENING SPECIFICATIONS Brake Line Fittings: @ Combination Valve .......................................................................................................................... ............................................. 170 inch lbs. @ Master Cylinder ........................................................... .................................................................................................................. 170 inch lbs. @ Wheel Cylinder ............................................................................................................................................... .............................. 145 inch lbs. Clip Bolt ............................................................................................................................................... ................................................... 250 inch lbs. Fittings, Front ............................................................. ............................................................................................................................. 145 inch lbs. Fittings, Rear ....................................................................................................................................... ..................................................... 170 inch lbs. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Page 5381 Brake Hose/Line: Description and Operation Flexible rubber hose is used at both front brakes and at the rear axle junction block. Double walled steel tubing is used to connect the master cylinder to the major hydraulic braking components and then to he flexible rubber hoses. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Page 5382 Brake Hose/Line: Testing and Inspection Flexible rubber hose is used at both front brakes and at the rear axle junction block. Inspect the hoses whenever the brake system is serviced, at every engine oil change, or whenever the vehicle is in for service. Inspect the hoses for surface cracking, scuffing, or worn spots. Replace any brake hose immediately if the fabric casing of the hose is exposed due to cracks or abrasions. Also, ensure brake hose installation will not result in kinked or twisted hoses, or contact with the wheels, tires or other chassis components. All of these conditions can lead to scuffing, cracking and eventual failure. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Page 5383 Brake Hose/Line: Service and Repair NOTE: Mopar preformed metal brake line is recommended and preferred for all repairs. However, double-wall steel line can be used for emergency repair when factory replacement parts are not readily available. NOTE: Special, heavy duty tube bending and flaring equipment is required to prepare double wall brake line. Special bending tools are needed to avoid kinking or twisting metal brake line. In addition, special flaring tools are needed to provide the inverted-type, double flare required on metal brake lines. FLARING PROCEDURE 1. Cut off damaged tube with tubing cutter. 2. Ream cut edges of tubing to ensure proper flare. 3. Install replacement tube nut on section of tube to be repaired. 4. Insert tube in flaring tool. Center tube in area between vertical posts. 5. Place gauge form over the end of the tube. 6. Push tubing through flaring tool jaws until tube contacts recessed notch in gauge that matches tube diameter. 7. Squeeze flaring tool jaws to lock tubing in place. 8. Insert plug on gauge in the tube, then swing compression disc over gauge and center tapered flaring screw in compression disc recess. Cutting And Flaring Of Brake Fluid Tubing 9. Tighten tool handle until plug gauge is seated on jaws of flaring tool. This will start the inverted flare. 10. Remove the plug gauge and complete the inverted flare. 11. Remove the flaring tools and verify that the inverted flare is correct. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications Brake Proportioning/Combination Valve: Specifications TIGHTENING SPECIFICATIONS Brake Lines To Valve .......................................................................................................................... ........................................... 19 Nm (170 inch lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation > Pressure Differential Switch Brake Proportioning/Combination Valve: Description and Operation Pressure Differential Switch The pressure differential switch is connected to the brake warning light. The switch is triggered by movement of the switch valve. The purpose of the switch is to monitor fluid pressure in the separate front/rear brake hydraulic circuits. A decrease or loss of fluid pressure in either hydraulic circuit will cause the switch valve to shuttle forward or rearward in response to the pressure differential. Movement of the switch valve will push the switch plunger upward. This closes the switch internal contacts completing the electrical circuit to the warning light. The switch valve may remain in an actuated position until repair restores system pressures to normal levels. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation > Pressure Differential Switch > Page 5389 Brake Proportioning/Combination Valve: Description and Operation Proportioning Valve/Pressure Differential Switch The pressure differential switch in the valve is connected to the brake warning lamp. The switch is triggered by movement of the switch valve. The purpose of the switch is to monitor fluid pressure in the separate front and rear brake hydraulic circuits. A decrease or loss of fluid pressure in either hydraulic circuit will cause the switch valve to shuttle forward or rearward in response to the pressure differential. Movement of the switch valve will push the switch plunger upward. This closes the switch internal contacts completing the electrical circuit to the warning lamp. The switch valve may remain in an actuated position until repair restores system pressures to normal levels. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Service and Repair > With Rear Wheel ABS Brake Proportioning/Combination Valve: Service and Repair With Rear Wheel ABS Anti-Lock Valve Assembly REMOVAL 1. Disconnect front and rear brake lines from valve. 2. Disconnect wiring harness connector from valve. 3. Remove mounting bolt from valve and remove valve. INSTALLATION 1. Install valve on bracket and tighten mounting bolt. 2. Connect brake lines to valve and torque to 19 Nm (170 inch lbs.). 3. Connect wire harnesses to valve. 4. Bleed brake system. See: Brake Bleeding/Service and Repair/Antilock Brake System Bleeding Procedures/W/ Rear Wheel Antilock Brakes Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Service and Repair > With Rear Wheel ABS > Page 5392 Brake Proportioning/Combination Valve: Service and Repair Without Antilock Brakes REMOVAL 1. Disconnect wire from the pressure differential switch. 2. Disconnect rear brake lines from combination valve. Combination Valve 3. Remove combination valve bolt, then the valve. INSTALLATION 1. Install bolt and combination valve on bracket. 2. Connect brake lines to combination valve. 3. Torque brake lines to 170 inch lbs. 4. Connect the wire to the pressure differential switch. 5. Bleed brake system. See: Brake Bleeding/Service and Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Specifications Hydraulic Control Unit: Specifications TIGHTENING SPECIFICATIONS Brake Line Fittings ............................................................................................................................................................. 16-23 Nm (140-200 inch lbs.) Mounting Nuts ...................................................................................... ........................................................................................... 12 Nm (102 inch lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Description and Operation > Hydraulic Control Unit (HCU) Hydraulic Control Unit: Description and Operation Hydraulic Control Unit (HCU) GENERAL INFORMATION The Hydraulic Control Unit (HCU) consists of a valve body, pump body, accumulator and pump motor. The pump, motor, and accumulators are combined into an assembly attached to the valve body. The accumulators store the extra fluid released to the system for Anti-Lock Brake System (ABS) mode operation. The pump provides the fluid volume needed and is operated by a DC type motor. The motor is controlled by the Controller Anti-Lock Brake (CAB). The valve body contains the solenoid valves. The valves modulate brake pressure during anti-lock braking and are controlled by the CAB. The HCU provides three channel pressure control to the front and rear brakes. One channel controls the rear wheel brakes in tandem. The two remaining channels control the front wheel brakes individually. During anti-lock braking, the solenoid valves are opened and closed as needed. The valves are not static. They are cycled rapidly and continuously to modulate pressure and control wheel slip and deceleration. During normal braking, the HCU solenoid valves and pump are not activated. The master cylinder and power booster operate the same as a vehicle without ABS. OPERATION When the brakes are applied, fluid is forced from the master cylinder outlet ports to the HCU inlet ports. This pressure is transmitted through three normally open isolation valves inside the HCU, then through the outlet ports of the HCU to the wheels. If the CAB senses that a wheel is about to lock, based on wheel speed sensor data, it pulls the normally open isolation valve closed for that circuit. This prevents any more fluid from entering that circuit. The CAB continues to look at the sensor signal to determine if the wheel is still decelerating. If deceleration is still taking place, the normally closed dump valve for that circuit is opened. This dumps any pressure that is trapped between the normally open valve and the brake back into an accumulator. Once the affected circuit comes back up to speed, the CAB returns the valves to their normal condition allowing the affected brake to be reapplied. The pump and accumulators are used to provide rapid response during the reapply sequence and to minimize pedal feedback. During anti-lock braking, solenoid valve pressure modulation occurs in three stages: pressure increase, pressure hold, and pressure decrease. The valves are all contained in the valve body portion of the HCU. PRESSURE MODULATION STAGES Pressure Decrease The outlet valve is opened and the inlet valve is closed during the pressure decrease cycle. A pressure decrease cycle is initiated when speed sensor signals indicate high wheel slip at one or more wheels. At this point, the CAB opens the outlet valve, which also opens the return circuit to the accumulators. Fluid pressure is allowed to bleed off (decrease) as needed to prevent wheel lock. Once the period of high wheel slip has ended, the CAB closes the outlet valve and begins a pressure increase or hold cycle as needed. Pressure Hold Both solenoid valves are closed in the pressure hold cycle. Fluid apply pressure in the control channel is maintained at a constant rate. The CAB maintains the hold cycle until sensor inputs indicate a pressure change is necessary. Pressure Increase The inlet valve is open and the outlet valve is closed during the pressure increase cycle. The pressure increase cycle is used to counteract unequal wheel speeds. This cycle controls re-application of fluid apply pressure due to changing road surfaces or wheel speed. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Description and Operation > Hydraulic Control Unit (HCU) > Page 5398 Hydraulic Control Unit: Description and Operation Rear Antilock Valve Circuit Operation NORMAL OPERATION CYCLE If the Controller Anti-Lock Brake (CAB) senses that rear wheel speed deceleration is excessive, it will energize an isolation solenoid by providing battery voltage to the solenoid. This prevents a further increase of driver induced brake pressure to the rear wheels. If this initial action is not enough to prevent rear wheel lock-up, the CAB will momentarily energize a dump solenoid (the CAB energizes the dump solenoid by providing battery voltage to the solenoid). This opens the dump valve to vent a small amount of isolated rear brake pressure to an accumulator. The action of fluid moving to the accumulator reduces the isolated brake pressure at the wheel cylinders. The dump (pressure venting) cycle is limited to very short time periods (milliseconds). The CAB will pulse the dump valve until rear wheel deceleration matches the vehicle deceleration rate or the desired slip rate programmed into the CAB. The system will switch to normal braking once wheel locking tendencies are no longer present. A predetermined maximum number of consecutive dump cycles can be performed during any one anti-lock stop. ABNORMAL ACTIVITY If excessive dump cycles occur, a Diagnostic Trouble Code (DTC) will be set and stored in the CAB memory. If, during an anti-lock stop, the driver releases the brake pedal, the reset switch contacts will open. This signal to the CAB is an indication that pressure has equalized across the Rear Wheel Anti-Lock (RWAL) valve. The CAB will then reset the dump cycle counter in anticipation of the next anti-lock stop. Additionally, any fluid stored in the accumulator will force its way past the dump valve, back into the hydraulic circuit and return to the master cylinder. A fuse inside the CAB provides a fail-safe device which prevents unwanted control over the isolation and dump solenoids. The fuse is in series with the isolation and dump solenoids output circuits. If the internal fuse is open, the CAB cannot provide voltage to energize either solenoid and anti-lock stops are prevented. If the fuse is open, the braking system will operate normally but without anti-lock control over rear brake pressure. CIRCUIT OPERATION The rear wheel anti-lock valve (RWAL) contains an isolation solenoid, a dump solenoid and a reset switch. Each is powered by the Controller, Antilock Brakes (CAB) on separate circuits. Circuit B108 from the CAB feeds the dump solenoid. The isolation solenoid is powered on circuit B101 from the CAB. Circuit Z6 provides ground for both solenoids. Circuit B111 from the CAB connects to the reset switch. The case grounded RWAL valve provides ground for the reset switch. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Description and Operation > Page 5399 Hydraulic Control Unit: Service and Repair HCU Brake Lines Hydraulic Control Unit (HCU) Mounting NOTE: The Hydraulic Control Unit (HCU) is serviced as an assembly. Neither the valve body or pump/motor are repairable components. The complete assembly must be replaced if diagnosis indicates a fault. REMOVAL 1. Disconnect battery negative cable. 2. Disconnect brake lines at front anti-lock valve. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Description and Operation > Page 5400 3. Disconnect harness from the Controller Anti-Lock Brake (CAB). 4. Remove mounting nuts attaching the assembly to bracket. 5. Lift the assembly upward off studs and remove assembly. 6. Remove the bracket from the HCU. 7. Remove the CAB mounting screws and disconnect the pump motor connector 8. Lift the CAB off the HCU. INSTALLATION 1. Install the CAB on the HCU. 2. Install the bracket on the HCU. 3. Install the assembly on the mounting studs. 4. Install and tighten the mounting nuts to 12 Nm (102 inch lbs.). 5. Connect the CAB harness. 6. Connect the brake lines to the HCU. Tighten brake line fittings to 16-23 Nm (140-200 inch lbs.). 7. Connect battery. 8. Bleed brake system as outlined in ABS Service and Repair. See: Brake Bleeding/Service and Repair/Antilock Brake System Bleeding Procedures/W/ Four Wheel Antilock Brakes Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications Brake Master Cylinder: Specifications TIGHTENING SPECIFICATIONS Brake Line Fittings @ Master Cylinder ................................................................................................................................... 19 N.m (170 inch lbs.) Master Cylinder Mounting Nuts ............................................................................................................................................... 28 N.m (250 inch lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 5404 Brake Master Cylinder: Service Precautions HYDRAULIC CONNECTIONS Care must be exercised when removing/installing the master cylinder connecting lines. The threads in the cylinder fluid ports can be damaged if care is not exercised. Start all brake line fittings by hand to avoid cross threading. The cylinder reservoir can be replaced when necessary. However, the aluminum body section of the master cylinder is not a repairable component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 5405 Brake Master Cylinder: Description and Operation A two-piece master cylinder is used on all models. The cylinder body containing the primary and secondary pistons is made of aluminum. The removable fluid reservoir is made of nylon reinforced with glass fiber. The reservoir is the only serviceable component. The fluid compartments of the nylon reservoir are interconnected to permit fluid level equalization. However, the equalization feature does not affect circuit separation in the event of a front or rear brake malfunction. The reservoir compartments will retain enough fluid to operate the functioning hydraulic circuit. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 5406 Brake Master Cylinder: Testing and Inspection NOTE: If diagnosis indicates that an internal malfunction has occurred, the aluminum body section must be replaced as an assembly. 1. Start engine and check booster vacuum hose connections. A hissing noise indicates vacuum leak. Correct any vacuum leak before proceeding. 2. Stop engine and shift transmission into Neutral. 3. Pump brake pedal until all vacuum reserve in booster is depleted. 4. Press and hold brake pedal under light foot pressure. The pedal should hold firm, if the pedal falls away master cylinder is faulty (internal leakage). 5. Start engine and note pedal action it should fall away slightly under light foot pressure then hold firm. If no pedal action is discernible, power booster, vacuum supply, or vacuum check valve is faulty. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding Brake Master Cylinder: Service and Repair Master Cylinder Bleeding NOTE: A new master cylinder should be bled before installation on the vehicle. Required bleeding tools include bleed tubes and a wood dowel to stroke the pistons. Bleed tubes can be fabricated from brake line. 1. Mount master cylinder in vise. 2. Attach bleed tubes to cylinder outlet ports, then position each tube end in matching reservoir fluid compartment. Fig 3 Bench Bleeding Master Cylinder NOTE: If master cylinder has one reservoir opening, position both bleed tubes into the single reservoir opening. 3. Fill reservoir with fresh brake fluid. CAUTION: Use Mopar brake fluid, or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. 4. Press cylinder pistons inward with wood dowel. Then release pistons and allow them to return under spring pressure. Continue bleeding operations until air bubbles are no longer visible in fluid. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 5409 Brake Master Cylinder: Service and Repair Master Cylinder Replacement Master Cylinder NOTE: If diagnosis indicates that an internal malfunction has occurred, the aluminum body section must be replaced as an assembly. REMOVAL 1. Remove brake lines from the master cylinder. 2. Remove mounting nut from the master cylinder. 3. Remove master cylinder. INSTALLATION NOTE: If master cylinder is replaced, bleed cylinder before installation. 1. Install master cylinder on booster mounting studs. 2. Install mounting nuts and tighten to 250 inch lbs. 3. Install brake lines and tighten to 170 inch lbs. 4. Fill and bleed brake system. See: Brake Bleeding/Service and Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 5410 Brake Master Cylinder: Service and Repair Master Cylinder Overhaul NOTE: The reservoir is the only part of the master cylinder that can be replaced. DISASSEMBLY (RESERVOIR REMOVAL) 1. Remove reservoir cap and empty fluid into drain container. 2. Clamp cylinder body in vise with brass protective jaws. 3. Remove pins that retain reservoir to master cylinder. Use hammer and pin punch to remove pins. Brake Fluid Reservoir Retaining Pins 4. Loosen reservoir from grommets with pry tool. Brake Fluid Reservoir Separation From Master Cylinder 5. Remove reservoir by rocking it to one side and pulling free of grommets. Brake Fluid Reservoir Removal 6. Remove old grommets from cylinder body. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 5411 Grommet Removal ASSEMBLY (RESERVOIR INSTALLATION) CAUTION: Do not use any type of tool to install the grommets. Tools may cut or tear the grommets, creating a leak problem after installation. Install the grommets using finger pressure only. 1. Lubricate new grommets with clean brake fluid and Install new grommets in cylinder body. Use finger pressure to install and seat grommets. Brake Fluid Reservoir Grommet Installation 2. Start reservoir in grommets. Then rock reservoir back and forth while pressing downward to seat it in grommets. 3. Install pins that retain reservoir to cylinder body. 4. Fill and bleed master cylinder on bench before installation in vehicle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Specifications Wheel Cylinder: Specifications Wheel Cylinder Bolts 1/4-20 11 ft.lb 5/16-18 16 ft.lb Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation Wheel Cylinder: Service and Repair Wheel Cylinder Removal and Installation REMOVAL 1. Raise and support vehicle, then remove wheel and tire assembly. 2. Remove brake drum. 3. Disconnect wheel cylinder brake line. 4. Remove brake shoe return springs and move shoes out of engagement with cylinder push rods. 5. Remove cylinder attaching bolts and remove cylinder from support plate. INSTALLATION 1. Apply bead of silicone sealer around cylinder mounting surface of support plate. 2. Install cylinder mounting bolts and proceed as follows: a. Torque 1/4-20 bolts to 11 ft. lbs. b. Torque 5/16-18 bolts to 16 ft. lbs. 3. Connect brake line to cylinder. 4. Install brake shoe return spring. 5. Install brake drum. 6. Install wheel and tire assembly. 7. Bleed brake system. See: Brake Bleeding/Service and Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation > Page 5417 Wheel Cylinder: Service and Repair Cleaning and Inspection CLEANING Clean the cylinder and pistons with clean brake fluid or brake cleaner only. Do not use any other cleaning agents. Dry the cylinder and pistons with compressed air. Do not use rags or shop towels to dry the cylinder components. Lint from cloth material will adhere to the cylinder bores and pistons. INSPECTION Inspect the cylinder bore. Light discoloration and dark stains in the bore are normal and will not impair cylinder operation. The cylinder bore can be lightly polished but only with crocus cloth. Replace the cylinder if the bore is scored, pitted or heavily corroded. Honing the bore to restore the surface is not recommended. Inspect the cylinder pistons. The piston surfaces should be smooth and free of scratches, scoring and corrosion. Replace the pistons if worn, scored, or corroded. Do attempt to restore the surface by sanding or polishing. Discard the old piston cups and the spring and expander. These parts are not reusable. The original dust boots may be reused but only if they are in good condition. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation > Page 5418 Wheel Cylinder: Service and Repair Wheel Cylinder Overhaul DISASSEMBLY 1. Remove push rods and boots. 2. Press pistons, cups and spring and expander out of cylinder bore. 3. Remove bleed screw. CLEANING Clean the cylinder and pistons with clean brake fluid or brake cleaner only. Do not use any other cleaning agents. Dry the cylinder and pistons with compressed air. Do not use rags or shop towels to dry the cylinder components. Lint from cloth material will adhere to the cylinder bores and pistons. NOTE: The cylinder bore can be lightly polished but only with crocus cloth. Replace the cylinder if the bore is scored, pitted or heavily corroded. Honing the bore to restore the surface is not recommended. ASSEMBLY 1. Lubricate wheel cylinder bore, pistons, piston cups and spring and expander with clean brake fluid. 2. Install first piston in cylinder bore. Then install first cup in bore and against piston. Be sure lip of piston cup is facing inward (toward spring and expander) and flat side is against piston. 3. Install spring and expander followed by remaining piston cup and piston. 4. Install boots on each end of cylinder and insert push rods in boots. 5. Install cylinder bleed screw. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Adjustments Parking Brake Cable: Adjustments NOTE: Cable tensioner adjustment is only necessary when the tensioner or a cable has been replaced or disconnected for service. When adjustment is necessary, perform adjustment only as described in the following procedure. This is necessary to avoid faulty park brake operation. 1. Raise and support vehicle. 2. Back off cable tensioner adjusting nut at equalizer to create slack in cables. 3. Remove rear wheel/tire assemblies, then remove brake drums. 4. Verify brakes are in good condition and operating properly. 5. Verify park brake cables operate freely and are not binding or seized. 6. Check rear brake shoe adjustment with standard brake gauge. 7. Install drums and verity that drums rotate freely without drag. 8. Reinstall wheel/tire assemblies after brake shoe adjustment is complete. 9. Lower vehicle enough for access to park brake foot pedal, then fully apply park brakes. NOTE: Leave park brakes applied until adjustment is complete. 10. Raise and support vehicle again. 11. Mark tensioner rod 1/4 inch from edge of tensioner bracket. Cable Tensioner Rod Adjustment Mark 12. Tighten adjusting nut at equalizer until mark on tensioner rod moves into alignment with tensioner bracket. CAUTION: Do not loosen or tighten the tensioner adjusting nut for any reason after completing adjustment. 13. Lower vehicle until rear wheels are 6-8 inches off shop floor. 14. Release park brake foot pedal and verify that rear wheels rotate freely without drag. Lower vehicle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Cable Replacement Parking Brake Cable: Service and Repair Front Cable Replacement REMOVAL 1. Raise and support the vehicle. 2. Loosen cable adjusting nut. Parking Brake Cable Tensioner 3. Disengage front cable from rear cable or extension cable, if equipped. Parking Brake Cable Connectors 4. Remove support cable from the front cable. Parking Brake Support Cable 5. Remove support and lower vehicle. 6. Remove left kick panel. 7. Fold left front edge of floor covering rearward and remove cable grommet from floor pan. 8. Engage parking brake pedal and remove cable from park brake pedal assembly. 9. Work cable and housing assembly up through floor pan. 10. Remove front cable from vehicle. INSTALLATION 1. Insert front cable through floor pan and install grommet. 2. Insert cable retainer into hole at bottom of pedal assembly bracket and connect cable end. 3. Install kick panel. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Cable Replacement > Page 5425 4. Raise and support vehicle. 5. Install support cable to the front cable. 6. Attach front cable to connector on rear cable or intermediate cable if equipped. 7. Adjust parking brakes. 8. Remove support and lower vehicle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Cable Replacement > Page 5426 Parking Brake Cable: Service and Repair Rear Cable Replacement REMOVAL 1. Raise and support vehicle and remove rear wheels. 2. Loosen tensioner adjuster nut. 3. Disconnect right rear cable from front cable or extension cable, if equipped. Parking Brake Cable Connectors 4. Remove right cable from tensioner. 5. Compress tabs on each cable retainer with hose clamp or pliers and release hose clamp or pliers. Fig 4 Compressing Cable Retainer Tabs 6. Remove right cable from frame bracket and left cable from adjuster nut bracket. 7. Remove brake drum and brake shoes. 8. Disconnect rear cable from lever on secondary brake shoe and remove cable spring. 9. Compress tabs on each cable retainer with hose clamp or pliers. Release hose clamp or pliers and remove cable from brake support plate. 10. Remove cable from vehicle. INSTALLATION 1. Insert cable through support plate hole and cable guide until cable retainer tabs lock into place. Pull on the cable to ensure it is lock in to the support plate. 2. Lubricate park brake lever pivot points, anchor pin and shoe contact pads on support plate with multi purpose grease. 3. Slide the spring over the cable, then connect the spring and cable to park brake lever. Ensure the spring and cable is seated in the lever. 4. Install the park brake lever to the secondary brake shoe. 5. Install brake shoes on support plate. Be sure park brake lever strut and spring are properly positioned before installing return springs. 6. Adjust brake shoes to drums with brake gauge. Then install brake drums and wheels. 7. Install right cable into frame bracket until cable retainer tabs lock into place. 8. Install left cable into adjuster nut bracket until cable retainer tabs lock into place. 9. Install right cable to tension and left cable to front cable or extension cable if equipped 10. Adjust park brake. 11. Lower vehicle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair Parking Brake Lever: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Unsnap the plastic retainer clip from the park brake linkage rod at the back of the park brake release handle, and remove the rod end from the handle. Park Brake Release Handle Remove/Install 3. Using a trim stick or another suitable wide flat-bladed tool, gently pry the park brake handle hinge tab away from the pivot pin on the instrument panel. 4. While prying the park brake release handle hinge tab, pull the handle firmly down and away from the pivot pin. 5. Reverse the removal procedures to install. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Diagrams Parking Brake Pedal Assembly Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Diagrams > Page 5433 Parking Brake Pedal: Service and Repair REMOVAL 1. Remove left side kick panel. 2. Remove brake release rod from pedal assembly. 3. Disconnect brake warning lamp switch. 4. Remove front parking brake cable. 5. Remove mounting nuts and mounting bolt. 6. Slide assembly rearward off the mounting studs. Parking Brake Pedal Assembly INSTALLATION 1. Install assembly on the mounting studs. 2. Install mounting bolt and nuts. 3. Install front parking brake cable. 4. Connect brake warning lamp switch. 5. Install brake release rod to pedal assembly. 6. Install left side kick panel. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair Parking Brake Shoe: Service and Repair REMOVAL 1. Raise and support vehicle. 2. Remove wheel and tire assembly. 3. Remove clip nuts securing brake drum to wheel studs. 4. Remove drum. If drum is difficult to remove, proceed as follows: a. Remove rear plug from access hole in support plate. b. BInsert a thin screwdriver into access hole and push lever away from adjuster screw star wheel. c. Insert an adjuster tool into brake adjusting hole and rotate adjuster star wheel to retract brake shoes. 5. Vacuum brake components to remove brake lining dust. If vacuum is not available, use water dampened cloths to remove dust. 6. Remove shoe return springs with brake spring plier tool. 7. Remove adjuster cable. Slide cable eye off anchor pin, then unhook and remove cable from adjuster lever. 8. Remove cable guide from secondary shoe and anchor plate from anchor pin. 9. Remove adjuster lever. Disengage lever from spring by sliding lever forward to clear pivot and work lever out from under spring. 10. Remove adjuster lever spring from pivot. 11. Disengage and remove shoe spring from brake shoes. 12. Disengage and remove adjuster screw assembly from brake shoes. 13. Remove brake shoe retainers and springs. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Page 5437 14. Remove secondary brake shoe from support plate. 15. Remove strut and spring. 16. Remove parking brake lever from secondary shoe. 17. Remove primary shoe from support plate. 18. Disengage parking brake lever from parking brake cable. INSTALLATION 1. Clean and inspect individual brake components. 2. Lubricate anchor pin and brake shoe contact pads on support plate with high temperature grease or Lubriplate. 3. Lubricate adjuster screw socket, nut, button and screw thread surfaces with grease or Lubriplate. 4. Attach parking brake cable to lever, then connect lever to secondary shoe. 5. Install primary shoe on support plate. Secure shoe with new spring retainers and pin. 6. Install spring on parking brake strut and engage strut in primary. 7. Install secondary shoe on support plate. Insert strut in shoe and guide shoe onto anchor pin. Temporarily secure shoe with retaining pin. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Page 5438 Fig 7 Installing Brake Shoes 8. Install anchor plate and adjuster cable eyelet on support plate anchor pin. 9. Install cable guide in secondary shoe and position cable in guide. 10. Assemble adjuster screw, then install between the brake shoes. NOTE: Be sure the adjuster screws are installed on the correct brake unit. The adjuster screws are marked L (left) and R (right) for identification. 11. Install adjuster lever and spring and connect adjuster cable to lever. 12. Install secondary shoe retainers and spring. 13. Install shoe spring. Connect spring to secondary shoe first, then to primary shoe. 14. Verity adjuster operation. Pull adjuster cable upward, cable should lift lever and rotate star wheel. Be sure adjuster lever properly engages star wheel teeth. 15. Adjust brake shoes to drum with brake gauge. See: Drum Brake System/Adjustments 16. Install wheel and tire assembly. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Page 5439 Parking Brake Shoe: Tools and Equipment Brake Shoe Adjuster Tool No. C-3784 Adjusting Brake Shoes With Gauge Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Lamp > Component Information > Description and Operation Parking Brake Warning Lamp: Description and Operation CIRCUIT OPERATION Ground for the park brake lamp is supplied through the case grounded park brake switch on circuit G11. If the vehicle is equipped with Rear Wheel Antilock (RWAL) brakes, circuit G11 provides an input to the Controller, Antilock Brakes (CAB) and splices to circuit G9. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Description and Operation Parking Brake Warning Switch: Description and Operation CIRCUIT OPERATION On circuit G11, the Controller, Antilock Brakes (CAB) senses when the park brake switch closes. Circuit G11 also connects to the park brake lamp in the instrument cluster and through a diode to circuit G9. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications Vacuum Brake Booster: Specifications BOOSTER SPECIFICATIONS Type ..................................................................................................................................................... ........................................... Single Diaphragm TIGHTENING SPECIFICATIONS Brake Booster Mounting Nuts .............................................................................................................. ................................................... 250 inch lbs. Brake Line Fittings @ Master Cylinder ................................................................................................................................................... 170 inch lbs. Master Cylinder Mounting Nuts .............................................................................................................................................................. 250 inch lbs. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 5450 Vacuum Brake Booster: Description and Operation CAUTION: The power brake booster is not a repairable component. The booster must be replaced as an assembly if diagnosis indicates a malfunction has occurred. TYPE AND APPLICATION All models are equipped with power assist brakes. A single diaphragm power brake booster is used for all applications. CONSTRUCTION The booster unit consists of a single housing divided into two chambers by a diaphragm. The outer edge of the diaphragm is secured to the housing. The booster push rod, which connects the booster to the brake pedal and master cylinder, is attached to the center of the diaphragm. CHECK VALVE A check valve is used in the booster outlet connected to the engine intake manifold. Power assist is generated by utilizing a combination of vacuum and atmospheric pressure to boost brake assist. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Check Valve Test Vacuum Brake Booster: Testing and Inspection Check Valve Test 1. Disconnect vacuum hose from check valve. 2. Remove check valve and valve seal from booster. 3. Use a hand operated vacuum pump for test. 4. Apply 15-20 inches vacuum at large end of check valve. Vacuum Check Valve & Seal 5. Vacuum should hold steady. If gauge on pump indicates vacuum loss, check valve is faulty and should be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Check Valve Test > Page 5453 Vacuum Brake Booster: Testing and Inspection Vacuum Test VACUUM SOURCE/LEAK TEST 1. Connect vacuum gauge to booster check valve with short length of hose and T-fitting. Booster Vacuum Test Connections 2. Start and run engine at curb idle speed for one minute. 3. Observe the vacuum supply. If vacuum supply is not adequate, repair vacuum supply. 4. Clamp hose shut between vacuum source and check valve. 5. Stop engine and observe vacuum gauge. 6. If vacuum drops more than one inch HG (33 millibars) within 15 seconds, booster diaphragm or check valve is faulty. 7. If the power booster vacuum test passes, rebuild booster vacuum reserve. Release brake pedal. Increase engine speed to 1500 rpm, close the throttle and immediately turn off ignition to stop engine. 8. Wait a minimum of 90 seconds and try brake action again. Booster should provide two or more vacuum assisted pedal applications. If vacuum assist is not provided, booster is faulty. VACUUM CHECK VALVE TEST 1. Disconnect vacuum hose from check valve. 2. Remove check valve and valve seal from booster. 3. Use a hand operated vacuum pump for test. 4. Apply 15-20 inches vacuum at large end of check valve. Vacuum Check Valve & Seal 5. Vacuum should hold steady. If gauge on pump indicates vacuum loss, check valve is faulty and should be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Page 5454 Vacuum Brake Booster: Service and Repair REMOVAL 1. Remove master cylinder. 2. Disconnect vacuum lines at booster. 3. Remove clip securing booster push rod to brake pedal. Brake Booster Rod & Pedal 4. Remove nuts from booster mounting studs. Brake Booster Mounting 5. Remove booster and gasket from front cowl panel. INSTALLATION 1. Position gasket on booster studs. 2. Guide booster studs into cowl panel holes and seat booster on panel. 3. Install and tighten booster attaching nuts to 28 N.m (250 inch lbs.). 4. Install booster push rod on brake pedal and install clip. 5. Install booster check valve if removed and connect vacuum hose to check valve. 6. Install master cylinder. 7. Fill and bleed brake system. See: Brake Bleeding/Service and Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Locations ABS Main Relay: Locations Anti-Lock Brake System (ABS) relays are located in the power distribution box in the engine compartment. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Locations > Page 5459 ABS Main Relay: Description and Operation The Anti-Lock Brake System (ABS) has two relays, one for the system and one for the pump motor. The system relay is used for the solenoid valves and Controller Anti-Lock Brake (CAB). The system relay is connected to the CAB at the power control relay terminal. The pump motor relay is used for the pump motor only. The pump motor relay starts/stops the pump motor when signaled by the CAB. The relays are located in the power distribution box in the engine compartment. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 5463 CAB Connectors Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > With Four Wheel Antilock Brakes Electronic Brake Control Module: Description and Operation With Four Wheel Antilock Brakes GENERAL INFORMATION The Controller Anti-Lock Brake (CAB) module is mounted on the top of the Hydraulic Control Unit (HCU). It operates the Anti-Lock Brake System (ABS) and is separate from other vehicle electrical circuits. CAB voltage comes through the ignition switch in the RUN position. The CAB contains dual microprocessors. A logic block in each microprocessor receives identical sensor signals. These signals are processed and compared simultaneously. OPERATION The module is used to monitor wheel speeds and modulate (control) hydraulic pressure in each brake channel. The modulated hydraulic pressure is used to prevent wheel lockup during braking. Brake switch input is monitored to determine whether or not to prepare for possible anti-lock braking. Wheel speed sensors are monitored to determine when a wheel is beginning to lock up. The CAB will operate the valves in the HCU to control braking pressure during anti-lock braking. SELF-DIAGNOSTIC FEATURES 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 Diagnostic Readout Box (DRB) scan tool. ABS faults remain in memory until cleared, or until after the vehicle is started approximately 50 times. Stored faults are not erased if the battery is disconnected. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > With Four Wheel Antilock Brakes > Page 5466 Electronic Brake Control Module: Description and Operation With Rear Wheel Antilock Brakes GENERAL INFORMATION The Controller Anti-Lock Brake (CAB) is a microprocessor which monitors and controls the Anti-Lock Brake System (ABS) operation. It has a 14 terminal connector to deliver power and ground and to connect all inputs and outputs associated with the system. The CAB primary functions are: ^ Detect wheel locking tendencies. ^ Control the application of brake fluid pressure to the rear brakes during ABS braking. ^ Monitor the Rear Wheel Anti-Lock (RWAL) brake system for proper operation. ^ Perform self-check diagnostics. The CAB continuously monitors the speed of the differential ring gear by monitoring signals generated by the rear wheel speed sensor. The CAB determines a wheel locking tendency when it recognizes the ring gear decelerating too rapidly. When a wheel-locking tendency is detected, the CAB energizes the isolation solenoid in the RWAL valve. When the isolation solenoid is energized, hydraulic pressure cannot be increased to the rear wheel cylinders. If the rear wheel speed sensor still indicate that the ring gear is decelerating too rapidly, the CAB then energizes the dump solenoid to reduce pressure at the rear wheel cylinders. The CAB continues this action until the wheel-locking tendency no longer exists. ON-BOARD DIAGNOSTICS When a fault is detected, the CAB will generate and store diagnostic trouble codes. Only one code can be stored at any one time. If the CAB senses a fault in any one of its monitored circuits, it will illuminate the red brake warning and ABS warning lamps. It will then generate a Diagnostic Trouble Code (DTC) and store it in memory. In general, the diagnostic trouble code will remain in memory when the ignition key has been turned Off. The exception to this is Diagnostic Trouble Codes 9 and 11, which are erased any time the key has been turned to the Off position. Also, Diagnostic Trouble Code 11 will be removed from memory when the ignition switch is in the Run or Accessory positions if the malfunction has been eliminated. If the malfunction remains, Diagnostic Trouble Codes 9 and 11 will be reset on the next ignition key cycle to On. INPUTS The CAB monitors the following inputs to determine when a wheel locking tendency may exist: ^ Rear Wheel Speed Sensor ^ Brake Lamp Switch ^ Brake Warning Lamp Switch ^ Reset Switch ^ 4WD Switch (If equipped) OUTPUTS The CAB controls the following outputs for anti-lock braking and brake warning information: ^ RWAL Valve ^ ABS Warning Lamp ^ Brake Warning Lamp POWER SUPPLY & GROUND Ignition voltage is provided to the CAB through connector pin 3 and is protected by a 20 amp fuse. Ignition voltage is supplied when the ignition switch is in the Run or Accessory positions. The CAB requires ignition voltage to be able to operate the anti-lock brakes. Battery voltage is provided to the CAB through pin 9 and is protected by a 20 amp fuse. This circuit supplies power to the memory cells so that the CAB can retain diagnostic information. Except for Diagnostic Trouble Codes 9 and 11, the CAB stores DTCs in the battery fed volatile memory. Volatile memories only retain information as long as power is supplied to the memory. If a DTC is stored in the battery fed volatile memory, the DTC can Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > With Four Wheel Antilock Brakes > Page 5467 be cleared from the memory by disconnecting the battery supply to the CAB. Diagnostic Trouble Codes 9 and 11 are also in a volatile memory but their memories are fed with ignition voltage. A ground is provided to the CAB through pin 12 of the 14-way connector. It is required by the CAB to be able to operate any of its circuits. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Four Wheel Antilock Brake System Electronic Brake Control Module: Service and Repair Four Wheel Antilock Brake System Pump Motor Connector REMOVAL 1. Disconnect harness connector from the Controller Anti-Lock Brake (CAB). 2. Remove screws attaching CAB to the Hydraulic Control Unit (HCU). 3. Lift the CAB up off the HCU and disconnect the pump motor connector. 4. Remove the CAB. INSTALLATION 1. Position controller over the HCU and connect the pump motor harness. NOTE: Ensure the CAB seal is in position before installation. 2. Place the CAB onto the HCU and install the mounting screws. 3. Connect the harness to the CAB. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Four Wheel Antilock Brake System > Page 5470 Electronic Brake Control Module: Service and Repair Rear Wheel Antilock Brake System Trim Panel RWAL Controller REMOVAL 1. Remove the trim panel, Data Link Connector (DLC) and knee blocker. 2. Remove bolts attaching module to the left side of the steering column support. 3. Disconnect wiring and remove module from vehicle. INSTALLATION 1. Connect wiring to control module. 2. Position module on steering column support. 3. Install control module mounting bolts. 4. Install the knee blocker, DLC and trim panel. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > 4WD Switch > Component Information > Description and Operation 4WD Switch: Description and Operation CIRCUIT OPERATION Circuit F12 from fuse 11 in the junction block supplies voltage for the four-wheel drive indicator lamp. The ground path for the lamp is provided when the switch closes. Circuit G107 connects the lamp to the four-wheel drive switch. The switch connects to ground circuit Z1. From circuit G107, the Controller Antilock Brakes (CAB) senses when the four-wheel drive switch closes. Circuit Gl07 connects to the CAB, for wheel drive switch and the four-wheel drive indicator lamp. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Description and Operation Brake Fluid Pressure Sensor/Switch: Description and Operation CIRCUIT OPERATION Circuit G9 from the Controller, Antilock Brakes (CAB) supplies ground for the brake warning lamp. The lamp can also be grounded when either the ignition switch is in the START position, the park brake switch closes or the brake warning lamp switch in the hydraulic combination valve closes. Circuit G14 connects the brake warning lamp switch to the lamp. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Description and Operation Parking Brake Warning Switch: Description and Operation CIRCUIT OPERATION On circuit G11, the Controller, Antilock Brakes (CAB) senses when the park brake switch closes. Circuit G11 also connects to the park brake lamp in the instrument cluster and through a diode to circuit G9. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions Wheel Speed Sensor: Technical Service Bulletins ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions NUMBER: 26-10-99I GROUP: Miscellaneous DATE: October, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1993-1997 Kelsey Hayes EBC-5H, EBC 310 ABS Diagnostic Manual - Publication Number 81-699-96026 DESCRIPTION OF CHANGES Revisions to the ABS test procedures for wheel speed sensors Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5485 39 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5486 43 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5487 45 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5488 47 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5489 51 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5490 55 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5491 57 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5492 59 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5493 63 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5494 67 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5495 69 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5496 71 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5497 173 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5498 177 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5499 179 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5500 181 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5501 187 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5502 191 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5503 193 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5504 195 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5505 201 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5506 205 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5507 207 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5508 209 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions > Page 5509 256 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Electrical Specifications Wheel Speed Sensor: Electrical Specifications Sensor Coil Resistance 1000 to 2500 ohms Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Electrical Specifications > Page 5512 Wheel Speed Sensor: Mechanical Specifications Front Sensor Mounting Bolt 160-220 in.lb Rear Sensor Mounting Bolt 170-230 in.lb Wheel Speed Sensor (WSS) Clearance 0.005-0.050 in WSS Attaching Bolt 170-230 in.lb Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations Wheel Speed Sensor: Component Locations Tone Wheels Toothed Tone Wheel Ring For Front Wheel Speed Sensor Rear Tone Wheel Location FRONT The toothed tone wheel ring for the front speed sensor is located on the hub/bearing. It is not a serviceable component. To replace the ring, the hub/bearing assembly must be replaced. Refer Steering and Suspension for the service procedure. REAR The toothed exciter (tone wheel) ring is press-fitted onto the differential carrier next to the final drive ring gear in the differential case. If the ring is damaged, the differential assembly must be serviced as outlined in Transmission and Drivetrain. Front Wheel Speed Sensor (WSS) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 5515 RWAL Wheel Speed Sensor Rear Wheel Speed Sensor (WSS) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 5516 Wheel Speed Sensor: Connector Locations Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 5517 Wheel Speed Sensor: Diagrams Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Circuit Operation Wheel Speed Sensor: Description and Operation Circuit Operation CIRCUIT OPERATION The all wheel Antilock Brake System (ABS) uses three wheel speed sensors; a single sensor for both rear wheels and individual sensors for the front wheels. The single sensor used for the rear wheels mounts on the top of the rear axle differential housing. Each sensor converts wheel speed into an electrical signal that is transmitted to the Controller Antilock Brakes (CAB). A pair of twisted wires connect to each sensor and provide signals to the CAB. Circuits B6 and B7 provide signals to the CAB from the right front wheel speed sensor. Circuit B6, which provides the LOW signal, connects to cavity 4 of the CAB. Circuit B7 connects to cavity 9 of the CAB and provides the HIGH signal. Circuits B8 and B9 provide signals to the CAB from the left front wheel speed sensor. Circuit B8, which provides the LOW signal, connects to cavity 3 of the CAB. Circuit B9 connects to cavity 8 and provides the HIGH signal. Circuit B114 connects to cavity 10 of the CAB and provides the rear wheel speed sensor LOW input. While circuit B113 provides the HIGH input to cavity 5 of the CAB. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Circuit Operation > Page 5520 Wheel Speed Sensor: Description and Operation Four Wheel Antilock Brakes Front Wheel Speed Sensor (WSS) Rear Wheel Speed Sensor (WSS) The Anti-Lock Brake System (ABS) uses three wheel speed sensors. A sensor is mounted to each front steering knuckles. The third sensor is mounted on top of the rear axle differential housing. The sensor is a magnet coil that is mounted over a tone wheel front/exciter ring rear with an air gap between them. The sensors measure the wheel speed by monitoring the rotation of the front tone wheels and rear exciter ring. As the teeth of the wheels and ring move through the magnetic field of the sensor, an AC voltage signal is generated. This signal frequency increases or decreases proportionally to the speed of the wheel. The Controller Anti-Lock Brake (CAB) monitors these signals for changes in wheel deceleration. If the CAB detects that a wheel or wheels are suddenly decelerating at a predetermined rate, the CAB will activate the ABS. Each wheel speed sensor's coil will have approximately 1000 to 2500 ohms of resistance. The CAB will disable anti-lock control, complete the anti-lock warning light circuit, and store trouble codes if it detects one of the following problems 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 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Circuit Operation > Page 5521 Wheel Speed Sensor: Description and Operation Rear Wheel Antilock Brakes RWAL Wheel Speed Sensor The rear Wheel Speed Sensor (WSS) is mounted in the rear differential housing. The WSS consists of a magnet surrounded by windings from a single strand of wire. The sensor sends a small AC signal to the Controller Anti-Lock Brake (CAB). This signal is generated by magnetic induction. The magnetic induction is created when a toothed ring (exciter ring or tone wheel) passes the stationary magnetic WSS. Toothed Exciter Ring The toothed ring is press-fitted onto the differential carrier next to the final drive ring gear. When the ring gear is rotated, the exciter ring passes the tip of the WSS. As the exciter ring passes the tip of the WSS, the magnetic lines of force of the sensor are cut, causing the magnetic field to be moved across the sensor's windings. This, in turn causes current to flow through the WSS circuit. Wheel Speed Sensor (WSS) Operation 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 sine wave) is Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Circuit Operation > Page 5522 interpreted by the CAB. It then compares the frequency of the sine wave 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 rotates, the stronger the signal will be. - Distance between the exciter ring teeth and WSS; the closer the WSS is to the exciter ring, the stronger the signal will be. The 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 to 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 left of the steering column and attached to the lower portion of the instrument panel. Data Link Connector (DLC) The rolls test terminal is spliced to the WSS circuit. The vehicle is then driven on a set of rollers and the WSS output is monitored for proper operation. CIRCUIT OPERATION The rear wheel speed sensor is mounted on the top of the rear axle differential. The sensor converts wheel speed into an electrical signal that is transmitted to the Controller, Antilock Brakes (CAB). Circuits B113 and B114, a pair of twisted wires, connect to the sensor and provide signals to the CAB. Circuit B113 connects to cavity 14 of the CAB. Circuit B114 connects to cavity 13 of the CAB. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Circuit Operation > Page 5523 Wheel Speed Sensor: Description and Operation Tone Wheels Toothed Tone Wheel Ring For Front Wheel Speed Sensor Rear Tone Wheel Location FRONT The toothed tone wheel ring for the front speed sensor is located on the hub/bearing. It is not a serviceable component. To replace the ring, the hub/bearing assembly must be replaced. Refer Steering and Suspension for the service procedure. REAR The toothed exciter (tone wheel) ring is press-fitted onto the differential carrier next to the final drive ring gear in the differential case. If the ring is damaged, the differential assembly must be serviced as outlined in Transmission and Drivetrain. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Page 5524 Wheel Speed Sensor: Testing and Inspection RWAL Speed Sensor Air Gap 1. Remove sensor from differential. 2. Measure and record the distance from the underside of the sensor flange to the end of the sensor pole piece. This distance represents dimension B. 3. Measure and record the distance between the sensor mounting surface of differential case and teeth at top of the exciter ring. This distance represents dimension A. 4. Subtract dimension B from dimension A to determine the Rear Wheel Anti-Lock (RWAL) speed sensor air gap. The gap should be a minimum of 0.127 mm (0.005 inch) and a maximum of 1.27 mm (0.050 inch). 5. If air gap is not within stated limits, proceed as follows: a. Dimension B distance should be 27.18-27.43 mm (1.070-1.080 inch). If the RWAL speed sensor is not within these limits, replace the RWAL speed sensor. b. Dimension A distance should be 27.56-28.45 mm (1.085-1.120 inch). If dimension A is not within the specification, replace the exciter ring or repair the differential. c. If dimension A and dimension B exceeds their specifications, replace both the RWAL speed sensor and exciter ring. Also, repair the differential if necessary. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Page 5525 Wheel Speed Sensor: Adjustments The Wheel Speed Sensor (WSS) is not adjustable. A clearance specification of 0.005 to 0.050 inch has been established for manufacturing tolerances. If the clearance is not within these specifications, the WSS or other components may be damaged. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement Front Front Wheel Speed Sensor Mounting CAUTION: Special bolts are used to attach the front sensor. The bolts have a special shoulder, thread length and surface treatment. If the original bolts must be replaced, use only a factory replacement part. Do not use substitute bolts under any circumstances. REMOVAL 1. Raise and support vehicle. 2. Remove bolt attaching sensor to the steering knuckle. 3. Remove clamps securing sensor wire to control arm and inner fender panel. 4. In engine compartment, disconnect sensor wire from harness and remove sensor. INSTALLATION 1. Position sensor in the knuckle and install sensor attaching bolts. Tighten bolts to 18-25 Nm (160-220 inch lbs.). 2. Secure sensor wire retaining clamps to control arm and fender panel. 3. In engine compartment, connect sensor wire to harness connector. Make sure wire is routed away from hot or rotating underhood components. 4. Turn steering wheel back and forth to verify that wire is clear of steering and suspension components. 5. Remove supports and lower vehicle. Rear Rear Speed Sensor Mounting REMOVAL Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 5528 1. Raise vehicle on hoist. 2. Remove bolt securing sensor and shield to differential housing. 3. Remove sensor and shield from differential housing. 4. Disconnect sensor wire harness and remove sensor. INSTALLATION 1. Connect harness to sensor. Be sure seal is securely in place between sensor and wiring connector. 2. Install O-ring on sensor (if removed). 3. Insert sensor in differential housing. 4. Install sensor shield. 5. Install and torque sensor attaching bolt to 19-29 N.m (170-230 in. lbs.). 6. Lower vehicle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 5529 Wheel Speed Sensor: Service and Repair Tone Wheel Replacement Rear Tone Wheel The toothed exciter ring is press-fitted onto the differential carrier next to the final drive ring gear in the differential case. If the ring is damaged, refer to Transmission and Drivetrain for service procedures. With Four Wheel Antilock Brakes Toothed Tone Wheel Ring For Front Wheel Speed Sensor Rear Tone Wheel Location FRONT The toothed tone wheel ring for the front speed sensor is located on the hub/bearing. It is not a serviceable component. To replace the ring, the hub/bearing assembly must be replaced. Refer Steering and Suspension for the service procedure. REAR The toothed exciter (tone wheel) ring is press-fitted onto the differential carrier next to the final drive ring gear in the differential case. If the ring is damaged, the differential assembly must be serviced as outlined in Transmission and Drivetrain. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations Battery Temp. Sensor Location Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 5535 Battery Temp. Sensor Connector Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 5536 Battery Temperature Sensor: Service Precautions WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN . Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 5537 Battery Temperature Sensor: Description and Operation SYSTEM OPERATION The battery temperature sensor 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. CIRCUIT OPERATION The Powertrain Control Module (PCM) determines battery temperature on circuit K118. Circuit K118 connects the PCM to the battery temperature sensor. Circuit K4 provides ground for the sensor. Circuit K118 connects to cavity C15 of the PCM. Circuit K4 connects to cavity A4. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Testing and Inspection > Testing Battery Temperature Sensor: Testing and Inspection Testing To perform a complete test of this sensor and its circuitry, refer to the appropriate Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Charts Procedures. To test the sensor only, refer to the following: Battery Temperature Sensor 1. The sensor is located under the battery and is attached to the battery tray. A two-wire pigtail harness is attached directly to the sensor. The opposite end of this harness connects the sensor to the engine wiring harness. 2. Disconnect the two-wire pigtail harness from the engine harness. 3. Attach ohmmeter leads to the wire terminals of the pigtail harness. 4. At room temperature of 25 °C (75 - 80 °F), an ohmmeter reading of 9,000 (9K) to 11,000 (11K) ohms should be observed. 5. If reading is above or below the specification, replace the sensor. 6. Refer to the Removal and Installation for procedures. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Testing and Inspection > Page 5540 Battery Temperature Sensor: Service and Repair Battery Temperature Sensor The battery temperature sensor is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray. The sensor is located under the battery on drivers side of vehicle. REMOVAL 1. Remove battery. 2. Disconnect sensor pigtail harness from engine wire harness. 3. Pry sensor straight up from battery tray mounting hole. INSTALLATION 1. Feed pigtail harness through mounting hole in top of battery tray and press sensor into top of tray (snaps in). 2. Connect pigtail harness. 3. Install battery. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Description and Operation Clutch Switch: Description and Operation A clutch pedal position switch has been added to the starter circuit. The switch, which is in circuit with the starter solenoid, requires that the clutch pedal be fully depressed in order to start the engine. The switch is located on the clutch master cylinder push rod. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Description and Operation Ignition Switch: Description and Operation IGNITION SWITCH AND KEY LOCK CYLINDER The ignition switch is located on the steering column. The Key-In-Switch is located in the ignition switch module. For electrical diagnosis of the Key-In-Switch, refer to Chime/Buzzer Warning Systems. For removal/installation of either the key lock cylinder or ignition switch, refer to Ignition Switch and Key Cylinder Removal/Installation. On vehicles equipped with an automatic transmission, a cable connects an interlock device within the steering column assembly to the transmission floor shift lever. This interlock device is used to lock the transmission shifter in the PARK position when the key is in the LOCKED or ACCESSORY position. The interlock device is not serviceable. If repair is necessary, the steering column assembly must be replaced. Refer to procedures. The shifter interlock cable can be adjusted or replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Description and Operation > Page 5547 Ignition Switch: Service and Repair Fig 46 Shroud Removal/Installation - Typical IGNITION SWITCH AND KEY CYLINDER The ignition key must be in the key cylinder for cylinder removal. KEY CYLINDER REMOVAL 1. Disconnect negative cable from battery. 2. If equipped with tilt column, remove tilt lever by turning it counterclockwise. 3. Remove upper and lower covers (shrouds) from steering column. 4. If equipped with automatic transmission, place shifter in PARK position. Fig 47 Retaining Pin 5. A retaining pin is located at side of key cylinder assembly. a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder from ignition switch. IGNITION SWITCH REMOVAL 1. Remove key lock cylinder. Refer to previous steps. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Description and Operation > Page 5548 Fig 48 Switch Mounting Screws 2. Remove 3 ignition switch mounting screws. Use tamper proof torx bit (Snap-On SDMTR10 or equivalent) to remove screws. 3. Gently pull switch away from column. Release connector locks on 7-terminal wiring connector at ignition switch and remove connector. 4. Release connector lock on 4-terminal halo lamp wiring connector and remove connector. IGNITION SWITCH AND KEY CYLINDER INSTALLATION If installing ignition key lock cylinder only, proceed to following steps 2, 3 and 4. Also refer to following steps 12 through 18. If installing both switch and key cylinder, refer to steps 1 through 18. Fig 50 Flag In RUN Position Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Description and Operation > Page 5549 Fig 51 Key Cylinder - Rear View 1. Rotate flag on rear of ignition switch until in RUN position. This step must be done to allow tang on key cylinder to fit into slots within ignition switch. Fig 52 Installing Key Cylinder Into Switch 2. With key into ignition key cylinder, rotate key clockwise until retaining pin can be depressed. 3. Install key cylinder into ignition switch by aligning retaining pin into retaining pin slot. Push key cylinder into switch until retaining pin engages. After pin engages, rotate key to OFF or LOCK position. 4. Check for proper retention of key cylinder by attempting to pull cylinder from switch. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Description and Operation > Page 5550 Fig 53 Ignition Switch View From Column Fig 54 Park Lock Linkage - Automatic Transmission - Typical 5. Automatic Transmission Only: Before attaching ignition switch to steering column, the transmission shifter must be in PARK position. The park lock dowel pin on rear of ignition switch must also be properly indexed into the park lock linkag before installing switch. 6. The flag at rear of ignition switch must be properly indexed into steering column before installing switch. This flag is used to operate the steering wheel lock lever in steering column. This lever allows steering wheel position to be locked when key switch is in LOCK position. 7. Place ignition switch in LOCK position. The switch is in the LOCK position when column lock flag is parallel to ignition switch terminals. 8. Automatic Transmission Only: Apply a light coating of grease to park lock dowel pin and park lock slider linkage. Before installing switch, push the park lock slider linkage forward until it bottoms. Do a final positioning by pulling it rearward about one-quarter inch. 9. Apply a light coating of grease to both column lock flag and shaft at end of flag. 10. Place ignition switch into openings on steering column. a. Automatic Transmission Only: Be sure park lock dowel pin on rear of ignition switch enters slot in park lock slider linkage. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Description and Operation > Page 5551 Fig 55 Steering Wheel Lock Lever b. Be sure flag on rear of switch is positioned above steering wheel lock lever. c. Align dowel pins on rear of switch into holes on side of steering column. d. Install 3 ignition switch mounting screws. Tighten screws to 3 Nm +/- 5 Nm (26 in lb +/- 4 in lb) torque. 11. Connect electrical connectors to ignition switch and halo lamp. Make sure that switch locking tabs are fully seated in wiring connectors. 12. Install steering column covers (shrouds). Tighten screws to 2 Nm (17 in lb) torque. 13. Install tilt column lever (if equipped). 14. Connect negative cable to battery. 15. Check for proper operation of halo light. 16. Automatic Transmission Only: Shifter should lock in PARK position when key is in LOCK position (if equipped with shift lock device). Shifter should unlock when key rotated to ON position. 17. Check for proper operation of ignition switch in ACCESSORY, LOCK, OFF, ON, RUN, and START positions. 18. Steering wheel should lock when key is in LOCK position. Rotate steering wheel to verify Steering wheel should unlock when key is rotated to ON position. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Specifications Neutral Safety Switch: Specifications Mounting Bolts ..................................................................................................................................... .................................................... 34 Nm (25 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Specifications > Page 5555 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Specifications > Page 5556 Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Specifications > Page 5557 Neutral Safety Switch: Description and Operation DESCRIPTION The park/neutral switch is located on the transmission housing and provides an input to the powertrain control module (PCM). This will indicate that the automatic transmission is in Park, Neutral or a drive gear selection. OPERATION This input is used to determine idle speed (varying with gear selection), fuel injector pulse width, ignition timing advance and vehicle speed control operation. CIRCUIT OPERATION Park/Neutral Position Switch When closed, the case-grounded Park/Neutral position switch provides a ground path on circuit T41 for the coil side of the engine starter motor relay Circuit A41 from the ignition switch provides battery voltage to the coil side of the relay. Circuit T41 splices to cavity A6 of the Powertrain Control Module (PCM). The Park/Neutral position switch provides an input to the PCM. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Specifications > Page 5558 Neutral Safety Switch: Testing and Inspection NOTE: The center terminal of the park/neutral position switch is the starter-circuit terminal. It provides the ground for the starter solenoid circuit through the selector lever in PARK and NEUTRAL positions only. The outer terminals on the switch are for the backup lamp circuit. To test the switch, remove the wiring connector. Test for continuity between the center terminal and the transmission case. Continuity should exist only when the transmission is in PARK or NEUTRAL. Shift the transmission into REVERSE and test continuity at the switch outer terminals. Continuity should exist only when the transmission is in REVERSE. Continuity should not exist between the outer terminals and the case. Check gearshift linkage adjustment before replacing a switch that tests faulty. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Specifications > Page 5559 Neutral Safety Switch: Service and Repair REPLACEMENT 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. 4. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 5. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 6. Test continuity of new switch with 12V test lamp. 7. Connect switch wires and lower vehicle. 8. Top off transmission fluid. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Power Distribution Center Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 5564 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 5565 Starter Relay: Description and Operation SYSTEM OPERATION The starter relay is a International Standards Organization (ISO) micro-relay The terminal designations and functions are the same as a conventional ISO relay. However, the micro-relay terminal orientation (or footprint) is different, the current capacity is lower, and the relay case dimensions are smaller than on the conventional ISO relay. The starter relay is a electro mechanical device that switches current to the pull-in coil of the starter solenoid when the ignition switch is turned to the Start position. The starter relay is located in the Power Distribution Center (PDC), in the engine compartment. Refer to the PDC label for relay identification and location. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 5566 Starter Relay: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Power Distribution Center 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC for starter relay identification and location. 4. Unplug the starter relay from the PDC. 5. Install the starter relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 6. Install the PDC cover. 7. Connect the battery negative cable. 8. Test the relay operation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations Battery Temp. Sensor Location Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Page 5571 Battery Temp. Sensor Connector Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Page 5572 Battery Temperature Sensor: Service Precautions WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN . Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Page 5573 Battery Temperature Sensor: Description and Operation SYSTEM OPERATION The battery temperature sensor 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. CIRCUIT OPERATION The Powertrain Control Module (PCM) determines battery temperature on circuit K118. Circuit K118 connects the PCM to the battery temperature sensor. Circuit K4 provides ground for the sensor. Circuit K118 connects to cavity C15 of the PCM. Circuit K4 connects to cavity A4. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Testing and Inspection > Testing Battery Temperature Sensor: Testing and Inspection Testing To perform a complete test of this sensor and its circuitry, refer to the appropriate Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Charts Procedures. To test the sensor only, refer to the following: Battery Temperature Sensor 1. The sensor is located under the battery and is attached to the battery tray. A two-wire pigtail harness is attached directly to the sensor. The opposite end of this harness connects the sensor to the engine wiring harness. 2. Disconnect the two-wire pigtail harness from the engine harness. 3. Attach ohmmeter leads to the wire terminals of the pigtail harness. 4. At room temperature of 25 °C (75 - 80 °F), an ohmmeter reading of 9,000 (9K) to 11,000 (11K) ohms should be observed. 5. If reading is above or below the specification, replace the sensor. 6. Refer to the Removal and Installation for procedures. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Testing and Inspection > Page 5576 Battery Temperature Sensor: Service and Repair Battery Temperature Sensor The battery temperature sensor is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray. The sensor is located under the battery on drivers side of vehicle. REMOVAL 1. Remove battery. 2. Disconnect sensor pigtail harness from engine wire harness. 3. Pry sensor straight up from battery tray mounting hole. INSTALLATION 1. Feed pigtail harness through mounting hole in top of battery tray and press sensor into top of tray (snaps in). 2. Connect pigtail harness. 3. Install battery. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Specifications > Electrical Specifications Generator: Electrical Specifications Voltage Powertrain Control Module (PCM) regulates charging system voltage by controlling the generator field source (+) circuit. The voltage range is 12.9 to 15.0 volts Rated Amps Denso Part # 56027912 Rated SAE Amps .......................................................................................... .......................................................................................................... 117 amps Minimum Test Amps ............................................................................................................................ ..................................................................... 90 amps Denso Part # 56027913 Rated SAE Amps .......................................................................................... .......................................................................................................... 136 amps Minimum Test Amps ............................................................................................................................ ................................................................... 120 amps Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Specifications > Electrical Specifications > Page 5582 Generator: Mechanical Specifications Description = Torque Generator Mounting Bolt = 41 N.m (30 ft. lbs.) Generator Pivot Bolt/Nut = 41 N.m (30 ft. lbs.) Battery Terminal Nut = 8.5 N.m (75 in. lbs.) Ground Terminal Nut = 8.5 N.m (75 in. lbs.) Harness Hold-down Nut = 8.5 N.m (75 in. lbs.) Field Terminal Nuts = 2.8 N.m (25 in. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Specifications > Page 5583 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Specifications > Page 5584 Generator: Description and Operation SYSTEM OPERATION The generator is belt-driven by the engine using a serpentine type drive belt. It is serviced only as a complete assembly If the generator fails for any reason, the entire assembly must be replaced. As the energized rotor begins to rotate within the generator, the spinning magnetic field induces a current into the windings of the stator coil. Once the generator begins producing sufficient current, it also provides the current needed to energize the rotor. The Y type stator winding connections deliver the induced AC current to 3 positive and 3 negative diodes for rectification. From the diodes, rectified DC current is delivered to the vehicle electrical system through the generator battery and ground terminals. Although the generators appear the same externally, different generators with different output ratings are used on this vehicle. Be certain that the replacement generator has the same output rating and part number as the original unit. Refer to Generator Ratings in the Specifications for amperage ratings and part numbers. Noise emitting from the generator may be caused by: worn, loose or defective bearings; a loose or defective drive pulley; incorrect, worn, damaged or misadjusted fan drive belt; loose mounting bolts; a misaligned drive pulley or a defective stator or diode. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Specifications > Page 5585 Generator: Service and Repair REMOVAL WARNING: DISCONNECT NEGATIVE CABLE FROM BATTERY BEFORE REMOVING BATTERY OUTPUT WIRE FROM GENERATOR. FAILURE TO DO SO CAN RESULT IN INJURY. 1. Disconnect negative battery cable. 2. Remove generator drive belt. Remove/Install Generators 3. Remove generator pivot and mounting bolts/nut. Position generator for access to wire connectors. Remove/Install Generator Connectors - Typical 4. Remove nuts from harness holddown, battery terminal, ground terminal and 2 field terminals. Remove wire connectors. A typical generator wiring harness is shown. Wiring harness routing as shown may be slightly different depending on vehicle model and/or engine. 5. Remove generator. 6. Reverse removal procedures to install. Tighten generator hardware as follows: - Generator mounting bolt - 41 N.m (30 ft. lbs.) - Generator pivot bolt/nut - 41 N.m (30 ft. lbs.) - Battery terminal nut - 8.5 N.m (75 in. lbs.) - Ground terminal nut - 8.5 N.m (75 in. lbs.) - Harness holddown nut - 8.5 N.m (75 in. lbs.) - Field terminal nuts - 2.8 N.m (25 in. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Specifications > Page 5586 CAUTION: - Never force a belt over a pulley rim using a screwdriver. The synthetic fiber of the belt can be damaged. - When installing a serpentine accessory drive belt, the belt MUST be routed correctly. The water pump will be rotating in the wrong direction if the belt is installed incorrectly, causing the engine to overheat. Refer to belt routing label in engine compartment. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Description and Operation Voltage Regulator: Description and Operation SYSTEM OPERATION The Electronic Voltage Regulator (EVR) is not a separate component. It is actually a voltage regulating circuit located within the Powertrain Control Module (PCM). The EVR is not serviced separately. If replacement is necessary, the PCM must be replaced. Operation: The amount of DC current produced by the generator is controlled by EVR circuitry contained within the PCM. This circuitry is connected in series with the generators second rotor field terminal and its ground. Voltage is regulated by cycling the ground path to control the strength of the rotor magnetic field. The EVR circuitry monitors system line voltage and battery temperature (refer to Battery Temperature Sensor for more information). It then compensates and regulates generator current output accordingly Also see Charging System Operation for additional information. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Description and Operation Clutch Switch: Description and Operation A clutch pedal position switch has been added to the starter circuit. The switch, which is in circuit with the starter solenoid, requires that the clutch pedal be fully depressed in order to start the engine. The switch is located on the clutch master cylinder push rod. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Description and Operation Ignition Lock: Description and Operation IGNITION SWITCH AND KEY LOCK CYLINDER The ignition switch is located on the steering column. The Key-In-Switch is located in the ignition switch module. For electrical diagnosis of the Key-In-Switch, refer to Chime/Buzzer Warning Systems. For removal/installation of either the key lock cylinder or ignition switch, refer to Ignition Switch and Key Cylinder Removal/Installation. On vehicles equipped with an automatic transmission, a cable connects an interlock device within the steering column assembly to the transmission floor shift lever. This interlock device is used to lock the transmission shifter in the PARK position when the key is in the LOCKED or ACCESSORY position. The interlock device is not serviceable. If repair is necessary, the steering column assembly must be replaced. Refer to procedures. The shifter interlock cable can be adjusted or replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Description and Operation > Page 5597 Ignition Lock: Service and Repair Fig 46 Shroud Removal/Installation - Typical IGNITION SWITCH AND KEY CYLINDER The ignition key must be in the key cylinder for cylinder removal. KEY CYLINDER REMOVAL 1. Disconnect negative cable from battery. 2. If equipped with tilt column, remove tilt lever by turning it counterclockwise. 3. Remove upper and lower covers (shrouds) from steering column. 4. If equipped with automatic transmission, place shifter in PARK position. Fig 47 Retaining Pin 5. A retaining pin is located at side of key cylinder assembly. a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder from ignition switch. IGNITION SWITCH REMOVAL 1. Remove key lock cylinder. Refer to previous steps. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Description and Operation > Page 5598 Fig 48 Switch Mounting Screws 2. Remove 3 ignition switch mounting screws. Use tamper proof torx bit (Snap-On SDMTR10 or equivalent) to remove screws. 3. Gently pull switch away from column. Release connector locks on 7-terminal wiring connector at ignition switch and remove connector. 4. Release connector lock on 4-terminal halo lamp wiring connector and remove connector. IGNITION SWITCH AND KEY CYLINDER INSTALLATION If installing ignition key lock cylinder only, proceed to following steps 2, 3 and 4. Also refer to following steps 12 through 18. If installing both switch and key cylinder, refer to steps 1 through 18. Fig 50 Flag In RUN Position Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Description and Operation > Page 5599 Fig 51 Key Cylinder - Rear View 1. Rotate flag on rear of ignition switch until in RUN position. This step must be done to allow tang on key cylinder to fit into slots within ignition switch. Fig 52 Installing Key Cylinder Into Switch 2. With key into ignition key cylinder, rotate key clockwise until retaining pin can be depressed. 3. Install key cylinder into ignition switch by aligning retaining pin into retaining pin slot. Push key cylinder into switch until retaining pin engages. After pin engages, rotate key to OFF or LOCK position. 4. Check for proper retention of key cylinder by attempting to pull cylinder from switch. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Description and Operation > Page 5600 Fig 53 Ignition Switch View From Column Fig 54 Park Lock Linkage - Automatic Transmission - Typical 5. Automatic Transmission Only: Before attaching ignition switch to steering column, the transmission shifter must be in PARK position. The park lock dowel pin on rear of ignition switch must also be properly indexed into the park lock linkag before installing switch. 6. The flag at rear of ignition switch must be properly indexed into steering column before installing switch. This flag is used to operate the steering wheel lock lever in steering column. This lever allows steering wheel position to be locked when key switch is in LOCK position. 7. Place ignition switch in LOCK position. The switch is in the LOCK position when column lock flag is parallel to ignition switch terminals. 8. Automatic Transmission Only: Apply a light coating of grease to park lock dowel pin and park lock slider linkage. Before installing switch, push the park lock slider linkage forward until it bottoms. Do a final positioning by pulling it rearward about one-quarter inch. 9. Apply a light coating of grease to both column lock flag and shaft at end of flag. 10. Place ignition switch into openings on steering column. a. Automatic Transmission Only: Be sure park lock dowel pin on rear of ignition switch enters slot in park lock slider linkage. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Description and Operation > Page 5601 Fig 55 Steering Wheel Lock Lever b. Be sure flag on rear of switch is positioned above steering wheel lock lever. c. Align dowel pins on rear of switch into holes on side of steering column. d. Install 3 ignition switch mounting screws. Tighten screws to 3 Nm +/- 5 Nm (26 in lb +/- 4 in lb) torque. 11. Connect electrical connectors to ignition switch and halo lamp. Make sure that switch locking tabs are fully seated in wiring connectors. 12. Install steering column covers (shrouds). Tighten screws to 2 Nm (17 in lb) torque. 13. Install tilt column lever (if equipped). 14. Connect negative cable to battery. 15. Check for proper operation of halo light. 16. Automatic Transmission Only: Shifter should lock in PARK position when key is in LOCK position (if equipped with shift lock device). Shifter should unlock when key rotated to ON position. 17. Check for proper operation of ignition switch in ACCESSORY, LOCK, OFF, ON, RUN, and START positions. 18. Steering wheel should lock when key is in LOCK position. Rotate steering wheel to verify Steering wheel should unlock when key is rotated to ON position. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Description and Operation Ignition Switch: Description and Operation IGNITION SWITCH AND KEY LOCK CYLINDER The ignition switch is located on the steering column. The Key-In-Switch is located in the ignition switch module. For electrical diagnosis of the Key-In-Switch, refer to Chime/Buzzer Warning Systems. For removal/installation of either the key lock cylinder or ignition switch, refer to Ignition Switch and Key Cylinder Removal/Installation. On vehicles equipped with an automatic transmission, a cable connects an interlock device within the steering column assembly to the transmission floor shift lever. This interlock device is used to lock the transmission shifter in the PARK position when the key is in the LOCKED or ACCESSORY position. The interlock device is not serviceable. If repair is necessary, the steering column assembly must be replaced. Refer to procedures. The shifter interlock cable can be adjusted or replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Description and Operation > Page 5605 Ignition Switch: Service and Repair Fig 46 Shroud Removal/Installation - Typical IGNITION SWITCH AND KEY CYLINDER The ignition key must be in the key cylinder for cylinder removal. KEY CYLINDER REMOVAL 1. Disconnect negative cable from battery. 2. If equipped with tilt column, remove tilt lever by turning it counterclockwise. 3. Remove upper and lower covers (shrouds) from steering column. 4. If equipped with automatic transmission, place shifter in PARK position. Fig 47 Retaining Pin 5. A retaining pin is located at side of key cylinder assembly. a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder from ignition switch. IGNITION SWITCH REMOVAL 1. Remove key lock cylinder. Refer to previous steps. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Description and Operation > Page 5606 Fig 48 Switch Mounting Screws 2. Remove 3 ignition switch mounting screws. Use tamper proof torx bit (Snap-On SDMTR10 or equivalent) to remove screws. 3. Gently pull switch away from column. Release connector locks on 7-terminal wiring connector at ignition switch and remove connector. 4. Release connector lock on 4-terminal halo lamp wiring connector and remove connector. IGNITION SWITCH AND KEY CYLINDER INSTALLATION If installing ignition key lock cylinder only, proceed to following steps 2, 3 and 4. Also refer to following steps 12 through 18. If installing both switch and key cylinder, refer to steps 1 through 18. Fig 50 Flag In RUN Position Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Description and Operation > Page 5607 Fig 51 Key Cylinder - Rear View 1. Rotate flag on rear of ignition switch until in RUN position. This step must be done to allow tang on key cylinder to fit into slots within ignition switch. Fig 52 Installing Key Cylinder Into Switch 2. With key into ignition key cylinder, rotate key clockwise until retaining pin can be depressed. 3. Install key cylinder into ignition switch by aligning retaining pin into retaining pin slot. Push key cylinder into switch until retaining pin engages. After pin engages, rotate key to OFF or LOCK position. 4. Check for proper retention of key cylinder by attempting to pull cylinder from switch. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Description and Operation > Page 5608 Fig 53 Ignition Switch View From Column Fig 54 Park Lock Linkage - Automatic Transmission - Typical 5. Automatic Transmission Only: Before attaching ignition switch to steering column, the transmission shifter must be in PARK position. The park lock dowel pin on rear of ignition switch must also be properly indexed into the park lock linkag before installing switch. 6. The flag at rear of ignition switch must be properly indexed into steering column before installing switch. This flag is used to operate the steering wheel lock lever in steering column. This lever allows steering wheel position to be locked when key switch is in LOCK position. 7. Place ignition switch in LOCK position. The switch is in the LOCK position when column lock flag is parallel to ignition switch terminals. 8. Automatic Transmission Only: Apply a light coating of grease to park lock dowel pin and park lock slider linkage. Before installing switch, push the park lock slider linkage forward until it bottoms. Do a final positioning by pulling it rearward about one-quarter inch. 9. Apply a light coating of grease to both column lock flag and shaft at end of flag. 10. Place ignition switch into openings on steering column. a. Automatic Transmission Only: Be sure park lock dowel pin on rear of ignition switch enters slot in park lock slider linkage. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Description and Operation > Page 5609 Fig 55 Steering Wheel Lock Lever b. Be sure flag on rear of switch is positioned above steering wheel lock lever. c. Align dowel pins on rear of switch into holes on side of steering column. d. Install 3 ignition switch mounting screws. Tighten screws to 3 Nm +/- 5 Nm (26 in lb +/- 4 in lb) torque. 11. Connect electrical connectors to ignition switch and halo lamp. Make sure that switch locking tabs are fully seated in wiring connectors. 12. Install steering column covers (shrouds). Tighten screws to 2 Nm (17 in lb) torque. 13. Install tilt column lever (if equipped). 14. Connect negative cable to battery. 15. Check for proper operation of halo light. 16. Automatic Transmission Only: Shifter should lock in PARK position when key is in LOCK position (if equipped with shift lock device). Shifter should unlock when key rotated to ON position. 17. Check for proper operation of ignition switch in ACCESSORY, LOCK, OFF, ON, RUN, and START positions. 18. Steering wheel should lock when key is in LOCK position. Rotate steering wheel to verify Steering wheel should unlock when key is rotated to ON position. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Specifications Neutral Safety Switch: Specifications Mounting Bolts ..................................................................................................................................... .................................................... 34 Nm (25 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Specifications > Page 5613 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Specifications > Page 5614 Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Specifications > Page 5615 Neutral Safety Switch: Description and Operation DESCRIPTION The park/neutral switch is located on the transmission housing and provides an input to the powertrain control module (PCM). This will indicate that the automatic transmission is in Park, Neutral or a drive gear selection. OPERATION This input is used to determine idle speed (varying with gear selection), fuel injector pulse width, ignition timing advance and vehicle speed control operation. CIRCUIT OPERATION Park/Neutral Position Switch When closed, the case-grounded Park/Neutral position switch provides a ground path on circuit T41 for the coil side of the engine starter motor relay Circuit A41 from the ignition switch provides battery voltage to the coil side of the relay. Circuit T41 splices to cavity A6 of the Powertrain Control Module (PCM). The Park/Neutral position switch provides an input to the PCM. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Specifications > Page 5616 Neutral Safety Switch: Testing and Inspection NOTE: The center terminal of the park/neutral position switch is the starter-circuit terminal. It provides the ground for the starter solenoid circuit through the selector lever in PARK and NEUTRAL positions only. The outer terminals on the switch are for the backup lamp circuit. To test the switch, remove the wiring connector. Test for continuity between the center terminal and the transmission case. Continuity should exist only when the transmission is in PARK or NEUTRAL. Shift the transmission into REVERSE and test continuity at the switch outer terminals. Continuity should exist only when the transmission is in REVERSE. Continuity should not exist between the outer terminals and the case. Check gearshift linkage adjustment before replacing a switch that tests faulty. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Specifications > Page 5617 Neutral Safety Switch: Service and Repair REPLACEMENT 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. 4. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 5. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 6. Test continuity of new switch with 12V test lamp. 7. Connect switch wires and lower vehicle. 8. Top off transmission fluid. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Description and Operation Starter Motor: Description and Operation SYSTEM OPERATION The starter motor incorporates several features to create a reliable, efficient, compact, and lightweight unit. A planetary gear system (intermediate transmission) is used between the electric motor and the pinion gear. This feature makes it possible to reduce the dimensions of the starter. At the same time, it allows higher armature rotational speed and delivers increased torque through the pinion gear to the starter ring gear on the automatic transmission torque converter or torque converter drive plate, or on the manual transmission flywheel. The use of a permanent magnet field also reduces the size and weight of the starter. The permanent magnet field consists of four high-strength permanent magnets. The magnets are aligned according to their polarity, and are permanently mounted in the starter field frame. The starter motors for all engines are activated by a solenoid mounted to the overrunning clutch housing. However, the starter motor and solenoid are serviced only as a complete assembly. If either component is faulty or damaged, the entire starter assembly must be replaced. CAUTION: Permanent magnet starters are highly sensitive to hammering, shocks, and external pressure. The permanent magnets may be damaged and the starter rendered unserviceable, if subjected to any of these conditions. - The starter motor must not be clamped in a vise by the starter field frame. Doing so may damage the permanent magnets. The starter should only be clamped by the mounting flange. - Do not connect the starter motor incorrectly when testing. Reverse polarity may damage the permanent magnets and render the starter unserviceable. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Description and Operation > Page 5621 Starter Motor: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Raise and support the vehicle. 3. If the vehicle is so equipped, remove the front axle skid plate and skid plate crossmember. Starter Remove/Install 4. Remove the nut and lock washer from the starter mounting stud. 5. Remove the screw from the upper starter mounting flange hole. If the vehicle is so equipped, slide the automatic transmission cooler tube bracket forward on the tubes far enough for clearance. 6. Move the starter towards the front of the vehicle until the starter gear housing nose clears the bellhousing. Then tilt the nose downwards and lower the starter far enough to access the starter solenoid wire harness connector. 7. Remove the two nuts that secure the battery cable and solenoid feed wire to the terminals on the starter solenoid. Remove the starter solenoid wire harness connector from the solenoid terminals. 8. Remove the starter motor from the vehicle. 9. Reverse the removal procedures to install. Tighten the starter hardware as follows: - Lower mounting nut - 68 N.m (50 ft. lbs.) - Upper mounting screw - 68 N.m (50 ft. lbs.) - Battery cable terminal nut - 14 N.m (120 in. lbs.) - Solenoid wire harness terminal nut - 6 N.m (55 in.lbs.). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations Starter Relay: Locations Power Distribution Center Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 5625 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 5626 Starter Relay: Description and Operation SYSTEM OPERATION The starter relay is a International Standards Organization (ISO) micro-relay The terminal designations and functions are the same as a conventional ISO relay. However, the micro-relay terminal orientation (or footprint) is different, the current capacity is lower, and the relay case dimensions are smaller than on the conventional ISO relay. The starter relay is a electro mechanical device that switches current to the pull-in coil of the starter solenoid when the ignition switch is turned to the Start position. The starter relay is located in the Power Distribution Center (PDC), in the engine compartment. Refer to the PDC label for relay identification and location. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 5627 Starter Relay: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Power Distribution Center 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC for starter relay identification and location. 4. Unplug the starter relay from the PDC. 5. Install the starter relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 6. Install the PDC cover. 7. Connect the battery negative cable. 8. Test the relay operation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5633 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 Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5634 Electrostatic Discharge Symbol All Electrostatic Discharge (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, especially 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. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5635 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5636 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5637 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5638 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5639 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5640 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5641 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5642 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. 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. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5643 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5644 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5645 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5646 Auxiliary Power Outlet: Diagnostic Aids 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 in 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 and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5647 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. 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 every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. 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 fuse circuit. 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 the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5648 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools 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 - This instrument is 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 vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. 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 non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5649 Auxiliary Power Outlet: Electrical Diagrams Horn/Cigar Lighter/Power Outlet (Part 1 Of 2) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5650 Horn/Cigar Lighter/Power Outlet (Part 2 Of 2) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 5651 Auxiliary Power Outlet: Description and Operation CIRCUIT OPERATION Battery voltage for the power outlet is supplied on circuit X22 or C28, depending on engine application. This circuit is protected by a 40 Amp fuse located in the PDC. Ground for the power outlet is supplied on circuit Z1. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 5652 Auxiliary Power Outlet: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the lower instrument panel bezel as described. Cigar Lighter And Power Outlet 3. Pull the cigar lighter knob and element out of the cigar lighter base, or remove the power outlet cap from the power outlet base. Cigar Lighter And Power Outlet Remove/Install 4. Look inside the cigar lighter or power outlet base and note the position of the rectangular retaining bosses of the mount that secures the base to the instrument panel lower bezel. 5. Insert a pair of external snap ring pliers into the cigar lighter or power outlet base and engage the tips of the pliers with the retaining bosses. 6. Squeeze the pliers to disengage the retaining bosses from the base, and using a gentle rocking motion pull the pliers and the base out of the mount. 7. Remove the cigar lighter or power outlet mount from the instrument panel lower bezel. 8. Reverse the removal procedures to install. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions Power Distribution Center: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5657 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 Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5658 Electrostatic Discharge Symbol All Electrostatic Discharge (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, especially 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. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5659 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5660 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5661 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5662 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5663 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5664 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5665 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5666 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. 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. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5667 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5668 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5669 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5670 Power Distribution Center: Diagnostic Aids 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 in 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 and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5671 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. 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 every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. 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 fuse circuit. 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 the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5672 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools 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 - This instrument is 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 vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. 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 non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5673 Power Distribution Center: Connector Views Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5674 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5675 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5676 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5677 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5678 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5679 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5680 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5681 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5682 Power Distribution NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5683 Power Distribution Center: Electrical Diagrams Power Distribution Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5684 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5685 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5686 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5687 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5688 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5689 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5690 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5691 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5692 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5693 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5694 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5695 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5696 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5697 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5698 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5699 Power Distribution NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Ground Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5700 Ground Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5701 Ground Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5702 Ground Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5703 Ground Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5704 Ground Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5705 Ground Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5706 Ground Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5707 Ground Distribution NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Customer Interest for Fuse: > 08-03-97 > Feb > 97 > Instrument Cluster - Gauges Inoperative Fuse: Customer Interest Instrument Cluster - Gauges Inoperative NO: 08-03-97 GROUP: Electrical DATE: Feb. 14, 1997 SUBJECT: Inoperative Gauges MODELS: 1997 (AN) Dakota SYMPTOM/CONDITION: Inoperative instrument cluster gauges and overhead console due to blown fuse 11 in the junction block. DIAGNOSIS: Inspect fuse 11 in the junction block to verify that the fuse is blown. If the fuse is blown, perform the following diagnostic procedure. If the instrument cluster gauges and/or overhead console is inoperative but fuse 11 is good, refer to the 1997 Dakota Service Manual (Publication No. 81-370-7110), Group 8E for instrument cluster service and Group 8V for overhead console service. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Customer Interest for Fuse: > 08-03-97 > Feb > 97 > Instrument Cluster - Gauges Inoperative > Page 5716 For the above diagnosis, refer to the 1997 AN Service Manual (Publication No. 81-370- 7110), page 8W-40-2 for circuit identification. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 08-03-97 > Feb > 97 > Instrument Cluster - Gauges Inoperative Fuse: All Technical Service Bulletins Instrument Cluster - Gauges Inoperative NO: 08-03-97 GROUP: Electrical DATE: Feb. 14, 1997 SUBJECT: Inoperative Gauges MODELS: 1997 (AN) Dakota SYMPTOM/CONDITION: Inoperative instrument cluster gauges and overhead console due to blown fuse 11 in the junction block. DIAGNOSIS: Inspect fuse 11 in the junction block to verify that the fuse is blown. If the fuse is blown, perform the following diagnostic procedure. If the instrument cluster gauges and/or overhead console is inoperative but fuse 11 is good, refer to the 1997 Dakota Service Manual (Publication No. 81-370-7110), Group 8E for instrument cluster service and Group 8V for overhead console service. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 08-03-97 > Feb > 97 > Instrument Cluster - Gauges Inoperative > Page 5722 For the above diagnosis, refer to the 1997 AN Service Manual (Publication No. 81-370- 7110), page 8W-40-2 for circuit identification. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions Multiple Junction Connector: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5727 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 Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5728 Electrostatic Discharge Symbol All Electrostatic Discharge (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, especially 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. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5729 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5730 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5731 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5732 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5733 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5734 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5735 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5736 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. 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. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5737 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5738 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5739 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5740 Multiple Junction Connector: Diagnostic Aids 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 in 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 and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5741 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. 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 every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. 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 fuse circuit. 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 the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5742 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools 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 - This instrument is 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 vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. 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 non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5743 Multiple Junction Connector: Connector Views Junction Block Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5744 Junction Block Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5745 Junction Block Junction Block NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5746 Multiple Junction Connector: Electrical Diagrams Junction Block (Part 1 Of 13) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5747 Junction Block (Part 2 Of 13) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5748 Junction Block (Part 3 Of 13) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5749 Junction Block (Part 4 Of 13) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5750 Junction Block (Part 5 Of 13) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5751 Junction Block (Part 6 Of 13) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5752 Junction Block (Part 7 Of 13) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5753 Junction Block (Part 8 Of 13) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5754 Junction Block (Part 9 Of 13) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5755 Junction Block (Part 10 Of 13) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5756 Junction Block (Part 11 Of 13) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5757 Junction Block (Part 12 Of 13) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5758 Junction Block (Part 13 Of 13) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations Power Distribution Center Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5763 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations Power Distribution Center Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5767 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5773 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 Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5774 Electrostatic Discharge Symbol All Electrostatic Discharge (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, especially 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. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5775 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5776 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5777 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5778 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5779 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5780 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5781 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5782 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. 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. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5783 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5784 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5785 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5786 Auxiliary Power Outlet: Diagnostic Aids 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 in 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 and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5787 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. 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 every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. 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 fuse circuit. 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 the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5788 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools 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 - This instrument is 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 vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. 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 non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5789 Auxiliary Power Outlet: Electrical Diagrams Horn/Cigar Lighter/Power Outlet (Part 1 Of 2) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5790 Horn/Cigar Lighter/Power Outlet (Part 2 Of 2) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 5791 Auxiliary Power Outlet: Description and Operation CIRCUIT OPERATION Battery voltage for the power outlet is supplied on circuit X22 or C28, depending on engine application. This circuit is protected by a 40 Amp fuse located in the PDC. Ground for the power outlet is supplied on circuit Z1. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 5792 Auxiliary Power Outlet: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the lower instrument panel bezel as described. Cigar Lighter And Power Outlet 3. Pull the cigar lighter knob and element out of the cigar lighter base, or remove the power outlet cap from the power outlet base. Cigar Lighter And Power Outlet Remove/Install 4. Look inside the cigar lighter or power outlet base and note the position of the rectangular retaining bosses of the mount that secures the base to the instrument panel lower bezel. 5. Insert a pair of external snap ring pliers into the cigar lighter or power outlet base and engage the tips of the pliers with the retaining bosses. 6. Squeeze the pliers to disengage the retaining bosses from the base, and using a gentle rocking motion pull the pliers and the base out of the mount. 7. Remove the cigar lighter or power outlet mount from the instrument panel lower bezel. 8. Reverse the removal procedures to install. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions Power Distribution Center: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5797 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 Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5798 Electrostatic Discharge Symbol All Electrostatic Discharge (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, especially 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. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5799 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5800 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5801 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5802 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5803 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5804 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5805 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5806 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. 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. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5807 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5808 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5809 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5810 Power Distribution Center: Diagnostic Aids 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 in 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 and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5811 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. 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 every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. 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 fuse circuit. 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 the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5812 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools 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 - This instrument is 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 vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. 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 non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5813 Power Distribution Center: Connector Views Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5814 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5815 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5816 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5817 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5818 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5819 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5820 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5821 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5822 Power Distribution NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5823 Power Distribution Center: Electrical Diagrams Power Distribution Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5824 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5825 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5826 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5827 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5828 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5829 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5830 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5831 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5832 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5833 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5834 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5835 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5836 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5837 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5838 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5839 Power Distribution NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Ground Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5840 Ground Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5841 Ground Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5842 Ground Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5843 Ground Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5844 Ground Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5845 Ground Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5846 Ground Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 5847 Ground Distribution NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Customer Interest for Fuse: > 08-03-97 > Feb > 97 > Instrument Cluster - Gauges Inoperative Fuse: Customer Interest Instrument Cluster - Gauges Inoperative NO: 08-03-97 GROUP: Electrical DATE: Feb. 14, 1997 SUBJECT: Inoperative Gauges MODELS: 1997 (AN) Dakota SYMPTOM/CONDITION: Inoperative instrument cluster gauges and overhead console due to blown fuse 11 in the junction block. DIAGNOSIS: Inspect fuse 11 in the junction block to verify that the fuse is blown. If the fuse is blown, perform the following diagnostic procedure. If the instrument cluster gauges and/or overhead console is inoperative but fuse 11 is good, refer to the 1997 Dakota Service Manual (Publication No. 81-370-7110), Group 8E for instrument cluster service and Group 8V for overhead console service. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Customer Interest for Fuse: > 08-03-97 > Feb > 97 > Instrument Cluster - Gauges Inoperative > Page 5856 For the above diagnosis, refer to the 1997 AN Service Manual (Publication No. 81-370- 7110), page 8W-40-2 for circuit identification. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 08-03-97 > Feb > 97 > Instrument Cluster - Gauges Inoperative Fuse: All Technical Service Bulletins Instrument Cluster - Gauges Inoperative NO: 08-03-97 GROUP: Electrical DATE: Feb. 14, 1997 SUBJECT: Inoperative Gauges MODELS: 1997 (AN) Dakota SYMPTOM/CONDITION: Inoperative instrument cluster gauges and overhead console due to blown fuse 11 in the junction block. DIAGNOSIS: Inspect fuse 11 in the junction block to verify that the fuse is blown. If the fuse is blown, perform the following diagnostic procedure. If the instrument cluster gauges and/or overhead console is inoperative but fuse 11 is good, refer to the 1997 Dakota Service Manual (Publication No. 81-370-7110), Group 8E for instrument cluster service and Group 8V for overhead console service. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 08-03-97 > Feb > 97 > Instrument Cluster - Gauges Inoperative > Page 5862 For the above diagnosis, refer to the 1997 AN Service Manual (Publication No. 81-370- 7110), page 8W-40-2 for circuit identification. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions Multiple Junction Connector: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5867 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 Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5868 Electrostatic Discharge Symbol All Electrostatic Discharge (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, especially 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. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5869 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5870 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5871 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5872 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5873 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5874 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5875 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5876 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. 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. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5877 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5878 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5879 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5880 Multiple Junction Connector: Diagnostic Aids 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 in 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 and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5881 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. 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 every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. 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 fuse circuit. 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 the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5882 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools 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 - This instrument is 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 vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. 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 non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5883 Multiple Junction Connector: Connector Views Junction Block Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5884 Junction Block Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5885 Junction Block Junction Block NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5886 Multiple Junction Connector: Electrical Diagrams Junction Block (Part 1 Of 13) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5887 Junction Block (Part 2 Of 13) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5888 Junction Block (Part 3 Of 13) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5889 Junction Block (Part 4 Of 13) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5890 Junction Block (Part 5 Of 13) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5891 Junction Block (Part 6 Of 13) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5892 Junction Block (Part 7 Of 13) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5893 Junction Block (Part 8 Of 13) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5894 Junction Block (Part 9 Of 13) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5895 Junction Block (Part 10 Of 13) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5896 Junction Block (Part 11 Of 13) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5897 Junction Block (Part 12 Of 13) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5898 Junction Block (Part 13 Of 13) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations Power Distribution Center Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5903 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations Power Distribution Center Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5907 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications Alignment: Specifications CASTER: Preferred Setting ................................................................................................................................. ....................................................................... +3.9° Range ................................................................ ................................................................................................................ (+3.9° +/-0.70°) +3.2° to +4.6° Max RH/LH Difference ............................................................................................................... .............................................................................. 0.50° CAMBER: Preferred Setting ................................................................................................................................. ..................................................................... +0.38° Range ................................................................ ........................................................................................................... (+0.38° +/-0.50°) -0.12° to +0.88° Max RH/LH Difference ............................................................................................................. ................................................................................ 0.50° TOTAL TOE: Preferred Setting ................................................................................................................................. ..................................................................... +0.15° Range ................................................................ .......................................................................................................... (+0.15° +/-0.10°) +0.05° to +0.25° Max RH/LH Difference ............................................................................................................. ..................................................................................... 0° Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 5912 Alignment: Description and Operation CAUTION: Do not attempt to modify any suspension or steering component by heating and bending. DESCRIPTION Wheel alignment involves the correct positioning of the wheels in relation to the vehicle. The positioning is accomplished through suspension and steering linkage adjustments. An alignment is considered essential for efficient steering, good directional stability and to minimize tire wear. The most important measurements of an alignment are caster, camber and toe. Caster - is the forward or rearward tilt of the steering knuckle from vertical. Tilting the top of the knuckle forward provides negative caster. Tilting the top of the knuckle rearward provides positive caster. Positive caster promotes directional stability. This angle enables the front wheels to return to a straight ahead position after turns. Camber - is the inward or outward tilt of the wheel relative to the center of the vehicle. Tilting the top of the wheel inward provides negative camber. Tilting the top of the wheel outward provides positive camber. Incorrect camber will cause wear on the inside or outside edge of the tire. Toe - is the difference between the leading inside edges and trailing inside edges of the front tires. Uneven wheel toe position cause's unstable steering, uneven tire wear and steering wheel off-center. The wheel toe position is the final front wheel alignment adjustment. Steering Axis Inclination Angle - is measured in degrees. It is the angle that the steering knuckles are tilted. The inclination angle has a fixed relationship with the camber angle. It will not change except when a spindle or ball stud is damaged or bent. The angle is not adjustable and the damaged component(s) must be replaced to correct the alignment. NOTE: Routine inspection of the front suspension and steering components is a good preventative maintenance practice. Inspection also helps to ensure safe operation of the vehicle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 5913 Alignment: Testing and Inspection PRE-ALIGNMENT INSPECTION Before starting wheel alignment, the following inspection and necessary corrections must be completed. Refer to Suspension and Steering System Diagnosis Chart. See: Testing and Inspection 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 5914 Alignment: Service and Repair CAMBER AND CASTER ADJUSTMENT Camber and caster angle adjustments involve changing the position of the upper suspension arm pivot bar. Adjuster C-4576 can be used to make camber/caster adjustments. CASTER Move only the rear position of the pivot bar in or out. This will change the caster angle significantly and camber angle only slightly. To retain the camber while adjusting caster, move the rear pivot bar in or out. Move the forward pivot very slightly in the opposite direction. The caster angle should be adjusted as close as possible to the preferred specification. NOTE: For example, to increase a positive caster angle, move the rear position of the pivot bar inward (toward the engine). Move the front of pivot bar outward (away from the engine) slightly until the original camber angle is obtained. CAMBER Move only the forward position of the pivot bar in or out. This will change the camber angle significantly and caster angle only slightly. The camber angle should be adjusted as close as possible to the preferred specification. After adjustment is made tighten the pivot bar nuts to proper torque specification. TOE ADJUSTMENT The wheel toe position adjustment should be the final adjustment. 1. Start the engine and turn wheels both ways before straightening the wheels. Secure the steering wheel with the front wheels in the straight-ahead position. 2. Loosen the tie rod jam nuts. NOTE: Each front wheel should be adjusted for one-half of the total toe position specification. This will ensure the steering wheel will be centered when the wheels are positioned straight-ahead. 3. Adjust the wheel toe position by turning the tie rod as necessary. 4. Tighten the tie rod jam nut to 75 Nm (55 ft. lbs.). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 5915 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Power Steering - Pressure Switch Torque Revisions Power Steering Pressure Switch: Technical Service Bulletins Power Steering - Pressure Switch Torque Revisions NUMBER: 26-10-96B GROUP: Miscellaneous DATE: October, 1996 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 Dakota - Publication Number 81-270-7146 DESCRIPTION OF CHANGES Revised power steering pressure switch torque (124-195 In. Lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Power Steering - Pressure Switch Torque Revisions > Page 5922 14-65 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Power Steering - Pressure Switch Torque Revisions > Page 5923 14-66 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Page 5924 Power Steering Pressure Switch: Specifications The content of this article reflects changes called for in TSB 26-10-96. Power Steering Pressure Switch ................................................................................................................................................ 14-22 Nm (124-195 in.lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Technical Service Bulletins > Front Caliper Mounting/Steering Knuckle - Thread Repair Front Steering Knuckle: Technical Service Bulletins Front Caliper Mounting/Steering Knuckle Thread Repair NUMBER: 05-03-99 GROUP: Brakes EFFECTIVE DATE: Apr. 23, 1999 SUBJECT: Front Brake Caliper Mounting To Steering Knuckle Thread Repair OVERVIEW: This bulletin involves repair of the threads on the steering knuckle or brake caliper mounting adapter that are used to install and retain the front brake caliper housing in its correct operating location. MODELS: 1986 - 1999 (AN) Dakota 1998 - 1999 (DN) Durango DISCUSSION: A Brake Knuckle Thread Repair Kit has been developed to repair stripped threads on the front brake caliper mounting attachment making it no longer necessary to replace the front steering knuckle/brake caliper mounting adapter when encountering stripped threads. The following information provides the repair procedure for using the Brake Knuckle Thread Repair Kit. DIAGNOSIS: 1. Place the vehicle on an appropriate hoist. 2. Remove the front tire/wheel assembly. 3. Remove the brake caliper housing assembly by loosening the mounting bolts. NOTE: IF HIGH TORQUE IS ENCOUNTERED DURING THE MOUNTING BOLT REMOVAL, IT IS LIKELY THAT THREAD DAMAGE WILL OCCUR OR HAS OCCURRED. 4. Remove the caliper housing assembly and hang the housing on the frame of the vehicle using an appropriate wire hanger. NOTE: DO NOT ALLOW THE CALIPER HOUSING TO HANG BY ITSELF FROM THE BRAKE HOSE AS DAMAGE TO THE HOSE MAY RESULT. 5. If the vehicle has a bolt-on brake caliper mounting adapter, remove the adapter. If the brake caliper mounts directly to the steering knuckle, remove retainers on the wheel studs and remove the rotor. 6. Inspect the mounting bolts and knuckle threads for damage. If either is damaged, it is likely that damage to the other has occurred as well. If damage has occurred to the threads in the form of knicks, thread pulling, or cross-threading, perform the Repair Procedure. PARTS REQUIRED: AR (1) 05016156AA Insert, Heli-Coil, M9 X 1.25 AR (1) 04886075AA Bolts, Caliper Housing Mounting EQUIPMENT REQUIRED: AR (1) 05016155AA Kit, Brake Knuckle Thread Repair Includes: 23/64 Drill Bit M9 X 1.25 Tap Heli-Coil Installation Tool Heli-Coil Tang Break-Off Rod (25) M9 X 1.25 Stainless Steel Heli-Coils REPAIR PROCEDURE: Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Technical Service Bulletins > Front Caliper Mounting/Steering Knuckle - Thread Repair > Page 5930 1. Using the 23/64 in. drill, drill through the brake caliper mounting attachment hole keeping the drill perpendicular to the knuckle. 2. Using the M9 X 1.25 tap, tap the drilled hole ensuring to tap the hole entirely through. 3. Install a Heli-Coil insert onto the installation tool (tool number 3747-9). Be sure the tang is properly engaged into the driving contour of the tool. 4. Install the Heli-Coil into the drilled/tapped hole by rotating the tool and exerting slight pressure onto the tool/Heli-Coil and into the drilled/tapped hole. Continue to rotate the tool until the insert is located 1/4 to 1/2 turn below the steering knuckle surface. 5. Back the Heli-Coil installation tool out of the installed Heli-Coil. Then, remove the tang from the Heli-Coil by breaking the tang off using the tang break-off tool. Place the break-off tool into the assembled insert until it rests on the Heli-Coil tang. Holding the tool squarely, strike the tool sharply with a hammer. 6. If the vehicle has a bolt-on brake caliper mounting adapter, install the adapter. Refer to the appropriate Service Manual for information regarding proper brake caliper adapter mounting information. If the brake caliper mounts directly to the steering knuckle, install the rotor. 7. Install the caliper using new mounting bolts p/n 04886075AA in any location that had a Heli-Coil installed. Tighten the bolts to 30 - 35 N.m (22-26 ft. lbs.). 8. Install the tire/wheel assembly. 9. Lower the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-80-20-93 Brake Caliper Mounting Support Thread Repair, Left Side 0.4 Hrs. 05-80-20-94 Brake Caliper Mounting Support Thread Repair, Right Side 0.4 Hrs. 05-80-20-50 Brake Caliper Mounting Support Thread Repair, Each Additional Same Side 0.1 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Technical Service Bulletins > Page 5931 Front Steering Knuckle: Service and Repair REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove disc brake caliper, rotor, shield and ABS speed sensor, refer to Brakes and Traction Control. 4. Remove tie-rod from steering knuckle arm. 5. Remove the hub/bearing. 6. Remove the shock absorber. 7. Install Spring Compressor DD-1278, or equivalent up through the lower suspension arm, coil spring and upper shock mounting hole. 8. Tighten the tool lower nut to compress the coil spring. 9. Remove the lower ball stud nut and separate the ball stud from the knuckle with Remover C-4150A, or equivalent. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Technical Service Bulletins > Page 5932 10. Remove the upper ball stud nut and separate the ball stud from the knuckle with Remover MB-991113, or equivalent. CAUTION: When install Remover MB-991113, or equivalent to separate the ball stud, be careful not to damage the ball stud seal. 11. Remove steering knuckle. INSTALLATION 1. Position steering knuckle on upper and lower ball studs and install nuts. Tighten lower nut to 127 Nm (94 ft. lbs.). Tighten upper nut to 81 Nm (60 ft. lbs.) and install new cotter pins. 2. Remove the spring compressor. 3. Install the shock absorber. 4. Install the hub/bearing. 5. Install ABS speed sensor, brake dust shield, rotor and caliper, refer to Brakes and Traction Control. 6. Install tie rod to steering knuckle arm. 7. Install the wheel and tire assembly. 8. Remove support and lower the vehicle Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage Power Steering Fluid: Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 5938 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 5939 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 5940 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 5941 Power Steering Fluid: Specifications The OE Service Manual does not provide a Power Steering Fluid Type Specification. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Specifications Power Steering Fluid Cooler: Specifications Mounting Bolts ..................................................................................................................................... .................................................... 41 Nm (30 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Service and Repair Power Steering Fluid Reservoir: Service and Repair NOTE: Discard all O-ring seals during disassembly, they are not re-usable. REMOVAL 1. Remove pump assembly. 2. Remove mounting studs and pressure fitting. Rock reservoir by hand or use a soft face mallet and remove reservoir. 3. Remove O-ring seals from housing and discard. 4. Remove flow control valve and spring from housing. NOTE: Clean all parts before installation. Lubricate new O-ring seals with Mopar (R) Power Steering Fluid or an equivalent product. INSTALLATION 1. Install flow control valve and spring. 2. Install new O-ring seals on housing and install reservoir. 3. Install mounting studs and tighten to 48 Nm (35 ft. lbs.). 4. Install fitting in flow control valve bore tighten to 75 Nm (55 ft. lbs.). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications Pressure Line ...................................................................................................................................... ...................................................... 35 Nm (25 ft. lbs.) Return Line ..................................................... .......................................................................................................................................... 35 Nm (25 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage Power Steering Pump: Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 5955 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 5956 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 5957 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications Power Steering Pump: Mechanical Specifications Bracket Bolts ....................................................................................................................................... ..................................................... 41 Nm (30 ft. lbs.) Mounting Bolts ................................................. ........................................................................................................................................ 41 Nm (30 ft. lbs.) Reservoir Bolts ............................................................................................................................ ............................................................. 48 Nm (35 ft. lbs.) Flow Control Valve ................................... ............................................................................................................................................... 75 Nm (55 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications > Page 5960 Power Steering Pump: Pressure, Vacuum and Temperature Specifications Pressure Relief .................................................................................................................................... ...................................... 10342 kPa (1450 - 1550 psi) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 5961 Power Steering Pump: Description and Operation The P-Series pump is used on this vehicle. The pump uses an integral reservoir. Hydraulic pressure is provided for the power steering gear by the belt driven power steering pump. The power steering pump is a constant flow rate and displacement, vane-type pump. The pump is connected to the steering gear via the pressure hose and the return hose. The pump shaft has a pressed-on pulley that is belt driven by the crankshaft pulley. Trailer tow option vehicles are equipped with a power steering pump oil cooler. The oil cooler is mounted to the radiator support. NOTE: Power steering pumps are not interchangeable with pumps installed on other vehicles. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 5962 Power Steering Pump: Testing and Inspection Refer to illustration for areas to inspect for leakage. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Initial Operation Power Steering Pump: Service and Repair Power Steering Pump Initial Operation WARNING: The fluid level should be checked with engine off to prevent injury from moving components. CAUTION: Use Mopar (R) Power Steering Fluid or equivalent. Do not use automatic transmission fluid and do not overfill. Wipe filler cap clean, then check the fluid level. The dipstick should indicate COLD when the fluid is at normal temperature. 1. Fill the pump fluid reservoir to the proper level and let the fluid settle for at least two (2) minutes. 2. Start the engine and let run for a few seconds then turn engine off. 3. Add fluid if necessary. Repeat the above procedure until the fluid level remains constant after running the engine. 4. Raise the front wheels off the ground. 5. Slowly turn the steering wheel right and left, lightly contacting the wheel stops at least 20 times. 6. Check the fluid level add if necessary. 7. Lower the vehicle, start the engine and turn the steering wheel slowly from lock to lock. 8. Stop the engine and check the fluid level and refill as required. 9. If the fluid is extremely foamy or milky looking allow the vehicle to stand a few minutes and repeat the procedure. CAUTION: Do not run a vehicle with foamy fluid for an extended period. This may cause pump damage. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Initial Operation > Page 5965 Power Steering Pump: Service and Repair Power Steering Pump Pulley Replacement REMOVE 1. Remove pump assembly. 2. Remove pulley from pump with Puller C-4333, or equivalent. Fig. 6 INSTALL 1. Replace pulley if bent, cracked, or loose. 2. Install pulley on pump with Installer C-4063-L, or equivalent flush with the end of the shaft. Ensure the tool and pulley remain aligned with the pump shaft. 3. Install pump assembly. 4. With Serpentine Belts; Run engine until warm (5 min) and note any belt chirp. If chirp exists, move pulley outward approximately 0.5 mm (0.020 inch). If noise increases, press on 1.0 mm (0.040 inch). Be careful that pulley does not contact mounting bolts. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Initial Operation > Page 5966 Power Steering Pump: Service and Repair Power Steering Pump Removal and Installation REMOVAL 1. Remove the serpentine drive belt. 2. Clamp the fluid return hose and disconnect the hoses from the power steering pump. Cap the fittings. 3. Remove battery ground cable and bracket bolts. 4. Remove pump assembly. 5. Remove the pump pulley. This will allow access to the pump attaching screws. 6. Remove the bracket to pump attaching bolts. INSTALLATION 1. Install the bracket to pump and tighten bolts to 41 Nm (30 ft. lbs.). 2. Install the pump pulley. 3. Install pump assembly on the engine block and tighten the bolts to 41 Nm (30 ft. lbs.). 4. Install the battery ground wire and tighten nut to 41 Nm (30 ft. lbs.). 5. Connect the fluid hoses to the pump. 6. Install the serpentine drive belt. 7. Fill the reservoir with power steering fluid, refer to Initial Operation for detailed instructions. See: Power Steering Pump Initial Operation Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Initial Operation > Page 5967 CAUTION: Do not use automatic transmission fluid to fill the reservoir. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Power Steering - Pressure Switch Torque Revisions Power Steering Pressure Switch: Technical Service Bulletins Power Steering - Pressure Switch Torque Revisions NUMBER: 26-10-96B GROUP: Miscellaneous DATE: October, 1996 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 Dakota - Publication Number 81-270-7146 DESCRIPTION OF CHANGES Revised power steering pressure switch torque (124-195 In. Lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Power Steering - Pressure Switch Torque Revisions > Page 5973 14-65 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Power Steering - Pressure Switch Torque Revisions > Page 5974 14-66 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Page 5975 Power Steering Pressure Switch: Specifications The content of this article reflects changes called for in TSB 26-10-96. Power Steering Pressure Switch ................................................................................................................................................ 14-22 Nm (124-195 in.lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Arming and Disarming The airbag system is a sensitive, complex electromechanical unit. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components you must first disconnect and isolate the battery negative (ground) cable. Then wait two minutes for the system capacitor to discharge before further system service. This is the only sure way to disable the airbag system. Failure to do this could result in accidental air-bag deployment and possible personal injury. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair Steering Column Cover: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Steering Column Opening Cover And Knee Blocker Remove/Install 2. Remove the three screws that secure the bottom of the steering column cover and knee blocker to the lower instrument panel reinforcement. 3. Using a trim stick or another suitable wide bladed flat tool, gently pry the top of the steering column opening cover and knee blocker to release the snap-clip retainers that secure it to the instrument panel on each side of the steering column. 4. Remove the steering column opening cover and knee blocker from the vehicle. 5. Reverse the removal procedures to install. Tighten the steering column opening cover and knee blocker mounting screws to 2.2 N.m (20 in. lbs.). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Steering - Steering Gear Service Procedure Revision Steering Gear: Technical Service Bulletins Steering - Steering Gear Service Procedure Revision NUMBER: 26-01-97B GROUP: Miscellaneous DATE: January, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997 Dakota - Publication Number 81-370-7110 DESCRIPTION OF CHANGES Revisions to the power steering gear service procedures. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Steering - Steering Gear Service Procedure Revision > Page 5987 19-24 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Steering - Steering Gear Service Procedure Revision > Page 5988 19-25 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Steering - Steering Gear Service Procedure Revision > Page 5989 19-26 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Steering - Steering Gear Service Procedure Revision > Page 5990 19-27 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Steering - Steering Gear Service Procedure Revision > Page 5991 19-28 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Steering - Steering Gear Service Procedure Revision > Page 5992 19-29 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Steering - Steering Gear Service Procedure Revision > Page 5993 19-30 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Page 5994 Steering Gear: Specifications To Frame Bolts .................................................................................................................................... ................................................. 258 Nm (190 ft. lbs.) Intermediate Shaft Bolt .................................... ......................................................................................................................................... 49 Nm (36 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Page 5995 Steering Gear: Description and Operation The rack and pinion steering gear cannot be adjusted or internally serviced. If a malfunction or a fluid leak occurs, the gear must be replaced as an assembly. If a boot seal becomes damaged, the steering gear must be removed to replace the boot seal. CAUTION: Components attached with a nut and cotter pin must be first torqued to specification. If the slot in the nut does not line up with the cotter pin hole, tighten nut until it is aligned. Never loosen the nut to align the cotter pin hole. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement Steering Gear: Service and Repair Steering Gear Replacement REMOVAL 1. Raise and support the vehicle. 2. Remove the cotter pins and nuts from the tie rod ends. 3. Separate tie rod ends from the knuckles with Puller C-3894-A, or equivalent. 4. Remove the power steering lines from the gear. 5. Remove the lower coupler bolt and slide the coupler off the gear. 6. Remove the mounting bolts from the gear to the front crossmember and remove the gear. NOTE: Before installing gear inspect bushings and replace if worn or damaged. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 5998 INSTALLATION 1. Install gear on front crossmember and tighten mounting bolts to 258 Nm (190 ft. lbs.). 2. Slide shaft coupler onto gear and tighten bolt to 49 Nm (36 ft. lbs.). 3. Clean tie rod end studs and knuckle tapers. 4. Install tie rod ends into the steering knuckles and tighten the nuts to 88 Nm (65 ft. lbs.). Install new cotter pins. 5. Install power steering lines to steering gear. 6. Remove support and lower vehicle. 7. Fill system with fluid and perform Power Steering Pump Initial Operation. 8. Adjust the toe position. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 5999 Steering Gear: Service and Repair Overhaul Housing End Plug The content of this article reflects changes called for in TSB 26-01-97. DISASSEMBLY 1. Unseat and remove retaining ring from groove with a punch through the hole in the end of the housing. 2. Slowly rotate stub shaft with 12 point socket COUNTER-CLOCKWISE to force the end plug out from housing. CAUTION: Do not turn stub shaft any further than necessary. The rack piston balls will drop out of the rack piston circuit if the stub shaft is turned too far. 3. Remove O-ring from the housing. ASSEMBLY 1. Lubricate O-ring with power steering fluid and install into the housing. 2. Install end plug by tapping the plug lightly with a plastic mallet into the housing. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 6000 3. Install retaining ring so one end of the ring covers the housing access hole. Pitman Shaft/Seals/Bearing The content of this article reflects changes called for in TSB 26-01-97. DISASSEMBLY 1. Clean exposed end of pitman shaft and housing with a wire brush. 2. Remove preload adjuster nut. 3. Rotate stub shaft with a 12 point socket from stop to stop and count the number of turns. 4. Center the stub shaft by rotating it from the stop 1/2 of the total amount of turns. 5. Remove side cover bolts and remove side cover, gasket and pitman shaft as an assembly. NOTE: The pitman shaft will not clear the housing if it is not centered. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 6001 6. Remove pitman shaft from the side cover. 7. Remove dust seal from the housing with a seal pick. CAUTION: Use care not to score the housing bore when prying out seals and washer. 8. Remove retaining ring with snap ring pliers. 9. Remove washer from the housing. 10. Remove oil seal from the housing with a seal pick. 11. Remove pitman shaft bearing from housing with a bearing driver and handle. ASSEMBLY 1. Install pitman shaft bearing into housing with a bearing driver and handle. 2. Coat the oil seals and washer with grease. 3. Install the oil seal with a driver and handle. 4. Install backup washer. 5. Install the retainer ring with snap ring pliers. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 6002 6. Install dust seal with a driver and handle. 7. Install pitman shaft to side cover by screwing shaft in until it fully seats to side cover. 8. Install preload adjuster nut. Do not tighten nut until after Over-Center Rotation Torque adjustment has been made. 9. Install gasket to side cover and bend tabs around edges of side cover. 10. Install pitman shaft assembly and side cover to housing. 11. Install side cover bolts and tighten to 60 Nm (44 ft. lbs.). 12. Adjust Over-Center Rotation Torque. Spool Valve The content of this article reflects changes called for in TSB 26-01-97. DISASSEMBLY 1. Remove lock nut. 2. Remove adjuster nut with Spanner Wrench C-4381, or equivalent. 3. Remove thrust support assembly out of the housing. 4. Pull stub shaft and valve assembly from the housing. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 6003 5. Remove stub shaft from valve assembly by lightly tapping on a block of wood to loosen shaft. Then disengage stub shaft pin from hole in spool valve and separate the valve assembly from stub shaft. 6. Remove spool valve from valve body by pulling and rotating the spool valve from the valve body. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 6004 7. Remove spool valve O-ring and valve body teflon rings and O-rings underneath the teflon rings. 8. Remove the O-ring between the worm shaft and the stub shaft. ASSEMBLY NOTE: Clean and dry all components, then lubricate with power steering fluid. 1. Install spool valve spool O-ring. 2. Install spool valve in valve body by pushing and rotating. Hole in spool valve for stub shaft pin must be accessible from opposite end of valve body. 3. Install stub shaft in valve spool and engage locating pin on stub shaft into spool valve hole. NOTE: Notch in stub shaft cap must fully engage valve body pin and seat against valve body shoulder. 4. Install O-rings and teflon rings over the O-rings on valve body. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 6005 5. Install O-ring into the back of the stub shaft. 6. Install stub shaft and valve assembly in the housing. Line up worm shaft to slots in the valve assembly. 7. Install thrust support assembly. NOTE: The thrust support is serviced as an assembly. If any component of the thrust support is damaged the assembly must be replaced. 8. Install adjuster nut and lock nut. 9. Adjust Thrust Bearing Preload and Over-Center Rotating Torque. Rack Piston and Worm Shaft The content of this article reflects changes called for in TSB 26-01-97. DISASSEMBLY 1. Remove housing end plug. 2. Remove rack piston plug. 3. Remove side cover and pitman shaft. 4. Turn stub shaft COUNTERCLOCKWISE until the rack piston begins to come out of the housing. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 6006 5. Insert Arbor C-4175, or equivalent into bore of rack piston and hold tool tightly against worm shaft. 6. Turn the stub shaft with a 12 point socket COUNTERCLOCKWISE, this will force the rack piston onto the tool and hold the rack piston balls in place. 7. Remove the rack piston and tool together from housing. 8. Remove tool from rack piston. 9. Remove rack piston balls. 10. Remove clamp bolts, clamp and ball guide. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 6007 11. Remove teflon ring and O-ring from the rack piston. 12. Remove the adjuster lock nut and adjuster nut from the stub shaft. 13. Pull the stub shaft with the spool valve and thrust support assembly out of the housing. 14. Remove the worm shaft from the housing. ASSEMBLY NOTE: Clean and dry all components and lubricate with power steering fluid. 1. Check for scores, nicks or burrs on the rack piston finished. Slight wear is normal on the worm gear surfaces. 2. Install O-ring and teflon ring on the rack piston. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear Replacement > Page 6008 3. Install worm shaft in the rack piston and align worm shaft spiral groove with rack piston ball guide hole. CAUTION: The rack piston balls must be installed alternately into the rack piston and ball guide. This maintains worm shaft preload. There are 12 black balls and 12 silver (Chrome) balls. The black balls are smaller than the silver balls. 4. Lubricate and install rack piston balls through return guide hole while turning worm shaft COUNTERCLOCKWISE. 5. Install remaining balls in guide using grease to hold the balls in place. 6. Install the guide onto rack piston and install clamp and clamp bolts. Tighten bolts to 58 Nm (43 ft. lbs.). 7. Insert Arbor C-4175, or equivalent into bore of rack piston and hold tool tightly against worm shaft. 8. Turn the worm shaft COUNTERCLOCKWISE while pushing on the arbor. This will force the rack piston onto the arbor and hold the rack piston balls in place. 9. Install the races and thrust bearing on the worm shaft and install shaft in the housing. 10. Install the stub shaft with spool valve, thrust support assembly and adjuster nut in the housing. 11. Install the rack piston and arbor tool into the housing. 12. Hold arbor tightly against worm shaft and turn stub shaft CLOCKWISE until rack piston is seated on worm shaft. 13. Install pitman shaft and side cover in the housing. 14. Install rack piston plug and tighten to 150 Nm (111 ft. lbs.). 15. Install housing end plug. 16. Adjust worm shaft thrust bearing preload and over-center rotating torque. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest for Steering Shaft: > 19-12-97 > Nov > 97 > Steering Column/Wheel - Clunk/Rattle Technical Service Bulletin # 19-12-97 Date: 971121 Steering Column/Wheel - Clunk/Rattle NO: 19-12-97 GROUP: Steering DATE: Nov. 21, 1997 SUBJECT: Clunk/Rattle Felt In Steering Column/Wheel MODELS: 1997 - 1998 (AN) Dakota 1998 (DN) Durango NOTE: THIS BULLETIN APPLIES TO 1998 DURANGOS BUILT BEFORE OCTOBER 27, 1997 (MDH 1127XX) AND ALL 1997 AND 1998 4X4 DAKOTAS. SYMPTOM/CONDITION: A clunk or rattle may be felt in the steering wheel/column during slow turns, rough road driving, and stops. DIAGNOSIS: Perform an inspection of front suspension and steering components, including a check of all fasteners for proper torque as specified in the appropriate Service Manual. Test drive the vehicle on a rough or bumpy road. With both hands on the steering wheel, feel for a clunk or listen for a rattling type noise. Perform the Repair Procedure if clunk or rattle is felt or heard. PARTS REQUIRED: 1 55351171AA Shaft, Intermediate, 4X4 2 06504926AA Bolt, Pinch 1 06101510 Nut POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-20-12-94 0.4 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves replacing the intermediate shaft with a revised part. 1. Position the front wheels straight ahead. Place a steering wheel holder, SNAP-ON TOOL, p/n WA96A, or equivalent, between the steering wheel and the driver's seat to secure the wheel. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest for Steering Shaft: > 19-12-97 > Nov > 97 > Steering Column/Wheel - Clunk/Rattle > Page 6017 2. Remove the toe plate nuts (Figure 1). 3. Remove the pinch bolt and nut securing the upper intermediate shaft to steering column. 4. Open the hood of the vehicle and remove the pinch bolt securing the lower intermediate shaft to the steering gear. 5. Compress the intermediate shaft and remove it from the vehicle. 6. Feed the new intermediate shaft, p/n 55351171AA, through the cowl panel and install it onto the shaft splines of the steering gear. Then, compress and/or lengthen the intermediate shaft enough to be able to install the shaft onto the lower end of the steering column. 7. Secure the intermediate shaft to the lower end of the steering column with a new pinch bolt, p/n 06504926AA, and nut, p/n 06101510, and tighten the nut to 49 Nm (36 ft. lbs.). 8. Secure the intermediate shaft to the steering gear with a new pinch bolt, p/n 06504926AA, and tighten the bolt to 49 Nm (36 ft. lbs.). 9. Install the toe plate onto the cowl panel studs. Tighten the toe plate nuts to 10 Nm (90 in. lbs.). 10. Remove the steering wheel holder from the steering wheel. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 19-12-97 > Nov > 97 > Steering Column/Wheel Clunk/Rattle Technical Service Bulletin # 19-12-97 Date: 971121 Steering Column/Wheel - Clunk/Rattle NO: 19-12-97 GROUP: Steering DATE: Nov. 21, 1997 SUBJECT: Clunk/Rattle Felt In Steering Column/Wheel MODELS: 1997 - 1998 (AN) Dakota 1998 (DN) Durango NOTE: THIS BULLETIN APPLIES TO 1998 DURANGOS BUILT BEFORE OCTOBER 27, 1997 (MDH 1127XX) AND ALL 1997 AND 1998 4X4 DAKOTAS. SYMPTOM/CONDITION: A clunk or rattle may be felt in the steering wheel/column during slow turns, rough road driving, and stops. DIAGNOSIS: Perform an inspection of front suspension and steering components, including a check of all fasteners for proper torque as specified in the appropriate Service Manual. Test drive the vehicle on a rough or bumpy road. With both hands on the steering wheel, feel for a clunk or listen for a rattling type noise. Perform the Repair Procedure if clunk or rattle is felt or heard. PARTS REQUIRED: 1 55351171AA Shaft, Intermediate, 4X4 2 06504926AA Bolt, Pinch 1 06101510 Nut POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-20-12-94 0.4 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves replacing the intermediate shaft with a revised part. 1. Position the front wheels straight ahead. Place a steering wheel holder, SNAP-ON TOOL, p/n WA96A, or equivalent, between the steering wheel and the driver's seat to secure the wheel. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 19-12-97 > Nov > 97 > Steering Column/Wheel Clunk/Rattle > Page 6023 2. Remove the toe plate nuts (Figure 1). 3. Remove the pinch bolt and nut securing the upper intermediate shaft to steering column. 4. Open the hood of the vehicle and remove the pinch bolt securing the lower intermediate shaft to the steering gear. 5. Compress the intermediate shaft and remove it from the vehicle. 6. Feed the new intermediate shaft, p/n 55351171AA, through the cowl panel and install it onto the shaft splines of the steering gear. Then, compress and/or lengthen the intermediate shaft enough to be able to install the shaft onto the lower end of the steering column. 7. Secure the intermediate shaft to the lower end of the steering column with a new pinch bolt, p/n 06504926AA, and nut, p/n 06101510, and tighten the nut to 49 Nm (36 ft. lbs.). 8. Secure the intermediate shaft to the steering gear with a new pinch bolt, p/n 06504926AA, and tighten the bolt to 49 Nm (36 ft. lbs.). 9. Install the toe plate onto the cowl panel studs. Tighten the toe plate nuts to 10 Nm (90 in. lbs.). 10. Remove the steering wheel holder from the steering wheel. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Specifications Steering Shaft Coupler: Specifications Bolts ..................................................................................................................................................... .................................................... 49 Nm (36 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Specifications Steering Wheel: Specifications Mounting Nut ....................................................................................................................................... .................................................... 47 Nm (35 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod Boot > Component Information > Service and Repair Tie Rod Boot: Service and Repair REMOVAL 1. Remove steering gear. 2. Loosen the locknut and remove the tie-rod. 3. Remove the outer clamp from the rubber boot. 4. Remove the boot inner clamp. 5. Mark the vent tube location on steering gear before removing the rubber boot. INSTALLATION 1. Align the vent tube with the reference mark on the steering gear. 2. Position and align the new boot over the housing. 3. Install inner clamp on the rubber boot. 4. Position outer clamp on the inner tie rod. 5. Install the tie-rod end. 6. Lubricate the boot outer groove (tie rod end) with silicone type lubricant. Ensure that the protective rubber boot is not twisted. 7. Install the outer clamp on the boot. 8. Install steering gear. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Specifications Tie Rod End: Specifications To Knuckle Nut .................................................................................................................................... .................................................... 88 Nm (65 ft. lbs.) Jam Nut ............................................................. ........................................................................................................................................ 75 Nm (55 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Outer Tie Rod End Tie Rod End: Service and Repair Outer Tie Rod End REMOVAL 1. Raise and support the vehicle. 2. Remove the cotter pin and nut from the tie rod end. 3. Separate the tie rod end from the steering knuckle with Puller C-3894-A, or equivalent. 4. Loosen the jam nut and unthread the tie rod end. INSTALLATION 1. Thread the tie rod end onto the tie rod. 2. Clean the tie rod end stud and knuckle taper. 3. Install the tie rod end stud into the steering knuckle and tighten the nut to 88 Nm (60 ft. lbs.). Install a new cotter pin. 4. Tighten the jam nut to 75 Nm (55 ft. lbs.). NOTE: Do not twist boot while tighten the jam nut. 5. Remove support and lower vehicle. 6. Adjust the wheel toe position. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Outer Tie Rod End > Page 6039 Tie Rod End: Service and Repair Inner Tie Rod End Chrysler does not provide a procedure to service the inner tie rod end separately from the rack and pinion assembly. The rack and pinion is serviced as a complete unit only. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Lower Ball Joint Ball Joint: Specifications Lower Ball Joint Ball Stud Nut ........................................................................................................................................ .................................................. 127 Nm (94 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Lower Ball Joint > Page 6045 Ball Joint: Specifications Upper Ball Joint Ball Stud Nut ........................................................................................................................................ .................................................... 81 Nm (60 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Lower Ball Joint Ball Joint: Testing and Inspection Lower Ball Joint 1. Raise the front of the vehicle. Install safety floor stands under both lower suspension arms as far outboard as possible. The upper suspension arms must not contact the rebound bumpers. 2. Install a dial indicator and clamp assembly to the lower suspension arm. 3. Position indicator plunger against knuckle arm and zero indicator. 4. Raise and lower the wheel and tire with a pry bar under the center of the tire. Measure the axial movement of the knuckle with respect to the suspension arm. 5. If the travel of the suspension arm is 1.52 mm (0.060 inch) or more, replace the lower suspension arm. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Lower Ball Joint > Page 6048 Ball Joint: Testing and Inspection Upper Ball Joint 1. Position a floor jack under the lower suspension arm. Raise the wheel and allow the tire to lightly contact the floor (vehicle weight relieved from the tire). 2. Mount a dial indicator on the upper suspension arm. Position the indicator plunger against the upper ball stud boss of the steering knuckle. 3. Grasp the top of the tire and apply force in and out. Look for movement at the ball joint between the upper suspension arm and steering knuckle. 4. If lateral movement is greater than 1.52 mm (0.060 inch), replace upper suspension arm. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > Upper Control Arm - Bushing Service Control Arm Bushing: Technical Service Bulletins Upper Control Arm - Bushing Service NUMBER: 02-006-00 GROUP: Suspension DATE: Oct. 27, 2000 SUBJECT: Upper Control Arm Bushing Service OVERVIEW: This bulletin provides service procedures for the removal and installation of the upper control arm bushing. MODELS: 1997 - 2000 (AN) Dakota 1998 - 2000 (DN) Durango NOTE: THIS BULLETIN APPLIES TO 4X2 VEHICLES. DISCUSSION: It is no longer necessary to replace the upper control arm assembly to service just the upper control arm bushings. Upper control arm bushing p/n 52037673 is now available through Mopar. The following Repair Procedure provides upper control arm bushing removal and installation information. Special Tool 8441 is required to remove and install upper control arm bushings and is now available through Miller Special Tools. PARTS REQUIRED: EQUIPMENT REQUIRED: REPAIR PROCEDURE: UPPER CONTROL ARM BUSHING REMOVAL 1. Remove the control arm from the vehicle. Refer to the appropriate Service Manual or the service information provided in the MDS2, Group 02, REMOVAL AND INSTALLATION - UPPER SUSPENSION ARM - REMOVAL. 2. Mount the control arm securely in a vise. 3. Remove the nut and washer from the upper control arm pivot bar shaft. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > Upper Control Arm - Bushing Service > Page 6054 4. Install Special Tool 8441, Upper Control Arm Bushing Remover/Installer (Fig. 1). 5. Press out the old bushings. UPPER CONTROL ARM BUSHING INSTALLATION 1. Slide the bushing over the pivot bar shaft and insert it into the control arm. 2. Install Special Tool 8441, Upper Control Arm Bushing Remover/Installer (Fig. 2). 3. Press the bushing into the control arm. 4. Install the washer and nut onto the upper control arm pivot bar shaft. Tighten the nut to 167 Nm (130 ft. lbs.). CAUTION: ENSURE THAT THE SELF-LOCKING FEATURE OF THE NUT IS STILL FUNCTIONAL. REPLACE THE NUT ANYTIME THE SELF-LOCKING FEATURE DOES NOT FUNCTION AS DESIGNED. 5. Remove the control arm from the vise. 6. Install the control arm in the vehicle. Refer to the appropriate Service Manual or the service information provided in the MDS2, Group 02, - REMOVAL AND INSTALLATION - UPPER SUSPENSION ARM - INSTALLATION. 7. Align the front suspension. Refer to the appropriate Service Manual or the service information provided in the MDS2, Group 02, ALIGNMENT. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > Upper Control Arm - Bushing Service > Page 6055 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > Customer Interest for Cross-Member: > 03-01-99A > Aug > 99 > Propeller Shaft Boot Torn/Cut Cross-Member: Customer Interest Propeller Shaft Boot - Torn/Cut NUMBER: 03-01-99 Rev. A GROUP: Axle And Propshafts DATE: Aug. 13, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 03-01-99, DATED FEB. 02, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE REPLACEMENT OF THE VEHICLE CROSSMEMBER ON AUTOMATIC TRANSMISSION EQUIPPED VEHICLES. SUBJECT: Two-Piece Propeller Shaft Boot Torn OVERVIEW: ** This bulletin involves replacing of the propeller shaft assembly and, on certain applications, the replacement of the vehicle crossmember.** MODELS: 1997 - 1998 (AN) Dakota NOTE: THIS BULLETIN APPLIES TO TWO WHEEL DRIVE VEHICLES WITH THE FOLLOWING CONFIGURATIONS: ^ ALL CLUB CAB VEHICLES EQUIPPED WITH A MANUAL TRANSMISSION ^ ALL STANDARD CAB/EIGHT FOOT BOX VEHICLES EQUIPPED WITH A MANUAL TRANSMISSION ^ CLUB CAB VEHICLES EQUIPPED WITH AN AUTOMATIC TRANSMISSION BUILT BEFORE SEPTEMBER 8, 1997 (MDH 0908XX). SYMPTOM/CONDITION: Two-piece propeller shaft boot is torn. DIAGNOSIS: Raise the vehicle on a hoist and inspect the two-piece propeller shaft boot for a cut or tear in the vicinity of the crossmember. If the boot shows signs that it had been cut or torn because it may have contacted the crossmember, perform the Repair Procedure. PARTS REQUIRED: (1) 52105850AA Propshaft, Two-Piece, 2.5L/3.9L Engine, Manual Transmission, Two Wheel Drive, Standard Cab, Eight Foot Box (1) 52105851AA Propshaft, Two-Piece, 2.5L/3.9L Engine, Manual Transmission, Two Wheel Drive, Club Cab (1) 52105873AA Propshaft, Two-Piece, 5.2L Engine, Manual Transmission, Two Wheel Drive, Standard Cab, Eight Foot Box (1) 52105874AA Propshaft, Two-Piece, 5.2L Engine, Manual Transmission, Two Wheel Drive, Club Cab **(1) 521112OOAA Propshaft, One-Piece, 3.9L/5.2L Engine, Automatic Transmission, Two Wheel Drive, Club Cab** **1 52020302AA Crossmember, 3.9L/5.2L Engine, Automatic Transmission, Two Wheel Drive, Club Cab** **4 06504677 Bolt, Crossmember** **4 06502979 Nut, Crossmember** REPAIR PROCEDURE: 1. Place the vehicle on a hoist and shift the transmission to the neutral position. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > Customer Interest for Cross-Member: > 03-01-99A > Aug > 99 > Propeller Shaft Boot Torn/Cut > Page 6064 2. Raise the vehicle. 3. Remove the bolts that attach the center bearing and heat shield to the crossmember. 4. Remove the bolts holding the universal joint clamps to the pinion yoke. 5. Slide the slip yoke off the transmission output shaft and remove the propeller shaft. For Manual Transmission Equipped Vehicles: 6. Slide the slip yoke of the new propeller shaft (see Parts Required section) onto the transmission output shaft. 7. Install the center bearing and heat shield onto the crossmember and attach the bearing with the bolts. Tighten the bolts to 68 N.m (50 ft. lbs.). 8. Position the universal joint into the axle yoke and attach the universal strap with the bolts. Tighten the bolts to 19 N.m (14 ft. lbs.). 9. Lower the vehicle. **For Automatic Transmission Equipped Vehicles: 10. Remove the crossmember attaching rivets and the crossmember. 11. Install the new crossmember (p/n 52020302AC). Attach the new crossmember to the vehicle frame with four (4) nuts and bolts (p/n 06504677 and 06052979). Tighten the bolts to 60 N.m (45 ft. lbs.). 12. Slide the slip yoke of the new propeller shaft (p/n 52111200AA) onto the transmission output shaft. 13. Position the universal joint into the axle yoke and attach the universal strap with the bolts. Tighten the bolts to 19 Nm (14 ft. lbs.). 14. Lower the vehicle.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 16-30-02-98 0.3 Hrs. Propeller Shaft - Replace Manual Transmission Equipped 16-30-02-99 0.6 Hrs. Propeller Shaft - Replace Automatic Trans. Equipped FAILURE CODE: PB - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cross-Member: > 03-01-99A > Aug > 99 > Propeller Shaft Boot - Torn/Cut Cross-Member: All Technical Service Bulletins Propeller Shaft Boot - Torn/Cut NUMBER: 03-01-99 Rev. A GROUP: Axle And Propshafts DATE: Aug. 13, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 03-01-99, DATED FEB. 02, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE REPLACEMENT OF THE VEHICLE CROSSMEMBER ON AUTOMATIC TRANSMISSION EQUIPPED VEHICLES. SUBJECT: Two-Piece Propeller Shaft Boot Torn OVERVIEW: ** This bulletin involves replacing of the propeller shaft assembly and, on certain applications, the replacement of the vehicle crossmember.** MODELS: 1997 - 1998 (AN) Dakota NOTE: THIS BULLETIN APPLIES TO TWO WHEEL DRIVE VEHICLES WITH THE FOLLOWING CONFIGURATIONS: ^ ALL CLUB CAB VEHICLES EQUIPPED WITH A MANUAL TRANSMISSION ^ ALL STANDARD CAB/EIGHT FOOT BOX VEHICLES EQUIPPED WITH A MANUAL TRANSMISSION ^ CLUB CAB VEHICLES EQUIPPED WITH AN AUTOMATIC TRANSMISSION BUILT BEFORE SEPTEMBER 8, 1997 (MDH 0908XX). SYMPTOM/CONDITION: Two-piece propeller shaft boot is torn. DIAGNOSIS: Raise the vehicle on a hoist and inspect the two-piece propeller shaft boot for a cut or tear in the vicinity of the crossmember. If the boot shows signs that it had been cut or torn because it may have contacted the crossmember, perform the Repair Procedure. PARTS REQUIRED: (1) 52105850AA Propshaft, Two-Piece, 2.5L/3.9L Engine, Manual Transmission, Two Wheel Drive, Standard Cab, Eight Foot Box (1) 52105851AA Propshaft, Two-Piece, 2.5L/3.9L Engine, Manual Transmission, Two Wheel Drive, Club Cab (1) 52105873AA Propshaft, Two-Piece, 5.2L Engine, Manual Transmission, Two Wheel Drive, Standard Cab, Eight Foot Box (1) 52105874AA Propshaft, Two-Piece, 5.2L Engine, Manual Transmission, Two Wheel Drive, Club Cab **(1) 521112OOAA Propshaft, One-Piece, 3.9L/5.2L Engine, Automatic Transmission, Two Wheel Drive, Club Cab** **1 52020302AA Crossmember, 3.9L/5.2L Engine, Automatic Transmission, Two Wheel Drive, Club Cab** **4 06504677 Bolt, Crossmember** **4 06502979 Nut, Crossmember** REPAIR PROCEDURE: 1. Place the vehicle on a hoist and shift the transmission to the neutral position. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cross-Member: > 03-01-99A > Aug > 99 > Propeller Shaft Boot - Torn/Cut > Page 6070 2. Raise the vehicle. 3. Remove the bolts that attach the center bearing and heat shield to the crossmember. 4. Remove the bolts holding the universal joint clamps to the pinion yoke. 5. Slide the slip yoke off the transmission output shaft and remove the propeller shaft. For Manual Transmission Equipped Vehicles: 6. Slide the slip yoke of the new propeller shaft (see Parts Required section) onto the transmission output shaft. 7. Install the center bearing and heat shield onto the crossmember and attach the bearing with the bolts. Tighten the bolts to 68 N.m (50 ft. lbs.). 8. Position the universal joint into the axle yoke and attach the universal strap with the bolts. Tighten the bolts to 19 N.m (14 ft. lbs.). 9. Lower the vehicle. **For Automatic Transmission Equipped Vehicles: 10. Remove the crossmember attaching rivets and the crossmember. 11. Install the new crossmember (p/n 52020302AC). Attach the new crossmember to the vehicle frame with four (4) nuts and bolts (p/n 06504677 and 06052979). Tighten the bolts to 60 N.m (45 ft. lbs.). 12. Slide the slip yoke of the new propeller shaft (p/n 52111200AA) onto the transmission output shaft. 13. Position the universal joint into the axle yoke and attach the universal strap with the bolts. Tighten the bolts to 19 Nm (14 ft. lbs.). 14. Lower the vehicle.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 16-30-02-98 0.3 Hrs. Propeller Shaft - Replace Manual Transmission Equipped 16-30-02-99 0.6 Hrs. Propeller Shaft - Replace Automatic Trans. Equipped FAILURE CODE: PB - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Technical Service Bulletins > Front Caliper Mounting/Steering Knuckle - Thread Repair Front Steering Knuckle: Technical Service Bulletins Front Caliper Mounting/Steering Knuckle Thread Repair NUMBER: 05-03-99 GROUP: Brakes EFFECTIVE DATE: Apr. 23, 1999 SUBJECT: Front Brake Caliper Mounting To Steering Knuckle Thread Repair OVERVIEW: This bulletin involves repair of the threads on the steering knuckle or brake caliper mounting adapter that are used to install and retain the front brake caliper housing in its correct operating location. MODELS: 1986 - 1999 (AN) Dakota 1998 - 1999 (DN) Durango DISCUSSION: A Brake Knuckle Thread Repair Kit has been developed to repair stripped threads on the front brake caliper mounting attachment making it no longer necessary to replace the front steering knuckle/brake caliper mounting adapter when encountering stripped threads. The following information provides the repair procedure for using the Brake Knuckle Thread Repair Kit. DIAGNOSIS: 1. Place the vehicle on an appropriate hoist. 2. Remove the front tire/wheel assembly. 3. Remove the brake caliper housing assembly by loosening the mounting bolts. NOTE: IF HIGH TORQUE IS ENCOUNTERED DURING THE MOUNTING BOLT REMOVAL, IT IS LIKELY THAT THREAD DAMAGE WILL OCCUR OR HAS OCCURRED. 4. Remove the caliper housing assembly and hang the housing on the frame of the vehicle using an appropriate wire hanger. NOTE: DO NOT ALLOW THE CALIPER HOUSING TO HANG BY ITSELF FROM THE BRAKE HOSE AS DAMAGE TO THE HOSE MAY RESULT. 5. If the vehicle has a bolt-on brake caliper mounting adapter, remove the adapter. If the brake caliper mounts directly to the steering knuckle, remove retainers on the wheel studs and remove the rotor. 6. Inspect the mounting bolts and knuckle threads for damage. If either is damaged, it is likely that damage to the other has occurred as well. If damage has occurred to the threads in the form of knicks, thread pulling, or cross-threading, perform the Repair Procedure. PARTS REQUIRED: AR (1) 05016156AA Insert, Heli-Coil, M9 X 1.25 AR (1) 04886075AA Bolts, Caliper Housing Mounting EQUIPMENT REQUIRED: AR (1) 05016155AA Kit, Brake Knuckle Thread Repair Includes: 23/64 Drill Bit M9 X 1.25 Tap Heli-Coil Installation Tool Heli-Coil Tang Break-Off Rod (25) M9 X 1.25 Stainless Steel Heli-Coils REPAIR PROCEDURE: Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Technical Service Bulletins > Front Caliper Mounting/Steering Knuckle - Thread Repair > Page 6075 1. Using the 23/64 in. drill, drill through the brake caliper mounting attachment hole keeping the drill perpendicular to the knuckle. 2. Using the M9 X 1.25 tap, tap the drilled hole ensuring to tap the hole entirely through. 3. Install a Heli-Coil insert onto the installation tool (tool number 3747-9). Be sure the tang is properly engaged into the driving contour of the tool. 4. Install the Heli-Coil into the drilled/tapped hole by rotating the tool and exerting slight pressure onto the tool/Heli-Coil and into the drilled/tapped hole. Continue to rotate the tool until the insert is located 1/4 to 1/2 turn below the steering knuckle surface. 5. Back the Heli-Coil installation tool out of the installed Heli-Coil. Then, remove the tang from the Heli-Coil by breaking the tang off using the tang break-off tool. Place the break-off tool into the assembled insert until it rests on the Heli-Coil tang. Holding the tool squarely, strike the tool sharply with a hammer. 6. If the vehicle has a bolt-on brake caliper mounting adapter, install the adapter. Refer to the appropriate Service Manual for information regarding proper brake caliper adapter mounting information. If the brake caliper mounts directly to the steering knuckle, install the rotor. 7. Install the caliper using new mounting bolts p/n 04886075AA in any location that had a Heli-Coil installed. Tighten the bolts to 30 - 35 N.m (22-26 ft. lbs.). 8. Install the tire/wheel assembly. 9. Lower the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 05-80-20-93 Brake Caliper Mounting Support Thread Repair, Left Side 0.4 Hrs. 05-80-20-94 Brake Caliper Mounting Support Thread Repair, Right Side 0.4 Hrs. 05-80-20-50 Brake Caliper Mounting Support Thread Repair, Each Additional Same Side 0.1 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Technical Service Bulletins > Page 6076 Front Steering Knuckle: Service and Repair REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove disc brake caliper, rotor, shield and ABS speed sensor, refer to Brakes and Traction Control. 4. Remove tie-rod from steering knuckle arm. 5. Remove the hub/bearing. 6. Remove the shock absorber. 7. Install Spring Compressor DD-1278, or equivalent up through the lower suspension arm, coil spring and upper shock mounting hole. 8. Tighten the tool lower nut to compress the coil spring. 9. Remove the lower ball stud nut and separate the ball stud from the knuckle with Remover C-4150A, or equivalent. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Technical Service Bulletins > Page 6077 10. Remove the upper ball stud nut and separate the ball stud from the knuckle with Remover MB-991113, or equivalent. CAUTION: When install Remover MB-991113, or equivalent to separate the ball stud, be careful not to damage the ball stud seal. 11. Remove steering knuckle. INSTALLATION 1. Position steering knuckle on upper and lower ball studs and install nuts. Tighten lower nut to 127 Nm (94 ft. lbs.). Tighten upper nut to 81 Nm (60 ft. lbs.) and install new cotter pins. 2. Remove the spring compressor. 3. Install the shock absorber. 4. Install the hub/bearing. 5. Install ABS speed sensor, brake dust shield, rotor and caliper, refer to Brakes and Traction Control. 6. Install tie rod to steering knuckle arm. 7. Install the wheel and tire assembly. 8. Remove support and lower the vehicle Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Specifications Stabilizer Link: Specifications Upper Nut ............................................................................................................................................ ..................................................... 37 Nm (27 ft. lbs.) Ball Stud Nut .................................................... ........................................................................................................................................ 47 Nm (35 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 02-05-00 > Mar > 00 > Rear Leaf Springs - Squeaking/Clicking Noise Suspension Spring ( Coil / Leaf ): Customer Interest Rear Leaf Springs - Squeaking/Clicking Noise BULLETIN NUMBER: 02-05-00 GROUP: Suspension DATE: Mar.17, 2000 SUBJECT: Squeaking/**Clicking** Noise From Rear Leaf Springs MODELS: 1997 - 2000 (AN) Dakota 1998 - 2000 (DN) Durango THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-15-99, DATED NOV. 5, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED SUBJECT, PART NUMBERS, AND DIAGNOSIS. OVERVIEW: This bulletin involves replacing the spring tip liners and installing spring clinch clips and isolators. SYMPTOM/CONDITION: Squeaking/**Clicking** noise coming from the rear of the vehicle. DIAGNOSIS: **If the customer indicates that the vehicle has a squeaking/clicking noise coming from the rear of the vehicle, verify that the noise is coming from the rear springs as the vehicle's suspension goes through jounce and rebound. If a squeaking/clicking noise is coming from the rear springs, perform the Repair Procedure.** **NOTE: PERFORM THE REPAIR PROCEDURE ON ANY VEHICLE THAT HAS MISSING TIP LINERS OR MISSING CLINCH CLIP ISOLATORS AND A SQUEAKING/CLICKING NOISE IS COMING FROM THE REAR SPRINGS. PARTS REQUIRED: EQUIPMENT REQUIRED: (2) Large C-Clamps (5 - 6 in.) Large Pry Bar REPAIR PROCEDURE: DAKOTA 1. Raise the vehicle on an appropriate frame support style lift (rear axle must be allowed to extend fully) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 02-05-00 > Mar > 00 > Rear Leaf Springs - Squeaking/Clicking Noise > Page 6090 Figure 1 2. Use an appropriate pry bar to bend open the rear spring clinch clip (Figure 1). Figure 2 3. Use the pry bar to spread apart the leaf (Figure 2). The clearance between the leaves should be enough to remove the old spring tip liner (if necessary) and install the new replacement spring tip liner. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 02-05-00 > Mar > 00 > Rear Leaf Springs - Squeaking/Clicking Noise > Page 6091 Figure 3 4. Remove the old spring tip liner by using a hammer to drive the spring tip liner from the leaf spring (Figure 3). 5. With the prybar still inserted between the leaves, install a new spring tip liner, pin 05017561AA, onto the leaf. 6. Firmly seat the spring tip liner onto the leaf. NOTE: THE SPRING TIP LINER IS PROPERLY INSTALLED WHEN THE RETAINING PIN IS POINTING TOWARD THE PAVEMENT AND THE WEAR PAD IS CONTACTING THE LEAF SPRING. 7 **Apply a small amount of lubricant pin 05018626AA to the tip liner wear Pad.** 8. Perform steps 3 through 7 to the other spring tip liner Figure 4 9. Remove the clinch clip isolator from Clinch Clip and Isolator Package pin 02808399. The isolator will need to be trimmed to properly fit on Dakota models. Scribe a mark on the isolator 127 mm (5 in.) from the end of the isolator (Figure 4) then, cut the excess from the isolator. 10. Install the isolator onto the new clinch clip. 11. Position the clinch clip onto the spring in the same location as where the old clinch clip was removed. 12. Install the bottom clamp of the clinch clip. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 02-05-00 > Mar > 00 > Rear Leaf Springs - Squeaking/Clicking Noise > Page 6092 Figure 5 13. Compress the clinch clip and the spring using a C-Clamp (Figure 5). Figure 6 14. With a hammer, bend the clinch clip tabs outboard and upward to secure the clinch clip onto the spring (Figure 6). 15. Repeat Steps 2 through 14 to remove and install all spring tip liners and clinch clips. 16. Lower the vehicle. DURANGO 1. Raise the vehicle on an appropriate frame support style lift (rear axle must be allowed to extend fully). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 02-05-00 > Mar > 00 > Rear Leaf Springs - Squeaking/Clicking Noise > Page 6093 Figure 7 2. Use an appropriate pry bar to bend open the rear spring clinch clip (Figure 7). 3. Use the pry bar to spread apart the leaf (Figure 2). The clearance between the leaves should be enough to remove the old spring tip liner (if necessary) and install the new replacement spring tip liner. 4. Remove the old spring tip liner by using a hammer to drive the spring tip liner from the leaf spring (Figure 3). 5. With the prybar still inserted between the leaves, install a new spring tip liner, p/n **52113135AA**, onto the leaf. 6. Firmly seat the spring tip liner onto the leaf. NOTE: THE SPRING TIP LINER IS PROPERLY INSTALLED WHEN THE RETAINING PIN IS POINTING TOWARD THE PAVEMENT AND THE WEAR PAD IS CONTACTING THE LEAF SPRING. 7. **Apply a small of lubricant p/n 05018626AA to the tip liner wear pad.** 8. Perform steps 3 through 7 to the other two spring tip liners. 9. Install the clinch clip isolator onto the new clinch clip (see Parts Required section). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 02-05-00 > Mar > 00 > Rear Leaf Springs - Squeaking/Clicking Noise > Page 6094 Figure 8 10. Position the new clinch clip so that the alignment tang lines up with the hole in the spring leaf (Figure 8). Figure 9 11. The clinch clip isolator and the leaf spring assembly will need to be compressed. Clamp the clinch clip and spring assembly using a C-Clamp (Figure 9). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 02-05-00 > Mar > 00 > Rear Leaf Springs - Squeaking/Clicking Noise > Page 6095 Figure 10 Figure 11 12. Tightly clamp the side of the clinch clip to the leaf spring assembly with a second C-Clamp as shown in Figure 10 and Figure 11. Make sure that the foot of the C-Clamp does not protrude below the bottom of the leaf spring. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 02-05-00 > Mar > 00 > Rear Leaf Springs - Squeaking/Clicking Noise > Page 6096 Figure 12 13. Remove the first C-Clamp that was installed in Step 10 (Figure 12). Figure 13 14. Using a hammer, bend the inboard clinch clip leg onto the leaf spring assembly until the locating tab is positioned into its locating hole on the leaf spring (Figure 13). 15. Next, bend the outboard clinch clip leg onto the leaf spring. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 02-05-00 > Mar > 00 > Rear Leaf Springs - Squeaking/Clicking Noise > Page 6097 Figure 14 16. Secure the clinch clip by bending the locking tab over (Figure 14). 17. Perform Steps 1 through 16 to all clinch clips and spring tip liners. 18. Lower the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8-New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 02-05-00 > Mar > 00 > Rear Leaf Springs - Squeaking/Clicking Noise Suspension Spring ( Coil / Leaf ): All Technical Service Bulletins Rear Leaf Springs Squeaking/Clicking Noise BULLETIN NUMBER: 02-05-00 GROUP: Suspension DATE: Mar.17, 2000 SUBJECT: Squeaking/**Clicking** Noise From Rear Leaf Springs MODELS: 1997 - 2000 (AN) Dakota 1998 - 2000 (DN) Durango THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-15-99, DATED NOV. 5, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED SUBJECT, PART NUMBERS, AND DIAGNOSIS. OVERVIEW: This bulletin involves replacing the spring tip liners and installing spring clinch clips and isolators. SYMPTOM/CONDITION: Squeaking/**Clicking** noise coming from the rear of the vehicle. DIAGNOSIS: **If the customer indicates that the vehicle has a squeaking/clicking noise coming from the rear of the vehicle, verify that the noise is coming from the rear springs as the vehicle's suspension goes through jounce and rebound. If a squeaking/clicking noise is coming from the rear springs, perform the Repair Procedure.** **NOTE: PERFORM THE REPAIR PROCEDURE ON ANY VEHICLE THAT HAS MISSING TIP LINERS OR MISSING CLINCH CLIP ISOLATORS AND A SQUEAKING/CLICKING NOISE IS COMING FROM THE REAR SPRINGS. PARTS REQUIRED: EQUIPMENT REQUIRED: (2) Large C-Clamps (5 - 6 in.) Large Pry Bar REPAIR PROCEDURE: DAKOTA 1. Raise the vehicle on an appropriate frame support style lift (rear axle must be allowed to extend fully) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 02-05-00 > Mar > 00 > Rear Leaf Springs - Squeaking/Clicking Noise > Page 6103 Figure 1 2. Use an appropriate pry bar to bend open the rear spring clinch clip (Figure 1). Figure 2 3. Use the pry bar to spread apart the leaf (Figure 2). The clearance between the leaves should be enough to remove the old spring tip liner (if necessary) and install the new replacement spring tip liner. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 02-05-00 > Mar > 00 > Rear Leaf Springs - Squeaking/Clicking Noise > Page 6104 Figure 3 4. Remove the old spring tip liner by using a hammer to drive the spring tip liner from the leaf spring (Figure 3). 5. With the prybar still inserted between the leaves, install a new spring tip liner, pin 05017561AA, onto the leaf. 6. Firmly seat the spring tip liner onto the leaf. NOTE: THE SPRING TIP LINER IS PROPERLY INSTALLED WHEN THE RETAINING PIN IS POINTING TOWARD THE PAVEMENT AND THE WEAR PAD IS CONTACTING THE LEAF SPRING. 7 **Apply a small amount of lubricant pin 05018626AA to the tip liner wear Pad.** 8. Perform steps 3 through 7 to the other spring tip liner Figure 4 9. Remove the clinch clip isolator from Clinch Clip and Isolator Package pin 02808399. The isolator will need to be trimmed to properly fit on Dakota models. Scribe a mark on the isolator 127 mm (5 in.) from the end of the isolator (Figure 4) then, cut the excess from the isolator. 10. Install the isolator onto the new clinch clip. 11. Position the clinch clip onto the spring in the same location as where the old clinch clip was removed. 12. Install the bottom clamp of the clinch clip. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 02-05-00 > Mar > 00 > Rear Leaf Springs - Squeaking/Clicking Noise > Page 6105 Figure 5 13. Compress the clinch clip and the spring using a C-Clamp (Figure 5). Figure 6 14. With a hammer, bend the clinch clip tabs outboard and upward to secure the clinch clip onto the spring (Figure 6). 15. Repeat Steps 2 through 14 to remove and install all spring tip liners and clinch clips. 16. Lower the vehicle. DURANGO 1. Raise the vehicle on an appropriate frame support style lift (rear axle must be allowed to extend fully). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 02-05-00 > Mar > 00 > Rear Leaf Springs - Squeaking/Clicking Noise > Page 6106 Figure 7 2. Use an appropriate pry bar to bend open the rear spring clinch clip (Figure 7). 3. Use the pry bar to spread apart the leaf (Figure 2). The clearance between the leaves should be enough to remove the old spring tip liner (if necessary) and install the new replacement spring tip liner. 4. Remove the old spring tip liner by using a hammer to drive the spring tip liner from the leaf spring (Figure 3). 5. With the prybar still inserted between the leaves, install a new spring tip liner, p/n **52113135AA**, onto the leaf. 6. Firmly seat the spring tip liner onto the leaf. NOTE: THE SPRING TIP LINER IS PROPERLY INSTALLED WHEN THE RETAINING PIN IS POINTING TOWARD THE PAVEMENT AND THE WEAR PAD IS CONTACTING THE LEAF SPRING. 7. **Apply a small of lubricant p/n 05018626AA to the tip liner wear pad.** 8. Perform steps 3 through 7 to the other two spring tip liners. 9. Install the clinch clip isolator onto the new clinch clip (see Parts Required section). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 02-05-00 > Mar > 00 > Rear Leaf Springs - Squeaking/Clicking Noise > Page 6107 Figure 8 10. Position the new clinch clip so that the alignment tang lines up with the hole in the spring leaf (Figure 8). Figure 9 11. The clinch clip isolator and the leaf spring assembly will need to be compressed. Clamp the clinch clip and spring assembly using a C-Clamp (Figure 9). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 02-05-00 > Mar > 00 > Rear Leaf Springs - Squeaking/Clicking Noise > Page 6108 Figure 10 Figure 11 12. Tightly clamp the side of the clinch clip to the leaf spring assembly with a second C-Clamp as shown in Figure 10 and Figure 11. Make sure that the foot of the C-Clamp does not protrude below the bottom of the leaf spring. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 02-05-00 > Mar > 00 > Rear Leaf Springs - Squeaking/Clicking Noise > Page 6109 Figure 12 13. Remove the first C-Clamp that was installed in Step 10 (Figure 12). Figure 13 14. Using a hammer, bend the inboard clinch clip leg onto the leaf spring assembly until the locating tab is positioned into its locating hole on the leaf spring (Figure 13). 15. Next, bend the outboard clinch clip leg onto the leaf spring. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 02-05-00 > Mar > 00 > Rear Leaf Springs - Squeaking/Clicking Noise > Page 6110 Figure 14 16. Secure the clinch clip by bending the locking tab over (Figure 14). 17. Perform Steps 1 through 16 to all clinch clips and spring tip liners. 18. Lower the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8-New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Specifications > Rear Suspension Spring ( Coil / Leaf ): Specifications Rear Spring Clamp Nuts .............................................................................................................................. ................................................. 163 Nm (120 ft. lbs.) Spring Eye Nut ................................................. .................................................................................................................................... 163 Nm (120 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Specifications > Rear > Page 6113 Suspension Spring ( Coil / Leaf ): Specifications Shackle Mounting Nuts ..................................................................................................................................... ................................................. 163 Nm (120 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Coil Springs Suspension Spring ( Coil / Leaf ): Description and Operation Coil Springs The coil springs control ride quality and maintain proper ride height. The springs mounted up in a well (pocket) in a bracket that is part of the frame rail. There is a rubber isolator between the top of the spring and bracket. The bottom of the spring seats on the lower suspension arm. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Coil Springs > Page 6116 Suspension Spring ( Coil / Leaf ): Description and Operation Leaf Springs The rear suspension system uses a multi-leaf springs and a solid drive axle. These vehicles use a 4-leaf 2-stage spring or 5-leaf single stage spring. The forward end of the springs are mounted to the frame rail hangers through rubber bushings. The rearward end of the springs are attached to the frame by the use of shackles. The spring and shackles use rubber bushings. The bushing help to isolate road noise. The shackles allow the springs to change their length as the vehicle moves over various road conditions. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation > Page 6117 Suspension Spring ( Coil / Leaf ): Testing and Inspection If the vehicle is used for severe, off-road operation, the springs should be examined periodically. Check for broken and shifted leafs, loose and missing clips and broken center bolts. Refer to illustration for additional information. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Coil Springs Suspension Spring ( Coil / Leaf ): Service and Repair Coil Springs REMOVAL 1. Raise and support the vehicle. 2. Remove wheel and tire assembly. 3. Remove the stabilizer bar link from the lower suspension arm. 4. Remove the shock absorber. 5. Install Spring Compressor DD-1278, or equivalent up through the lower suspension arm, coil spring and upper shock mounting hole. 6. Tighten the tool lower nut to compress the coil spring. 7. Remove the lower ball stud nut and separate the ball stud from the knuckle with Remover C-4150A, or equivalent. 8. Loosen the spring compressor lower nut to relieve spring tension. 9. Remove the tool and pull down on the lower suspension arm to remove the spring. NOTE: The ramped or open end of the coil spring is the bottom of the spring. INSTALLATION 1. Tape the isolator pad to the top of the coil spring. Position the spring in the lower suspension arm well. Be sure that the coil spring is seated in the well. 2. Install Spring Compressor DD-1278, or equivalent up through the lower suspension arm, coil spring upper shock mounting hole. 3. Tighten the tool nut to compress the coil spring. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Coil Springs > Page 6120 4. Install the lower ball stud into the knuckle and tighten the nut to 127 Nm (94 ft. lbs.). Install cotter pin. 5. Remove the spring compressor tool. 6. Install the stabilizer bar link to the lower suspension arm and tighten nut to 47 Nm (35 ft. lbs.). 7. Install the shock absorber. 8. Install the wheel and tire assembly. 9. Remove support and lower the vehicle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Coil Springs > Page 6121 Suspension Spring ( Coil / Leaf ): Service and Repair Rear Leaf Spring Replace CAUTION: The rear of the vehicle must be lifted only with a jack or hoist. The lift must be placed under the frame rail crossmember located aft of the rear axle. Use care to avoid bending the side rail flange. REMOVAL 1. Raise the vehicle at the frame. 2. Use a hydraulic jack to relieve the axle weight. 3. Remove the wheel and tire assemblies. 4. Remove the nuts, the U-bolts and spring plate from the axle. 5. Remove the nut and bolt from the spring front eye. 6. Remove the nut and bolt that attaches the spring shackle to the rear frame bracket. 7. Remove the spring from the vehicle. 8. Remove the shackle from the spring. INSTALLATION 1. Install the spring shackle on the spring finger tight. 2. Position the spring on the rear axle pad. Make sure the spring center bolt is inserted in the pad locating hole. 3. Align front spring eye with the bolt hole in the front frame bracket. Install the spring eye bolt and nut and tighten the spring eye nut finger-tight. 4. Align spring shackle eye with the bolt hole in the rear frame bracket. Install the bolt and nut and tighten the spring shackle eve nut finger-tight. 5. Install the U-bolts, spring plate, and washers and nuts. 6. Tighten the nuts to 163 Nm (120 ft. lbs.). 7. Install the wheel and tire assemblies. 8. Remove the support stands from under the frame rails. Lower the vehicle until the springs are supporting the weight of the vehicle. 9. Tighten the spring eye pivot bolt nut and all shackle nuts to 163 Nm (120 ft. lbs.). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications > Front Suspension Strut / Shock Absorber: Specifications Front Upper Nut ............................................................................................................................................ ..................................................... 26 Nm (19 ft. lbs.) Lower Bolts ...................................................... ........................................................................................................................................ 28 Nm (21 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications > Front > Page 6126 Suspension Strut / Shock Absorber: Specifications Rear Lower Bolt ............................................................................................................................................ .................................................... 95 Nm (70 ft. lbs.) Upper Bolt ......................................................... ....................................................................................................................................... 95 Nm (70 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Description and Operation > Front Suspension Strut / Shock Absorber: Description and Operation Front Ride control is accomplished through the use of low-pressure gas charged shock absorbers. The shocks dampen the jounce and rebound as the vehicle travels over various road conditions. The top of the shock absorbers are bolted to the frame. The bottom of the shocks are bolted to the lower suspension arm. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Description and Operation > Front > Page 6129 Suspension Strut / Shock Absorber: Description and Operation Rear Ride control is accomplished through the use of gas charged shock absorbers. The shocks dampen jounce and rebound as the vehicle travels over various road conditions. The shock absorbers are mounted to the frame and the axle. The shocks are mounted staggered, one ahead and one behind the axle housing. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Description and Operation > Page 6130 Suspension Strut / Shock Absorber: Testing and Inspection A noise from a shock absorber may be caused by movement between mounting bushings and metal brackets or attaching components. This noise can usually be stopped by tightening the attaching nuts. If the noise persists, inspect for damaged and worn bushings, and attaching components. Repair as necessary if any of these conditions exist. The shock absorbers are not refillable or adjustable. If a malfunction occurs, the shock absorber must be replaced. To test a shock absorber, hold it in an upright position and force the piston in and out of the cylinder four or five times. The action throughout each stroke should be smooth and even. The shock absorber bushings do not require any type of lubrication. Do not attempt to stop bushing noise by lubricating them. Grease and mineral oil-base lubricants will deteriorate the bushing. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension Strut / Shock Absorber: Service and Repair Front REMOVAL 1. Remove the upper shock nut, retainer and grommet from the shock absorber stud. 2. Raise and support the vehicle. 3. Remove the lower mounting bolts and remove shock absorber through the lower suspension arm. NOTE: Upper shock nut must be replaced or use 242 Loctite on existing nut. INSTALLATION 1. Install the lower retainer (lower retainer is stamped with a L) and grommet on the shock absorber stud and extend the shock. Insert the shock absorber through the lower suspension arm and upper mounting hole. 2. Install the lower mounting bolts and tighten to 28 Nm (21 ft. lbs.). 3. Remove support and lower the vehicle. 4. Install the upper grommet and retainer (upper retainer is stamped with a U) on the shock absorber stud. Install a new nut or use 242 Loctite on existing nut and tighten to 26 Nm (19 ft. lbs.). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 6133 Suspension Strut / Shock Absorber: Service and Repair Rear REMOVAL 1. Raise vehicle and support rear axle. 2. Remove shock absorber lower nut and bolt from the axle bracket. 3. Remove shock absorber upper nut and bolt from the frame bracket and remove the shock absorber. INSTALLATION 1. Install shock absorber and upper mounting bolt and nut. Tighten nut to 95 Nm (70 ft. lbs.). 2. Install shock absorber into the axle bracket. Install the bolt and nut and tighten nut to 95 Nm (70 ft. lbs.). 3. Remove axle support and lower vehicle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Specifications Suspension Travel Bumper: Specifications Mounting Nuts ..................................................................................................................................... ..................................................... 54 Nm (40 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Specifications > Page 6137 Suspension Travel Bumper: Description and Operation The jounce bumpers are used to limit the spring and axle travel. They are bolted to the frame rail above the axle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Front Hub Seals - Grease Purge Explanation Wheel Bearing: Technical Service Bulletins Front Hub Seals - Grease Purge Explanation NUMBER: 02-06-99 Rev. A GROUP: Suspension DATE: Dec. 17, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-06-99, DATED JUNE 11, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF 4X2 MODELS AND ADDITIONAL MODEL YEARS. SUBJECT: Front Wheel Bearing Grease Is Evident On The Bearing Seal Area. MODELS: 1997 - **2000** (AN) Dakota 1994 - **2000** (BR/BE) Ram Truck 1998 - **2000** (DN) Durango DISCUSSION: Front wheel bearings may be incorrectly diagnosed as faulty due to the evidence of wheel bearing grease on the bearing seal areas. This grease purge is a normal design condition. The factory fill of the bearings includes a slightly greater amount of grease than is required for the bearing lifetime lubricant. A portion of the grease purges through the self-venting seal in the initial few thousand miles to form an additional barrier in the area of the seal and the stamped slinger. This barrier aids in the prevention of contaminants passing through the seal and into the bearing. Do not remove or clean the purged grease as part of normal maintenance due to the fact that it provides additional protection and once removed, damage to the seal and bearing could result. NOTE: UNDER NORMAL CONDITIONS, THERE MAY BE A SPLATTERING OF GREASE RADIALLY OUTWARD ON THE STEERING KNUCKLE FROM THE GREASE BARRIER AREA THAT CAN BE AS THICK AS 4 MM (0.125 IN.). Front wheel bearings should be replaced only if: ^ The seal shows visible damage ^ The bearing endplay is greater than 0.13 mm (0.005 in.) ^ The bearing was operated without the proper clamping force from the spindle nut ^ The bearing has a rough, sticky feel when rotated POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Page 6142 Wheel Bearing: Specifications Lubricant Type Lubricant Type Wheel Bearing Grease NLGI GC rated automotive grease Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Page 6143 Wheel Bearing: Service and Repair REMOVAL 1. Raise and support vehicle. 2. Remove wheel and tire assembly. 3. Remove brake caliper and rotor, refer to Brakes and Traction Control. 4. Remove hub/bearing spindle nut. 5. Slide hub/bearing off spindle. INSTALLATION 1. Slide hub/bearing on spindle. 2. Install hub/bearing spindle nut and tighten to 251 Nm (185 ft. lbs.). 3. Install brake rotor and caliper, refer to Brakes and Traction Control. 4. Install wheel and tire assembly. 5. Remove support and lower vehicle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Nut ....................................................................................................................................................... ................................................. 251 Nm (185 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Description and Operation Spare Tire: Description and Operation The temporary spare tire is designed for emergency use only. The original tire should be repaired and reinstalled at the first opportunity, or replaced with a new. Do not exceed speeds of 50 MPH when the temporary spare tire is in use on the vehicle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Tire & Wheel - Runout Wheels: Technical Service Bulletins Tire & Wheel - Runout NO: 22-01-97 GROUP: Wheels & Tires DATE: Jun. 13, 1997 SUBJECT: Tire & Wheel Runout MODELS: 1994 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1994 - 1997 (AB) Ram Van/Wagon 1994 - 1995 (AJ) LeBaron Convertible 1994 - 1997 (AN) Dakota 1994 (AP) Shadow/Sundance 1994 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 1997 (BR) Ram Pickup 1994 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1997 (FJ) Sebring/Avenger/Talon 1996 - 1997 (GS) Chrysler Voyager (International Market) 1995 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1994 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1997 (NS) Town & Country/Caravan/Voyager 1995 - 1997 (PL) Neon 1994 - 1997 (SR) Viper/Viper GTS 1997 (TJ) Wrangler 1994 - 1997 (XJ) Cherokee 1994 - 1995 (YJ) Wrangler 1994 - 1997 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Radial runout is the vertical distance between the high and low points on the tire or wheel edge measured at the center line of the tread. Lateral runout is the horizontal movement of the tire or wheel measured near the shoulder of the tire. Runout of more than the preferred specification may cause the vehicle to shake. Refer to the following specifications and appropriate Service Manual procedures. PREFERRED TIRE & WHEEL RUNOUT Usually runout can be reduced by relocating the wheel and tire on the wheels studs and/or rotating the tire on the wheel (match mounting). POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 6157 Wheels: Service Precautions CAUTION: Do not use chrome plated lug nuts with chrome plated wheels. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 6158 Wheels: Description and Operation Fig. 1 Available rim sizes are on the safety certification label located on the drivers door shut face. Rim size is determined by the drivetrain package. Original equipment wheels are designed for operation up to the specified maximum vehicle capacity. All models use steel or cast aluminum wheels. Every wheel has raised sections between the rim flanges and rim drop well called safety humps. Initial inflation of the tire forces the bead over these raised sections. In case of rapid loss of air pressure, the raised sections help hold the tire on the wheel. Cast aluminum wheels require coated balance weights and special alignment equipment. The wheel studs and nuts are designed for specific applications and must be replaced with equivalent parts. Do not use replacement parts of lesser quality or a substitute design. All aluminum and some steel wheels have wheel stud nuts with an enlarged nose. This enlarged nose is necessary to ensure proper retention of the wheels. Before installing the wheel, remove any build up of corrosion on the wheel mounting surfaces. CAUTION: Installing wheels without good metal-to-metal contact could cause loosening of wheel nuts. This could adversely affect the safety and handling of your vehicle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 6159 Wheels: Testing and Inspection CAUTION: - Failure to use equivalent replacement wheels may adversely affect the safety and handling of the vehicle. - Replacement with used wheels is not recommended. The service history of the rim may have included severe treatment or very high mileage. The rim could fail without warning. - Wheel repairs employing hammering, heating, welding or repairing leaks are not allowed. Wheels must be replaced if they: - Have excessive run out - Are bent or dented - Leak air from any area or surface of the rim - Have damaged wheel lug/ nut holes NOTE: Original equipment replacement wheels should be used. When obtaining replacement wheels, they should be equivalent in load carrying capacity. The physical dimensions (diameter, width, offset, pilot hole and bolt circle) of the wheel should be the same as the original wheel. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 6160 Wheels: Service and Repair REPLACEMENT NOTES: Wheels must be replaced if they have: Excessive runout - Bent or dented - Leak air through welds - Have damaged bolt holes , NOTE: Wheel repairs employing hammering, heating, or welding are not allowed. Original equipment wheels are available through your dealer. Replacement wheels from any other source should be equivalent in: Load carrying capacity - Diameter - Width - Offset - Mounting configuration Failure to use equivalent replacement wheels may affect the safety and handling of your vehicle. Replacement with used wheels is not recommended. Their service history may have included severe treatment. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Front Hub Seals - Grease Purge Explanation Wheel Bearing: Technical Service Bulletins Front Hub Seals - Grease Purge Explanation NUMBER: 02-06-99 Rev. A GROUP: Suspension DATE: Dec. 17, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-06-99, DATED JUNE 11, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF 4X2 MODELS AND ADDITIONAL MODEL YEARS. SUBJECT: Front Wheel Bearing Grease Is Evident On The Bearing Seal Area. MODELS: 1997 - **2000** (AN) Dakota 1994 - **2000** (BR/BE) Ram Truck 1998 - **2000** (DN) Durango DISCUSSION: Front wheel bearings may be incorrectly diagnosed as faulty due to the evidence of wheel bearing grease on the bearing seal areas. This grease purge is a normal design condition. The factory fill of the bearings includes a slightly greater amount of grease than is required for the bearing lifetime lubricant. A portion of the grease purges through the self-venting seal in the initial few thousand miles to form an additional barrier in the area of the seal and the stamped slinger. This barrier aids in the prevention of contaminants passing through the seal and into the bearing. Do not remove or clean the purged grease as part of normal maintenance due to the fact that it provides additional protection and once removed, damage to the seal and bearing could result. NOTE: UNDER NORMAL CONDITIONS, THERE MAY BE A SPLATTERING OF GREASE RADIALLY OUTWARD ON THE STEERING KNUCKLE FROM THE GREASE BARRIER AREA THAT CAN BE AS THICK AS 4 MM (0.125 IN.). Front wheel bearings should be replaced only if: ^ The seal shows visible damage ^ The bearing endplay is greater than 0.13 mm (0.005 in.) ^ The bearing was operated without the proper clamping force from the spindle nut ^ The bearing has a rough, sticky feel when rotated POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Page 6165 Wheel Bearing: Specifications Lubricant Type Lubricant Type Wheel Bearing Grease NLGI GC rated automotive grease Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Page 6166 Wheel Bearing: Service and Repair REMOVAL 1. Raise and support vehicle. 2. Remove wheel and tire assembly. 3. Remove brake caliper and rotor, refer to Brakes and Traction Control. 4. Remove hub/bearing spindle nut. 5. Slide hub/bearing off spindle. INSTALLATION 1. Slide hub/bearing on spindle. 2. Install hub/bearing spindle nut and tighten to 251 Nm (185 ft. lbs.). 3. Install brake rotor and caliper, refer to Brakes and Traction Control. 4. Install wheel and tire assembly. 5. Remove support and lower vehicle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Nut ....................................................................................................................................................... ................................................. 251 Nm (185 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Tightening Sequence Wheel Fastener: Specifications Wheel Tightening Sequence Wheel Torque Sequence - Master Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Tightening Sequence > Page 6175 Wheel Fastener: Specifications Lug Nut Torque Lug Nut ................................................................................................................................................ ................................ 115 - 150 Nm (85 - 110 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 6176 Wheel Fastener: Service and Repair REMOVAL 1. Raise and support vehicle. 2. Remove wheel and tire assembly. 3. Remove brake caliper and rotor, refer to Brakes and Traction Control. 4. Remove stud from hub with Remover C-4150A, or equivalent. INSTALLATION 1. Install new stud into hub flange. 2. Install three washers onto stud, then install lug nut with the flat side of the nut against the washers. 3. Tighten lug nut until the stud is pulled into the hub flange. Verify that the stud is properly seated into the flange. 4. Remove lug nut and washers. 5. Install the brake rotor and caliper, refer to Brakes and Traction Control. 6. Install wheel and tire assembly, use new lug nut on stud or studs that were replaced. 7. Remove support and lower vehicle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications Accumulator HVAC: Specifications Refrigerant Oil Capacity 120 ml (4 oz) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 6181 Accumulator HVAC: Description and Operation Accumulator The accumulator is mounted in the engine compartment between the evaporator coil outlet tube and the compressor inlet. Refrigerant enters the accumulator canister as a low pressure vapor through the inlet tube. Accumulator - Typical Any liquid, oil-laden refrigerant falls to the bottom of the canister, which acts as a separator. A desiccant bag is mounted inside the accumulator canister to absorb any moisture which may have entered and become trapped within the refrigerant system. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 6182 Accumulator HVAC: Service and Repair Fig 30 Accumulator Removal/Installation WARNING: Review the Service Precautions before performing the following operation. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. 3. Unplug the wire harness connector from the low pressure cycling clutch switch. 4. If the vehicle is so equipped, remove the nuts that secure the vehicle speed control servo mounting bracket to the studs on the cowl plenum panel and move the servo far enough to access the accumulator refrigerant line couplers. 5. Loosen the screw that secures the accumulator retaining band to the support bracket on the dash panel. 6. Disconnect the suction line refrigerant line coupler from the accumulator, then disconnect the accumulator refrigerant line coupler from the evaporator outlet tube. A/C Hose/Line -- A/C Coupler for the procedures. Install plugs in, or tape over all of the open refrigerant fittings. 7. Slide the accumulator retaining band screw out of the slot in the support bracket and remove the accumulator from the vehicle. INSTALLATION 1. Install the accumulator retaining band screw in the support bracket slot. 2. Remove the tape or plugs from all of the refrigerant fittings, and install the accumulator refrigerant line coupler to the evaporator outlet tube. Then install the suction line refrigerant line coupler to the accumulator. See Refrigerant A/C Coupler for the procedures. 3. Tighten the accumulator retaining band screw in the support bracket to 4.5 N.m (40 in. lbs.). 4. Plug the wire harness connector into the low pressure cycling clutch switch. 5. Evacuate and charge the refrigerant system. NOTE: If the accumulator is replaced, add 120 ml (4 oz.) of refrigerant oil to the refrigerant system. 6. Connect the battery negative cable. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Floor Door Actuator Replacement Air Door Actuator / Motor: Service and Repair Floor Door Actuator Replacement Fig 46 Floor-Defrost Door Actuator Removal/Installation WARNING: On vehicles equipped with Air-Bags, failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel assembly. Refer to: "Instrument Panel, Gauges and Wiring Indicators : Instrument Panel : Service and Repair" See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair 3. Unplug the two vacuum harness connectors from the floor-defrost door actuator. 4. Remove the push nut retainer that secures the floor-defrost door actuator link to the floor-defrost door crank arm. 5. Remove the two screws that secure the floor-defrost door actuator to the heater-A/C housing. 6. Disengage the floor-defrost door actuator link from the crank arm and remove the actuator from the heater-A/C housing. INSTALLATION 1. Install the floor-defrost door actuator link over the end of the floor-defrost door crank arm. Install the push nut retainer over the end of the crank arm to secure the actuator link. 2. Install the two screws that secure the floor-defrost door actuator to the heater-A/C housing. Tighten the screws enough to seat the actuator to the housing. 3. Plug in the two vacuum harness connectors to the floor-defrost door actuator nipples. 4. Reinstall the instrument panel assembly. Refer to: "Instrument Panel, Gauges and Wiring Indicators : Instrument Panel : Service and Repair" See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair 5. Connect the battery negative cable. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Floor Door Actuator Replacement > Page 6188 Air Door Actuator / Motor: Service and Repair Panel/Defrost Door Actuator Replacement Fig 47 Panel-defrost Door Actuator WARNING: On vehicles equipped with Air-Bags, failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel assembly. Refer to: "Instrument Panel, Gauges and Wiring Indicators : Instrument Panel : Service and Repair" See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair 3. Unplug the vacuum harness connector from the panel-defrost door actuator. 4. Remove the two screws that secure the panel- defrost door actuator to the heater-A/C housing. 5. Rotate the panel-defrost door actuator clockwise about one-quarter turn to disengage the hooked end of the actuator link from the hole on the end of the panel-defrost door lever. 6. Remove the panel-defrost door actuator from the heater-A/C housing. INSTALLATION 1. From underneath the panel-defrost door lever insert the hooked end of the panel-defrost door actuator link into the hole on the end of the lever. Rotate the panel-defrost door actuator counterclockwise about one-quarter turn to fully engage the link to the lever. 2. Install the two screws that secure the panel-defrost door actuator to the heater-A/C housing. Tighten the screws enough to seat the actuator to the heater-A/C housing. 3. Plug in the vacuum harness connector to the panel-defrost door actuator nipples. 4. Reverse the remaining removal procedures to complete the installation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Floor Door Actuator Replacement > Page 6189 Air Door Actuator / Motor: Service and Repair Recirculation Air Door Actuator Replacement Fig 48 Recirculation Air Door Actuator Removal/Installation WARNING: On vehicles equipped with Air-Bags, failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel assembly. Refer to: "Instrument Panel, Gauges and Wiring Indicators : Instrument Panel : Service and Repair" See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair . 3. If the vehicle is so equipped, and the heater-A/C housing is in its installed position in the vehicle, remove the Infinity speaker system amplifier. Refer to: "Accessories and Optional Equipment : Radio, Stereo and Compact Disc" See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Amplifier 4. Unplug the two vacuum harness connectors from the actuator. 5. Remove the two stamped nuts that secure the actuator to the blower motor housing cover. 6. Unhook the actuator link from the recirculation air door lever. 7. Remove the actuator from the blower motor housing cover. INSTALLATION 1. Install the hooked end of the actuator link into the hole at the end of the recirculation air door lever. 2. Position the actuator on the blower motor housing cover. 3. Install the two stamped nuts that secure the actuator to the blower motor housing cover. Tighten the nuts until the actuator is seated to the cover. 4. Plug in the two vacuum harness connectors to the actuator nipples. 5. If the vehicle is so equipped, and the heater- A/C housing is in its installed position in the vehicle, reinstall the Infinity speaker system amplifier. 6. Reinstall the instrument panel assembly. 7. Connect the battery negative cable. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Adjustments Air Door Cable: Adjustments Fig 39 Heater & A/C Control Connectors Fig 45 Temperature Control Cable Removal/Installation Any time the heater-A/C control or the temperature control cable are removed and/or replaced, the following procedure must be performed. 1. The temperature control cable housing and core must be installed at both the heater-A/C control and the heater-A/C housing ends, and the heater-A/C control must be installed in the instrument panel. 2. Rotate the temperature control knob on the heater-A/C control so that the knob pointer is in the 12 o'clock position. 3. Pull the temperature control knob straight out from the heater-A/C control base until the perimeter of the knob (not the knob pointer) protrudes about 6 mm (0.25 inch) from the face of the control base. 4. Rotate the temperature control knob to the 1 o'clock position. Push in on the knob slightly and continue rotating the knob to its full clockwise stop. The knob pointer should be aimed at a position about 3 mm (0.125 inch) beyond the end of the graduated red strobe temperature control graphic on the face of the heater-A/C control base. If the knob is not pointed to the correct position, go back to Step 2 and repeat the adjustment procedure. 5. Rotate the temperature control knob counterclockwise until the knob pointer is in the 12 o'clock position again. 6. Push the temperature control knob straight in towards the heater-A/C control base until the perimeter of the knob (not the knob pointer) is flush with the face of the heater-A/C control base. 7. Rotate the knob to its full clockwise stop again. The knob pointer should be aimed at the end of the graduated red strobe temperature control graphic on the face of the heater-A/C control base. If OK, the temperature control cable adjustment is complete. If not OK, go back to Step 2 and repeat the adjustment procedure. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Adjustments > Page 6193 Air Door Cable: Service and Repair Fig 45 Temperature Control Cable Removal/Installation WARNING: On vehicles equipped with Air-Bags, failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Roll down the instrument panel assembly, but do not remove it from the vehicle. 3. Disconnect the temperature control cable from the heater-A/C control. 4. Disconnect the temperature control cable housing flag retainer from the top of the heater-A/C housing. 5. Pull the temperature control cable core adjuster clip off of the pin on the end of the blend-air door lever. 6. Remove the temperature control cable from the vehicle. INSTALLATION 1. Push the temperature control cable core adjuster clip onto the pin on the end of the blend-air door lever. 2. Snap the temperature control cable housing flag retainer into the receiver on the top of the heater-A/C housing. 3. Reinstall the instrument panel assembly. 4. Connect the temperature control cable to the heater-A/C control. 5. Connect the battery negative cable. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Technical Service Bulletins > Customer Interest for Air Duct: > 240497 > Apr > 97 > Heater - Low Performance Air Duct: Customer Interest Heater - Low Performance NO: 24-04-97 GROUP: Heating & A/C DATE: Apr. 4, 1997 SUBJECT: Poor Heater Performance On Passenger Side MODELS: 1997 (AN) Dakota SYMPTOM/CONDITION: Low heater performance due to improperly directed heater air flow. DIAGNOSIS: Inspect the passenger side floor duct outlet to verify the direction of airflow from the outlet. If the airflow direction from the duct is perpendicular (straight down) to the heater housing, perform the Repair Procedure. If the floor duct is directing the airflow toward the passenger's legs, further diagnosis of the heater/A/C system is required. Refer to the 1997 Service Manual (Publication No. 81-370-7110), pages 24-10 through 24-15 for information regarding heater performance. PARTS REQUIRED: 1 04734717AB Duct, Floor REPAIR PROCEDURE: This bulletin involves replacing the floor duct with a revised part. 1. Disconnect and isolate the battery negative cable. 2. Remove the three screws that secure the bottom of the steering column opening cover/knee blocker to the lower instrument panel reinforcement (Figure 1). 3. Using a trim stick or other suitable wide-bladed flat tool, gently pry the top of the steering column opening cover/knee blocker on each side of the steering column to release the snap-clip retainers that secure it to the instrument panel and remove the cover/knee blocker from the vehicle. 4. If the vehicle is equipped with an automatic transmission, apply the parking brake then, turn the ignition key to the RUN position and move the transmission gear selector to the LOW position. 5. If the vehicle is equipped with a tilt steering column, set the tilt mechanism to its lowest position. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Technical Service Bulletins > Customer Interest for Air Duct: > 240497 > Apr > 97 > Heater - Low Performance > Page 6202 6. Using a trim stick or other suitable wide-bladed flat tool, gently pry around the perimeter of the instrument cluster bezel to disengage the nine snap-clip retainers that secure the bezel to the instrument panel (Figure 2). 7. Remove the fog lamp switch or the fog lamp harness connector from the instrument panel bezel by pressing the tabs to release the switch/connector. 8. Remove the instrument cluster bezel from the vehicle. 9. Open the glove box. 10. Remove the two screws that secure the bottom of the instrument panel lower bezel to the instrument panel (Figure 3). 11. Remove the four screws that secure the top of the instrument panel lower bezel to the instrument panel (Figure 3). 12. If the vehicle is so equipped, pull the bezel away from the instrument panel far enough to unplug the wire harness connectors from the cigar lighter and the power outlet and unclip the ash receiver lamp and hood from the ash receiver flame shield. 13. Remove the instrument panel lower bezel from the vehicle. 14. Pull the carpet back from the front of the floor pan transmission tunnel far enough to access the center support bracket mounting screws. 15. Remove the two screws that secure the center support bracket to the lower instrument panel. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Technical Service Bulletins > Customer Interest for Air Duct: > 240497 > Apr > 97 > Heater - Low Performance > Page 6203 16. Remove the three screws (two screws on the left and one screw on the right) that secure the center support bracket to the Airbag Control Module (ACM) bracket on the floor pan transmission tunnel and remove the center support bracket (Figure 4). 17. Remove the screw that secures the instrument panel wire harness ground eyelet to the left side of the floor pan transmission tunnel. 18. Unplug the ACM wire harness connector. To unplug the connector, first pull the two white locks out about 3 mm (0.125 in.) from each side of the connector (Figure 5). Then squeeze the two connector latches between the thumb and forefinger, while pulling the connector out from the ACM. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Technical Service Bulletins > Customer Interest for Air Duct: > 240497 > Apr > 97 > Heater - Low Performance > Page 6204 19. Remove the three screws that secure the ACM mounting bracket to the floor pan transmission tunnel and remove the ACM and its bracket as an assembly (Figure 6). 20. Remove the four floor duct screws (Figure 7). 21. Remove the floor duct by sliding the duct out from the driver's side of the vehicle. 22. Install the new duct (p/n 04734717AB) onto the heater housing assembly and secure it with the four floor duct screws. 23. Install the ACM and attach it to the floor pan transmission tunnel with the three mounting screws. Tighten the mounting screws to 11.8 Nm (105 in. lbs.) of torque. NOTE: THE ARROW ON THE TOP OF THE ACM MUST BE POINTING FORWARD WHEN INSTALLING THE ACM. 24. Plug in the wire harness connector to the ACM. Be certain that the connector latches are fully engaged and that the connector locks are pushed in. 25. Secure the instrument panel wire harness ground eyelet to the left side of the floor pan transmission tunnel. 26. Attach the center support bracket to the Airbag Control Module (ACM) bracket on the floor pan transmission tunnel. Secure the bracket to the ACM bracket with three screws (two screws on the left and one screw on the right) and secure the bracket to the lower instrument panel with two screws (Figure 4). Re-position the carpet. 27. If the vehicle is so equipped, connect the wire harness to the cigar lighter and the power outlet and clip the ash receiver lamp and hood to the ash receiver flame shield. 28. Install the instrument panel lower bezel onto the instrument panel. 29. Connect the fog lamp switch/connector to the instrument panel bezel. 30. Attach the instrument cluster bezel to the instrument panel. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Technical Service Bulletins > Customer Interest for Air Duct: > 240497 > Apr > 97 > Heater - Low Performance > Page 6205 31. Attach the steering column opening cover/knee blocker to the instrument panel. 32. Turn the ignition key to the RUN position and connect the battery negative cable. 33. Reset the clock. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-64-49-90 1.6 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Duct: > 240497 > Apr > 97 > Heater - Low Performance Air Duct: All Technical Service Bulletins Heater - Low Performance NO: 24-04-97 GROUP: Heating & A/C DATE: Apr. 4, 1997 SUBJECT: Poor Heater Performance On Passenger Side MODELS: 1997 (AN) Dakota SYMPTOM/CONDITION: Low heater performance due to improperly directed heater air flow. DIAGNOSIS: Inspect the passenger side floor duct outlet to verify the direction of airflow from the outlet. If the airflow direction from the duct is perpendicular (straight down) to the heater housing, perform the Repair Procedure. If the floor duct is directing the airflow toward the passenger's legs, further diagnosis of the heater/A/C system is required. Refer to the 1997 Service Manual (Publication No. 81-370-7110), pages 24-10 through 24-15 for information regarding heater performance. PARTS REQUIRED: 1 04734717AB Duct, Floor REPAIR PROCEDURE: This bulletin involves replacing the floor duct with a revised part. 1. Disconnect and isolate the battery negative cable. 2. Remove the three screws that secure the bottom of the steering column opening cover/knee blocker to the lower instrument panel reinforcement (Figure 1). 3. Using a trim stick or other suitable wide-bladed flat tool, gently pry the top of the steering column opening cover/knee blocker on each side of the steering column to release the snap-clip retainers that secure it to the instrument panel and remove the cover/knee blocker from the vehicle. 4. If the vehicle is equipped with an automatic transmission, apply the parking brake then, turn the ignition key to the RUN position and move the transmission gear selector to the LOW position. 5. If the vehicle is equipped with a tilt steering column, set the tilt mechanism to its lowest position. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Duct: > 240497 > Apr > 97 > Heater - Low Performance > Page 6211 6. Using a trim stick or other suitable wide-bladed flat tool, gently pry around the perimeter of the instrument cluster bezel to disengage the nine snap-clip retainers that secure the bezel to the instrument panel (Figure 2). 7. Remove the fog lamp switch or the fog lamp harness connector from the instrument panel bezel by pressing the tabs to release the switch/connector. 8. Remove the instrument cluster bezel from the vehicle. 9. Open the glove box. 10. Remove the two screws that secure the bottom of the instrument panel lower bezel to the instrument panel (Figure 3). 11. Remove the four screws that secure the top of the instrument panel lower bezel to the instrument panel (Figure 3). 12. If the vehicle is so equipped, pull the bezel away from the instrument panel far enough to unplug the wire harness connectors from the cigar lighter and the power outlet and unclip the ash receiver lamp and hood from the ash receiver flame shield. 13. Remove the instrument panel lower bezel from the vehicle. 14. Pull the carpet back from the front of the floor pan transmission tunnel far enough to access the center support bracket mounting screws. 15. Remove the two screws that secure the center support bracket to the lower instrument panel. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Duct: > 240497 > Apr > 97 > Heater - Low Performance > Page 6212 16. Remove the three screws (two screws on the left and one screw on the right) that secure the center support bracket to the Airbag Control Module (ACM) bracket on the floor pan transmission tunnel and remove the center support bracket (Figure 4). 17. Remove the screw that secures the instrument panel wire harness ground eyelet to the left side of the floor pan transmission tunnel. 18. Unplug the ACM wire harness connector. To unplug the connector, first pull the two white locks out about 3 mm (0.125 in.) from each side of the connector (Figure 5). Then squeeze the two connector latches between the thumb and forefinger, while pulling the connector out from the ACM. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Duct: > 240497 > Apr > 97 > Heater - Low Performance > Page 6213 19. Remove the three screws that secure the ACM mounting bracket to the floor pan transmission tunnel and remove the ACM and its bracket as an assembly (Figure 6). 20. Remove the four floor duct screws (Figure 7). 21. Remove the floor duct by sliding the duct out from the driver's side of the vehicle. 22. Install the new duct (p/n 04734717AB) onto the heater housing assembly and secure it with the four floor duct screws. 23. Install the ACM and attach it to the floor pan transmission tunnel with the three mounting screws. Tighten the mounting screws to 11.8 Nm (105 in. lbs.) of torque. NOTE: THE ARROW ON THE TOP OF THE ACM MUST BE POINTING FORWARD WHEN INSTALLING THE ACM. 24. Plug in the wire harness connector to the ACM. Be certain that the connector latches are fully engaged and that the connector locks are pushed in. 25. Secure the instrument panel wire harness ground eyelet to the left side of the floor pan transmission tunnel. 26. Attach the center support bracket to the Airbag Control Module (ACM) bracket on the floor pan transmission tunnel. Secure the bracket to the ACM bracket with three screws (two screws on the left and one screw on the right) and secure the bracket to the lower instrument panel with two screws (Figure 4). Re-position the carpet. 27. If the vehicle is so equipped, connect the wire harness to the cigar lighter and the power outlet and clip the ash receiver lamp and hood to the ash receiver flame shield. 28. Install the instrument panel lower bezel onto the instrument panel. 29. Connect the fog lamp switch/connector to the instrument panel bezel. 30. Attach the instrument cluster bezel to the instrument panel. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Duct: > 240497 > Apr > 97 > Heater - Low Performance > Page 6214 31. Attach the steering column opening cover/knee blocker to the instrument panel. 32. Turn the ignition key to the RUN position and connect the battery negative cable. 33. Reset the clock. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-64-49-90 1.6 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Demister Duct and Outlet Replacement Air Duct: Service and Repair Demister Duct and Outlet Replacement Fig 43 Demister Duct Adapter Removal/Installation WARNING: On vehicles equipped with airbags, refer to Restraint Systems / Air Bag Systems before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. ADAPTER 1. Disconnect and isolate the battery negative cable. 2. Roll the instrument panel assembly down, but do not remove it from the vehicle. 3. Disconnect the flexible demister duct hose from the demister duct adapter on the top of the heater- A/C housing. 4. Remove the two screws that secure the demister duct adapter to the top of the heater-A/C housing. 5. Remove the demister duct adapter from the heater-A/C housing. 6. Reverse the removal procedures to install. Tighten the demister duct adapter screws enough to seat the adapter to the heater-A/C housing. HOSE 1. Disconnect and isolate the battery negative cable. 2. Remove the heater-A/C control. 3. Reach through the heater-A/C control opening in the instrument panel and remove the screw that secures the flexible demister duct hose to the demister duct tee. 4. Roll the instrument panel assembly down, but do not remove it from the vehicle. 5. Disconnect the flexible demister duct hose from the demister duct adapter on the top of the heater- A/C housing. 6. Remove the demister duct hose. 7. Reverse the removal procedures to install. Fig 44 Demister Ducts Removal/Installation DUCTS AND OUTLETS 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel top cover from the instrument panel. 3. Remove the screws (two - left side, three - right side) that secure the demister ducts to the instrument panel top cover. 4. Using a trim stick or another suitable widebladed flat tool, pry between the end of the demister duct and the demister outlet flange to release the duct from the outlet. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Demister Duct and Outlet Replacement > Page 6217 5. Remove the demister ducts and the tee from the instrument panel top cover. 6. Squeeze the demister outlet flange from the underside of the instrument panel top cover and push it out through the top of the top cover. 7. Reverse the removal procedures to install. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Demister Duct and Outlet Replacement > Page 6218 Air Duct: Service and Repair Floor Duct Replacement Fig 51 Floor Duct Removal/Installation WARNING: On vehicles equipped with Air-Bags, refer to Air Bags and Seat Belts/Air Bags before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel assembly. 3. Remove the heater-A/C housing. 4. Remove the four screws that secure the floor duct to the bottom of the heater-A/C housing. 5. Remove the floor duct from the heater-A/C housing. INSTALLATION 1. Position the floor duct to the bottom of the heater-A/C housing. 2. Install the four screws that secure the floor duct to the heater-A/C housing. Tighten the mounting screws enough to seat the duct to the housing. 3. Reinstall the heater-A/C housing. 4. Reinstall the instrument panel assembly. 5. Connect the battery negative cable. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Defroster/Demister Duct and Outlet Replacement Air Register: Service and Repair Defroster/Demister Duct and Outlet Replacement Fig 43 Demister Duct Adapter Removal/Installation WARNING: On vehicles equipped with airbags, refer to Restraint Systems / Air Bag Systems before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. ADAPTER 1. Disconnect and isolate the battery negative cable. 2. Roll the instrument panel assembly down, but do not remove it from the vehicle. 3. Disconnect the flexible demister duct hose from the demister duct adapter on the top of the heater- A/C housing. 4. Remove the two screws that secure the demister duct adapter to the top of the heater-A/C housing. 5. Remove the demister duct adapter from the heater-A/C housing. 6. Reverse the removal procedures to install. Tighten the demister duct adapter screws enough to seat the adapter to the heater-A/C housing. HOSE 1. Disconnect and isolate the battery negative cable. 2. Remove the heater-A/C control. 3. Reach through the heater-A/C control opening in the instrument panel and remove the screw that secures the flexible demister duct hose to the demister duct tee. 4. Roll the instrument panel assembly down, but do not remove it from the vehicle. 5. Disconnect the flexible demister duct hose from the demister duct adapter on the top of the heater- A/C housing. 6. Remove the demister duct hose. 7. Reverse the removal procedures to install. Fig 44 Demister Ducts Removal/Installation DUCTS AND OUTLETS 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel top cover from the instrument panel. 3. Remove the screws (two - left side, three - right side) that secure the demister ducts to the instrument panel top cover. 4. Using a trim stick or another suitable widebladed flat tool, pry between the end of the demister duct and the demister outlet flange to release the duct from the outlet. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Defroster/Demister Duct and Outlet Replacement > Page 6223 5. Remove the demister ducts and the tee from the instrument panel top cover. 6. Squeeze the demister outlet flange from the underside of the instrument panel top cover and push it out through the top of the top cover. 7. Reverse the removal procedures to install. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Defroster/Demister Duct and Outlet Replacement > Page 6224 Air Register: Service and Repair Instrument Panel Outlet Replacement Fig 42 Panel Outlets 1. Using a trim stick or another suitable wide bladed flat tool, gently pry at the sides of the panel outlets to release the snap-fit pivots on the outlet from the pivot pins in the instrument panel top cover or the instrument cluster bezel. 2. To install the outlet, align the snap-fit pivots on the outlet with the pivot pins on the instrument panel top cover or the instrument cluster bezel. Then push in evenly on each side of the outlet until it snaps into position. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Description and Operation Ambient Temperature Sensor / Switch HVAC: Description and Operation CIRCUIT OPERATION The ambient temperature sensor is a variable resistor. Circuit G31 supplies voltage from the overhead console to the sensor. Circuit G32 is the signal return from the sensor to the overhead console. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Description and Operation > Page 6228 Ambient Temperature Sensor / Switch HVAC: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Ambient Temperature Sensor Remove/Install 2. Locate the ambient temperature sensor, on the radiator yoke behind the grille. 3. Unplug the sensor wire harness connector. 4. Remove the screw that secures the ambient temperature sensor to the radiator yoke. 5. Remove the ambient temperature sensor. 6. Reverse the removal procedures to install. Tighten the ambient temperature sensor mounting screw to 5.6 N.m (50 in lbs.). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations Blower Motor: Locations The blower motor and blower wheel are located in the passenger side end of the heater-A/C housing, below the glove box. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and Operation > Circuit Operation Blower Motor: Description and Operation Circuit Operation CIRCUIT OPERATION Power for the HVAC relay, located in the Power Distribution Center (PDC), is supplied from two circuits. Circuit F19 supplies power to the coil side of the relay This circuit is protected by a 10 Amp fuse located in the junction block. Ground for the coil side of the relay is supplied on circuit Z1. Power for the contact side of the relay is supplied on circuit AS. This circuit is HOT at all times and protected by a 40 Amp fuse located in the PDC. When the contacts in the relay CLOSE circuit AS is connected to circuit C1. The C1 circuit connects from the relay to the blower motor. Ground for the blower motor is supplied on circuit H6 from the motor to the blower motor resistor. Blower motor speed is controlled by the switch position. Circuit C4 is used for LOW speed operation. Circuit C5 is used for M1 speed and C6 for M2 speed. In the HIGH speed mode circuit H6 connects directly to circuit C7. No resistors are used in the HIGH speed mode. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and Operation > Circuit Operation > Page 6234 Blower Motor: Description and Operation System Operation SYSTEM OPERATION The blower motor and blower wheel are located in the right end of the heater-A/C housing, below the glove box. The blower motor controls the velocity of the air flowing through the heater-A/C housing by spinning a squirrel cage-type blower wheel within the blower housing at the selected speed. The blower motor and blower wheel can only be serviced with the heater-A/C housing removed from the passenger compartment. The blower motor will only operate when the ignition switch is in the On position, and the heater-A/C mode control switch is in any position except Off. The blower motor receives battery feed through the contacts of the blower motor relay, located in the Power Distribution Center (PDC), whenever the ignition switch is in the On position. The blower motor battery feed circuit is protected by fuse a in the PDC. The blower motor relay control circuit is protected by a fuse in the junction block. Blower motor speed is controlled by regulating the ground path through the heater-A/C mode control switch, the blower motor switch, and the blower motor resistor. The blower motor and blower wheel cannot be repaired and, if faulty or damaged, they must be replaced. The blower motor and blower wheel are each serviced separately. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Testing and Inspection > Flow of Diagnosis Blower Motor: Flow of Diagnosis POSSIBLE CAUSES Possible causes of an inoperative blower motor include: Faulty fuse - Faulty blower motor relay - Faulty blower motor battery feed circuit - Faulty blower motor ground circuit - Faulty blower motor resistor - Faulty blower motor switch - Faulty heater-A/C mode control switch - Faulty blower motor. Possible causes of the blower motor not operating in all speeds include: Faulty fuse - Faulty blower motor relay - Faulty blower motor battery feed circuit - Faulty blower motor resistor - Faulty blower motor switch. Vibration Possible causes of blower motor vibration include: Improper blower motor mounting - Improper blower wheel mounting - Blower wheel out of balance or bent - Blower motor faulty Noise To verify that the blower is the source of the noise, unplug the blower motor wire harness connector and operate the heater-A/C system. If the noise goes away possible causes include: Foreign material in the heater-A/C housing - Improper blower motor mounting - Improper blower wheel mounting - Blower motor faulty Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Testing and Inspection > Flow of Diagnosis > Page 6237 Blower Motor: Component Tests and General Diagnostics - Check the 10 Amp fuse located in the junction block - Check the 40 Amp fuse located in the PDC Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Blower Motor Housing Cover Blower Motor: Service and Repair Blower Motor Housing Cover Fig 56 Blower Motor Housing Cover Removal/Installation WARNING: On vehicles equipped with Air-Bags, refer to Air Bags and Seat Belts/Air Bags before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel assembly from the vehicle. 3. Remove the heater-A/C housing from the vehicle. 4. Remove the heater-A/C housing cover. 5. If the vehicle is so equipped, remove the recirculation air door actuator and the recirculation air door. 6. Remove the six screws that secure the blower motor housing cover to the heater-A/C housing. 7. Remove the blower motor housing cover from the heater-A/C housing. Fig 57 Blower Motor Housing Cover Sealant INSTALLATION 1. Before installing the blower motor housing cover, be certain that the blower motor housing cover sealant is in place and in good condition. 2. Position the blower motor housing cover to the heater-A/C housing. 3. Install the six screws that secure the blower motor housing cover to the heater-A/C housing. Tighten the screws enough to seat the blower motor housing cover sealant to the heater-A/C housing. 4. If the vehicle is so equipped, install the recirculation air door and the recirculation air door actuator. 5. Install the heater-A/C housing cover. 6. Install the heater-A/C housing in the vehicle. 7. Install the instrument panel assembly. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Blower Motor Housing Cover > Page 6240 Blower Motor: Service and Repair Blower Motor Replacement Fig 58 Blower Motor Removal/Installation WARNING: On vehicles equipped with Air-Bags, refer to Air Bags and Seat Belts/Air Bags before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel assembly from the vehicle. 3. Remove the heater-A/C housing. 4. Remove the heater-A/C housing cover. 5. Remove the blower motor housing cover. 6. Remove the three screws that secure the blower motor and blower wheel assembly to the heater-A/C housing. 7. Pull the blower motor and wheel assembly out of the heater-A/C housing while feeding the blower motor wire harness, grommet and connector through the hole on the other side of the heater-A/C housing. Fig 59 Blower Motor Wheel Removal/Installation 8. Remove the blower wheel retainer clip and remove the wheel from the blower motor shaft. INSTALLATION 1. Press the blower wheel hub onto the blower motor shaft. Be sure the flat on the motor shaft lines up with the flat inside the wheel hub. 2. Install the retainer clip. The ears of the retainer clip must be over the flat surface on the motor shaft. 3. Feed the blower motor wire harness connector through the grommet hole inside the heater-A/C housing. 4. Pull the blower motor wiring through the hole from the outside of the heater-A/C housing, while positioning the blower motor and blower wheel assembly inside the housing. 5. Install the three screws that secure the blower motor and blower wheel assembly to the heater-A/C housing and tighten to 2.2 N.m (20 in. lbs.). 6. Install the blower motor housing cover. 7. Install the heater-A/C housing cover. 8. Reinstall the heater-A/C housing. 9. Reinstall the instrument panel assembly in the vehicle. 10. Connect the battery negative cable. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations Blower Motor Relay: Locations Fig 40 Power Distribution Center The blower motor relay is located in the PDC in the engine compartment. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Page 6244 Blower Motor Relay: Description and Operation Blower Motor Relay Fig 40 Power Distribution Center The blower motor relay is a International Standards Organization (ISO)-type relay. The relay is a electromechanical device that switches battery current from a fuse in the Power Distribution Center (PDC) to the blower motor, whenever the ignition switch is in the On position. This arrangement reduces the amount of battery current that must flow through the ignition switch. When the ignition switch is in the On position, the relay is energized by a fused battery feed signal to the relay coil. The relay control circuit is protected by a fuse located in the junction block. When the relay is de-energized, the blower motor receives no battery feed. See the Diagnosis and Testing section of this group for more information on the operation of the relay. The blower motor relay is located in the PDC in the engine compartment. The relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Page 6245 Blower Motor Relay: Testing and Inspection Blower Motor Relay Fig 40 Power Distribution Center RELAY TEST Remove the blower motor relay from its wire harness connector as described to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK. go to Step 2. If not OK, replace the faulty relay 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 +/- 5 ohms. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, see the Relay Circuit Test procedure. If not OK, replace the faulty relay. RELAY CIRCUIT TEST 1. The relay common feed terminal cavity (30) is connected to battery voltage and should be hot at all times. If OK, go to Step 2. If not OK, repair the open circuit to the fuse in the PDC as required. 2. The relay normally closed terminal cavity (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3. 3. The relay normally open terminal cavity (87) is connected to the blower motor. When the relay is energized, terminal 87 is connected to terminal 30 and provides full battery current to the blower motor. There should be continuity between this cavity and the blower motor relay output circuit cavity of the blower motor wire harness connector at all times. If OK, go to Step 4. If not OK, repair the open circuit to the blower motor as required. 4. The coil battery terminal cavity (86) is connected to the electromagnet in the relay It is energized when the ignition switch is in the On position. Check for battery voltage at the cavity for relay terminal 86 with the ignition switch in the On position. If OK, go to Step 5. If not OK, repair the open circuit to the ignition switch through the fuse in the junction block as required. 5. The coil ground terminal cavity (85) is connected to ground. This terminal supplies the ground for the relay electromagnetic coil. There should be continuity between the cavity for relay terminal 85 and a good ground at all times. If not OK, repair the open circuit as required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Page 6246 Blower Motor Relay: Service and Repair Fig 40 Power Distribution Center 1. Disconnect and isolate the battery negative cable. 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC for blower motor relay identification and location. 4. Unplug the blower motor clutch relay from the PDC. 5. Install the blower motor relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 6. Install the PDC cover. 7. Connect the battery negative cable. 8. Test the relay operation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations Blower Motor Resistor: Locations Fig 3 Blower Motor Resistor -- Factory Installation Fig 41 Blower Motor Resistor Removal/Installation During vehicle assembly, the blower motor resistor is mounted to the dash plenum panel inside the passenger compartment prior to instrument panel roll-up. However, a resistor mounting plate has been designed so that the resistor can be removed through an access hole in the cowl plenum panel just below the windshield. It can be accessed by removing the cowl plenum cover/grille panel. The blower motor resistor cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 6250 Blower Motor Resistor: Description and Operation Fig 3 Blower Motor Resistor -- Factory Installation Fig 41 Blower Motor Resistor Removal/Installation During vehicle assembly, the blower motor resistor is mounted to the dash plenum panel inside the passenger compartment prior to instrument panel roll-up. However, a resistor mounting plate has been designed so that the resistor can be removed through an access hole in the cowl plenum panel just below the windshield. It can be accessed by removing the cowl plenum cover/grille panel. See the removal procedures in this group. The resistor has multiple resistor wires, each of which will change the resistance in the blower motor ground path to change the blower motor speed. The blower motor switch directs the ground path through the correct resistor wire to obtain the selected blower motor speed. With the blower motor switch in the lowest speed position, the ground path for the motor is applied through all of the resistor wires. Each higher speed selected with the blower motor switch applies the blower motor ground path through fewer of the resistor wires, increasing the blower motor speed. When the blower motor switch is in the highest speed position, the blower motor resistor is bypassed and the blower motor receives a direct path to ground. The blower motor resistor cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 6251 Blower Motor Resistor: Testing and Inspection To test the blower motor resistor, unplug the resistor wire harness connector. Each blower motor switch input terminal on the resistor must have continuity to the resistor output terminal, which is connected to the circuit going to the blower motor. If the blower motor resistor continuity does not check OK, replace the faulty resistor. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 6252 Blower Motor Resistor: Service and Repair Fig 41 Blower Motor Resistor Removal/Installation Fig 3 Blower Motor Resistor -- Factory Installation REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the cowl plenum cover/grille panel. 3. Reach through the cowl plenum access hole to remove the two hex screws that secure the resistor to the plenum panel. 4. Pull the blower motor resistor and its wire harness out of the plenum panel and through the cowl plenum access hole far enough to reach the wire harness connector. 5. Unplug the blower motor resistor wire harness connector. 6. Remove the blower motor resistor from the cowl plenum. INSTALLATION 1. Plug in the blower motor resistor wire harness connector. 2. Install the blower motor resistor to the plenum panel by feeding the resistor and wire harness back through the cowl plenum access hole. 3. Install and tighten the two screws that secure the resistor to the cowl plenum panel. 4. Reinstall the cowl plenum cover/grille panel. 5. Connect the battery negative cable. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Description and Operation Blower Motor Switch: Description and Operation The heater-only or heater-A/C blower motor is controlled by a rotary switch mounted in the heater-A/C control panel. The switch allows for the selection of four blower motor speeds and an Off position, but will only operate with the ignition switch in the On position, and the heater-A/C mode control switch in any position except Off. The blower motor switch is connected in series with the blower motor ground path through the heater-A/C mode control switch. The blower motor switch directs this ground path to the blower motor through the blower motor resistor wires, or directly to the blower motor, as required to achieve the selected blower motor speed. The blower motor switch cannot be repaired and, if faulty or damaged, it must be replaced. The switch is serviced only as a part of the heater-only or heater-A/C control assembly. The blower motor switch knob is serviced separately. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Description and Operation > Page 6256 Blower Motor Switch: Testing and Inspection The blower motor switch is only serviced as a part of the heater-only or heater-A/C control assembly. 1. Turn the ignition switch to the Off position. Remove the heater-A/C control from the instrument panel. Check for continuity between the ground circuit cavity of the control wire harness connector and a good ground. There should be continuity. If OK, go to Step 2. If not OK, repair the open circuit to ground as required. 2. With the heater-A/C control wire harness connector unplugged, place the mode control switch knob in any position except the Off position. Check for continuity between the ground circuit terminal and each of the blower motor driver circuit terminals of the control as you move the blower switch to each of the four speed positions. There should be continuity at each driver circuit terminal in only one blower motor switch speed position. If OK, test and repair the blower driver circuits between the control connector and the blower motor resistor as required. If not OK, replace the faulty heater-A/C control unit. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications Compressor Clutch: Specifications Clutch Air Gap ..................................................................................................................................... ............................ 0.41 - 0.79 mm (0.016 - 0.031 in.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 6261 Compressor Clutch: Description and Operation Fig 5 Compressor Clutch -- Typical The compressor clutch assembly consists of a stationary electromagnetic coil, a hub bearing and pulley assembly and a clutch plate. The electromagnetic coil and pulley are retained on the compressor with snap rings. The clutch plate is mounted on the compressor shaft and secured with a nut. These components provide the means to engage and disengage the compressor from the engine serpentine accessory drive belt. When the clutch coil is energized, it magnetically draws the clutch into contact with the pulley and drives the compressor shaft. When the coil is not energized, the pulley freewheels on the clutch hub bearing, which is part of the pulley. The compressor clutch and coil are the only serviced parts on the compressor. The compressor clutch is controlled by several components: the heater-A/C mode control switch, the low pressure cycling clutch switch, the high pressure cutoff switch, the compressor clutch relay, and the Powertrain Control Module (PCM). The PCM may delay compressor clutch engagement for up to thirty seconds. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Clutch Break-In Compressor Clutch: Service and Repair Clutch Break-In After a new compressor clutch has been installed, cycle the compressor clutch approximately twenty times (five seconds on, then five seconds off). During this procedure, set the heater-A/C mode control switch in Recirculation (A/C) mode, the blower motor switch in the highest speed position, and the engine speed at 1,500 - 2,000 rpm. This procedure (burnishing) will seat the opposing friction surfaces and provide a higher compressor clutch torque capability. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Clutch Break-In > Page 6264 Compressor Clutch: Service and Repair Compressor Clutch / Coil Assembly Replacement Fig 13 Compressor Shaft Nut Removal/Installation NOTE: The refrigerant system can remain fully-charged during compressor clutch, pulley, or coil replacement. The compressor clutch can be serviced in the vehicle. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. On models with the diesel engine option, remove the compressor. Do not remove the refrigerant lines or fittings. 3. Insert the two pins of the spanner wrench (Special Tool 6462 in Kit 6460) into the holes of the clutch plate. Hold the clutch plate stationary and remove the hex nut. Fig 14 Clutch Puller -- Diesel Models 4. Remove the clutch plate. On models with the diesel engine option, a puller (Special Tool 6461 in Kit 6460) is used to remove the clutch plate. This compressor also uses a shaft key which must be removed. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Clutch Break-In > Page 6265 Fig 15 External Snap Ring Removal 5. Remove the external front rotor snap ring with snap ring pliers. Fig 16 Shaft Protector And Puller 6. Install the lip of the rotor puller (Special Tool C-6141-1 in Kit 6460) into the snap ring groove exposed in the previous step, and install the shaft protector (Special Tool C-6141-2 in Kit 6460). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Clutch Break-In > Page 6266 Fig 17 Install Puller Plate 7. Install the puller through-bolts (Special Tool C-6461) through the puller flange and into the jaws of the rotor puller and tighten. Turn the puller center bolt clockwise until the rotor pulley is free. Fig 18 Clutch Coil Wire Harness 8. Remove the screw and retainer from the clutch coil wire harness on the compressor front housing. Fig 19 Clutch Field Coil Snap Ring Removal 9. Remove the snap ring from the compressor hub and remove the clutch field coil. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Clutch Break-In > Page 6267 Fig 20 Rotor Installer Set INSTALLATION 1. Install the clutch field coil and snap ring. 2. Install the clutch coil wire harness retainer clip on the compressor front housing and tighten the retainer screw. 3. Align the rotor assembly squarely on the front compressor housing hub. 4. Thread the handle (Special Tool 6464 in Kit 6460) into the driver (Special Tool 6143 in Kit 6460). Fig 21 Rotor Installation 5. Place the driver tool assembly into the hearing cavity on the rotor. Make certain the outer edge of the tool rests firmly on the rotor hearing inner race. 6. Tap the end of the driver while guiding the rotor to prevent binding. Tap until the rotor bottoms against the compressor front housing hub. Listen for a distinct change of sound during the tapping process to indicate the bottoming of the rotor. 7. Install the external front rotor snap ring. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > Clutch Break-In > Page 6268 Fig 22 Clutch Plate Installation 8. Check that the original clutch shims are in place on the compressor shaft and install the clutch plate. On models with the diesel engine option, install the shaft key. On all models use the shaft protector (Special Tool 6141-2 in Kit 6460) to install the clutch plate on the compressor shaft. Tap the clutch plate over the compressor shaft until it has bottomed against the clutch shims. Listen for a distinct change of sound during the tapping process, to indicate the bottoming of the clutch plate. 9. Replace the compressor shaft hex nut. Tighten the nut to 14.4 N.m (10.5 ft. lbs.). Fig 23 Check Clutch Air Gap 10. Check the clutch air gap with a feeler gauge. If the air gap does not meet the specification, add or subtract shims as required. The specification is 0.41 to 0.79 mm (0.016 to 0.031 inch). If the air gap is not consistent around the circumference of the clutch, lightly pry up at the minimum variations. Lightly tap down at the points of maximum variation. NOTE: The air gap is determined by the spacer shims. When installing an original, or a new clutch assembly, try the original shims first. When installing a new clutch onto a compressor that previously did not have a clutch, use 0.040 in, 0.020 in, and 0.005 in shims from the clutch hardware package that is provided with the new clutch. 11. Reverse the remaining removal procedures to complete the installation. CLUTCH BREAK-IN After a new compressor clutch has been installed, cycle the compressor clutch approximately twenty times (five seconds on, then five seconds off). During this procedure, set the heater-A/C mode control switch in Recirculation (A/C) mode, the blower motor switch in the highest speed position, and the engine speed at 1,500 - 2,000 rpm. This procedure (burnishing) will seat the opposing friction surfaces and provide a higher compressor clutch torque capability. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Testing and Inspection Compressor Clutch Coil: Testing and Inspection NOTE: The battery must be fully-charged before performing the following tests. 1. Connect an ammeter (0 to 10 ampere scale) in series with the clutch coil terminal. Use a voltmeter (0 to 20 volt scale) with clip-type leads for measuring the voltage across the battery and the compressor clutch coil. 2. With the heater-A/C mode control switch in any A/C mode, and the blower motor switch in the lowest speed position, start the engine and run it at normal idle. 3. The compressor clutch coil voltage should read within two volts of the battery voltage. If there is voltage at the clutch coil, but the reading is not within two volts of the battery voltage, test the clutch coil feed circuit for excessive voltage drop and repair as required. If there is no voltage reading at the clutch coil, refer to the proper Powertrain Management/Computers and Control Systems/ Diagnostic Procedures for testing of the compressor clutch circuit. The following components must be checked and repaired as required before you can complete testing of the clutch coil: Fuses in the fuse block module and the Power Distribution Center - Heater-A/C mode control switch - Compressor clutch relay - High pressure cut-off switch - Low pressure cycling clutch switch - Powertrain Control Module. 4. The compressor clutch coil is acceptable if the current draw measured at the clutch coil is 2.0 to 3.9 amperes with electrical system voltage at 11.5 to 12.5 volts. This should only be checked with the work area temperature at 21 °C (70 °F). If system voltage is more than 12.5 volts, add electrical loads by turning on electrical accessories until the system voltage drops below 12.5 volts. a. If the clutch coil current reading is 4 amperes or more, the coil is shorted and should be replaced. b. If the clutch coil current reading is zero, the coil is open and should be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Component Locations Compressor Clutch Relay: Component Locations Power Distribution Center Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Component Locations > Page 6276 Power Distribution Fig 27 Power Distribution Center Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Component Locations > Page 6277 Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 6278 Compressor Clutch Relay: Description and Operation Fig 27 Power Distribution Center The compressor clutch relay is a International Standards Organization (ISO) micro-relay The terminal designations and functions are the same as a conventional ISO relay However, the micro-relay terminal orientation (footprint) is different, the current capacity is lower and the relay case dimensions are smaller than on the conventional ISO relay. The compressor clutch relay is a electromechanical device that switches current to the compressor clutch coil when the Powertrain Control Module (PCM) grounds the coil side of the relay The PCM responds to inputs from the heater-A/C mode control switch, the low pressure cycling clutch switch, and the high pressure cut-off switch. The compressor clutch relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the PDC label for relay identification and location. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 6279 Compressor Clutch Relay: Testing and Inspection Compressor Clutch Relay RELAY TEST The compressor clutch relay is located in the Power Distribution Center (PDC). Refer to the PDC label for relay identification and location. Remove the relay from the PDC to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2. If not OK, replace the faulty relay. 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 +/-5 ohms. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, SEE the Relay Circuit Test. If not OK, replace the faulty relay. RELAY CIRCUIT TEST 1. The relay common feed terminal cavity (30) is connected to fused battery feed. There should be battery voltage at the cavity for relay terminal 30 at all times. If OK, go to Step 2. If not OK, repair the open circuit to the 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 Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 6280 Compressor Clutch Relay: Service and Repair Fig 27 Power Distribution Center 1. Disconnect and isolate the battery negative cable. 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC for compressor clutch relay identification and location. 4. Unplug the compressor clutch relay from the PDC. 5. Install the compressor clutch relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 6. Install the PDC cover. 7. Connect the battery negative cable. 8. Test the relay operation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Description and Operation Compressor Fitting HVAC: Description and Operation The refrigerant system service ports are used to charge,recover/recycle, evacuate, and test the air conditioning refrigerant system. Unique service port fitting sizes are used on the R-134a system, to ensure that the refrigerant system is not accidentally contaminated by the use of the wrong refrigerant (R-12), or refrigerant system service equipment. The high pressure service port is located on the compressor manifold or plumbing, near the front of the engine compartment. The low pressure service port is located on the suction line, near the front of the engine compartment. After servicing the refrigerant system, always reinstall the service port caps. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications Condenser HVAC: Specifications Refrigerant Oil Capacity 30 ml (1 oz) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 6287 Condenser HVAC: Description and Operation The condenser is located in front of the engine cooling radiator. It is a heat exchanger that allows the high-pressure refrigerant gas to give up its heat to the air passing over the condenser fins. This causes the refrigerant gas to condense into a high-pressure liquid refrigerant. The condenser is serviced only as an assembly. The condenser cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 6288 Condenser HVAC: Service and Repair Fig 32 Condenser Removal/Installation WARNING: Review the Service Precautions before performing the following operation. CAUTION: Before removing the condenser, note the location of each of the radiator and condenser air seals. These seals are used to direct air through the condenser and radiator. The air seals must be reinstalled in their proper locations in order for the air conditioning and engine cooling systems to perform as designed. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. 3. Disconnect the refrigerant line couplers at the condenser inlet and outlet tubes. See A/C Coupler for the procedures. Install plugs in, or tape over all of the open refrigerant fittings. 4. Remove the two screws that secure the radiator and fan shroud module to the inside of the upper radiator crossmember. 5. Remove the two screws that secure the condenser to the outside of the upper radiator cross- member. 6. Tilt the top of the radiator and fan shroud module towards the engine, using care not to damage the radiator fins on the engine cooling fan. 7. With the radiator and fan shroud module tilted, carefully lift the condenser upwards until the lower condenser mounts are clear of the isolators in the lower crossmember. 8. Remove the condenser from the vehicle. INSTALLATION 1. With the radiator and fan shroud module tilted towards the engine, carefully position the lower con- denser mounts in the lower crossmember isolators. 2. Reinstall the two screws that secure the condenser to the outside of the upper radiator crossmember and tighten to 8 N.m (75 in. lbs.). 3. Reinstall the two screws that secure the radiator and fan shroud module to the inside of the upper radiator crossmember. 4. Remove the plugs or tape from the refrigerant fittings. Connect the refrigerant lines to the condenser inlet and outlet tubes. See A/C Coupler for the procedures. 5. Check that all of the condenser and radiator air seals are in their proper locations. 6. Evacuate and charge the refrigerant system. NOTE: If the condenser is replaced, add 30 ml (1 oz.) of refrigerant oil to the refrigerant system. 7. Connect the battery negative cable. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode - Unbalanced Vent Air Flow Technical Service Bulletin # 24-20-99A Date: 991217 A/C Bi-Level Mode - Unbalanced Vent Air Flow NUMBER: 24-20-99 Rev. A GROUP: Heating & A/C DATE: Dec. 17, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-20-99, DATED OCT. 8, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL PARTS AND PROCEDURES. SUBJECT: While In Bi-level Mode, Air Flow From Panel Vents Is Less Than That Of The Floor Vents OVERVIEW: This bulletin involves installing a panel-defrost control lever **and a retaining push nut**. MODELS: 1997 - 2000 (AN) Dakota 1998 - 2000 (DN) Durango SYMPTOM/CONDITION: While in bi-level mode, air flow from panel vents is less than that of the floor vents. DIAGNOSIS: While in bi-level mode, there should be an approximately 50% air distribution between the panel vents and the heater outlets. Operate the heater A/C system in panel, bi-level, and heater modes. If the air distribution is good in the heater and panel modes, but when in bi-level mode, air distribution to the heater outlets is greater than the panel outlets, perform the Repair Procedure. PARTS REQUIRED: 1 03847858 Lever, Panel-Defrost Control **1 06031147 Push Nut** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-50-33-91 1.4 Hrs. FAILURE CODE: P8 - New Part Repair Procedure THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. WARNING: REFER TO THE APPROPRIATE SERVICE MANUAL, GROUP 8M-PASSIVE RESTRAINT SYSTEMS, BEFORE ATTEMPTING TO SERVICE THE HEATER-A/C HOUSING ASSEMBLY. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Rotate the steering wheel so that the steering wheel is in an upside down position then, remove the ignition key to lock the steering wheel in this position. 2. Position the front seats in the full rearward position. 3. Disconnect and isolate the battery negative cable. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode - Unbalanced Vent Air Flow > Page 6297 4. Using a trim stick, pry up the door sill trim cover from the door sill on both sides of the vehicle (Figure 1) and separate the cover from the vehicle. 5. Remove the two screws that attach the cowl trim cover to the cowl (Figure 2). 6. Using a trim stick pry the cowl trim cover away from the cowl to disengage the clips. 7. Separate the cowl trim cover from the vehicle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode - Unbalanced Vent Air Flow > Page 6298 8. Remove the three screws that secure the lower edge of the steering column opening cover to the lower instrument panel reinforcement (Figure 3). 9. Using a trim stick, disengage the snap clip retainers from the receptacles in the instrument panel by gently prying the upper edge of the steering column opening cover away from the instrument panel. Pry on the cover just below the instrument cluster bezel on each side of the steering column. 10. Remove the steering column opening cover from the instrument panel. 11. Remove the four screws that secure the lower reinforcement to the instrument panel (Figure 4). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode - Unbalanced Vent Air Flow > Page 6299 12. If the vehicle is equipped with a column shift automatic transmission, put the transmission range selector into Park. Then, remove the PRNDL drive cable from the PRNDL lever (Figure 5). Push the tabs on top of the cable retainer, then squeeze the sides to remove the retainer from the column. 13. Disconnect the driver side airbag module wire harness connector from the instrument panel wire harness near the instrument panel lower reinforcement. 14. If the vehicle is so equipped, disconnect the overdrive lockout switch wire harness connector from the instrument panel wire harness near the instrument panel lower reinforcement. 15. Remove the tilt lever from the steering column. 16. Remove the lower and upper steering column shrouds. 17. Disconnect the multifunction switch, speed control switch, and ignition switch wiring harnesses (Figure 6). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode - Unbalanced Vent Air Flow > Page 6300 18. Remove the steering column mounting nuts (Figure 7) and lower the steering column to the floor. 19. Remove the screw from the center of the headlamp and dash to instrument panel bulkhead wire harness connectors and disconnect the connectors. 20. Disconnect the two body wire harness connectors from the two instrument panel wire harness connectors that are secured to the outboard side of the instrument panel bulkhead connectors. 21. Disconnect the three wire harness connectors (one from the body wire harness and two from the headlamp and dash wire harness) from the three junction block connector receptacles located closest to the dash panel. 22. Disconnect the instrument panel wire harness connector form the stop lamp switch connector receptacle. 23. Remove the park brake release rod from the pedal assembly (Figure 8). 24. Pull the floor carpet back from the front of the floor panel transmission tunnel far enough to access the center support bracket mounting screws. 25. Remove the two screws that secure the center support bracket to the instrument panel. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode - Unbalanced Vent Air Flow > Page 6301 26. Remove the two screws on the left and one screw on the right that secure the instrument panel center support bracket to the Airbag Control Module (ACM) bracket on the floor panel transmission tunnel (Figure 9). 27. Remove the center support bracket from the instrument panel. 28. Disconnect the vacuum harness connector located near the left end of the heater-A/C housing 29. Remove the screw that secures the instrument panel wire harness ground eyelets to the left side of the Airbag Control Module (ACM) mount on the floor panel transmission tunnel. 30. Disconnect the instrument panel wire harness connector from the ACM connector receptacle. 31. Open the glove box. 32. Locate the three screws in the bottom of the glove box bin. Remove only the center screw. 33. Depress the two sides of the glove box bin far enough so that the rubber stop bumpers located on each side of the bin will clear the metal stops located on the bracket on each side of the glove box opening. 34. While holding the sides of the glove box bin depressed, roll the glove box downward until the stop bumpers are beyond the stops, then release the sides of the bin. 35. Grasp the upper outboard corner of the glove box door securely with both hands. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode - Unbalanced Vent Air Flow > Page 6302 36. Pull the door firmly and quickly away from the instrument panel to unsnap the three glove box hinge hooks (Figure 10) from the three hinge pins on the instrument panel (Figure 11). 37. Reaching through the instrument panel glove box opening, perform the following: a) Disconnect the two halves of the radio antenna coaxial cable connector near the center of the lower instrument panel glove box opening. b) Disengage the antenna half of the radio antenna coaxial cable from the retainer clip near the outboard side of the lower instrument panel glove box opening. 38. From under the passenger side of the instrument panel , perform the following: a) If the vehicle is so equipped, disconnect the two instrument panel wire harness connectors from the infinity speaker amplifier connector receptacles on the right cowl side inner panel. b) Remove the nut that secures the instrument panel wire harness radio ground eyelet to the stud on the right cowl side inner panel. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode - Unbalanced Vent Air Flow > Page 6303 39. Loosen the right and left instrument panel cowl side roll-down bracket screws about 6 mm (0.25 in.) (Figure 12). 40. Remove the five screws that secure the top of the instrument panel to the top of the dash panel, removing the center screw last. 41. Pull the lower instrument panel rearward until the right and left cowl side roll-down bracket screws are in the roll-down slot position of both brackets (Figure 13). 42. Roll down the instrument panel and install a temporary hook in the center hole on top of the instrument panel. Secure the other end of the hook to the center hole in the top of the dash panel. The hook should support the instrument panel in its rolled down position about 46 cm (18 in.) from the dash panel. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode - Unbalanced Vent Air Flow > Page 6304 43. Using a trim stick, gently pry the panel-defrost door lever off the panel-defrost door pivot shaft (Figure 14). 44. Slide the panel-defrost door lever off from the panel-defrost door actuator link. 45. Slide the new panel-defrost door lever, p/n 03847858, onto the panel-defrost door actuator link. 46. Snap the panel-defrost door lever onto the panel-defrost door pivot shaft. 47. **Slide push nut p/n 06031147 over the end of the actuator link until the push nut is tight against the panel-defrost door actuator lever (Figure 15).** 48. Push the lower instrument panel forward until the right and left cowl side roll-down bracket screws are in the installed slot position of both brackets. 49. Remove the temporary hook from the instrument panel and roll the instrument panel up to the installed position against the dash panel. 50. Install and tighten the five screws that secure the top of the instrument panel to the top of the dash panel. Tighten the screws to 3.2 N.m (28 in. lbs.). 51. Tighten the right and left instrument panel cowl side roll-down bracket screws. Tighten the screws to 12 N.m (105 in. lbs.). 52. From under the passenger side of the instrument panel, perform the following: Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode - Unbalanced Vent Air Flow > Page 6305 a) If the vehicle is so equipped, reconnect the two instrument panel wire harness connectors to the Infinity speaker amplifier connector receptacles on the right cowl side inner panel. b) Install and tighten the nut that secures the instrument panel wire harness radio ground eyelet to the stud on the right cowl side inner panel. Tighten the nut to 3.9 N.m (35 in. lbs.). 52. Reaching through the instrument panel glove box opening, perform the following: a) Reconnect the two halves of the radio antenna coaxial cable connector near the center of the lower instrument panel glove box opening. b) Engage the antenna half of the radio antenna coaxial cable into the retainer clip near the outboard side of the lower instrument panel glove box opening. 53. Position the glove box to the instrument panel with the bin inserted in the glove box opening far enough so that the rubber stop bumpers, located on each side of the bin, are behind the metal stops located on the bracket on each side of the glove box opening. 54. Starting on the outboard side of the glove box, insert the first glove box hinge hook over the first hinge pin on the instrument panel. 55. Use a slight twisting action on the glove box door to insert the second hinge hook under the second hinge pin. 56. Finally, again using a slight twisting action on the glove box door, insert the last hinge hook under the last hinge pin. 57. Depress the two sides of the glove box bin far enough so that the rubber stop bumpers located on each side of the bin will clear the metal stops located on the bracket on each side of the glove box opening. Then, push the glove box up until the rubber stop bumpers are past the stop bumper brackets. 58. Install and tighten the center screw in the bottom of the glove box bin. Tighten the screw to 2.2 N.m (20 in. lbs.). 59. Close the glove box and then reopen it to check for proper hinge operation. 60. Install and tighten the screw that secures the instrument panel wire harness ground eyelets to the left side of the ACM mount on the floor panel transmission tunnel. Tighten the screw to 3.4 N.m (30 in. lbs.). 61. Reconnect the instrument panel wire harness connector to the ACM connector receptacle. 62. Position the center support bracket to the ACM bracket on the floor panel transmission tunnel. 63. Install and tighten the two screws on the left and the one screw on the right that secure the instrument panel center support bracket to the ACM bracket on the floor panel transmission tunnel. Tighten the screws to 12 N.m (105 in. lbs.). 64. Align the screw holes in the instrument panel with the mounting holes in the center support bracket. 65. Install and tighten the two screws that secure the center support bracket to the instrument panel. Tighten the screws to 12 N.m (105 in. lbs.). 66. Reposition the floor carpet on the front of the floor panel transmission tunnel to conceal the instrument panel center support bracket. 67. From under the driver side of the instrument panel, perform the following. a) Reconnect the headlamp and dash to instrument panel bulkhead wire harness connector Tighten the screw in the center of the connector to 3.5 N.m (31 in. lbs.). b) Reconnect the two body wire harness connectors to the two instrument panel wire harness connectors that are secured to the outboard side of the instrument panel bulkhead connector. c) Reconnect the three wire harness connectors (one from the body wire harness, and two from the headlamp and dash wire harness) to the three junction block connector receptacles located closest to the dash panel. d) Engage the linkage rod end into the lever on the back side of the park brake release handle and snap the plastic retainer clip that secures the rod to the lever over the linkage rod. e) Reconnect the instrument panel wire harness connector to the stop lamp switch connector receptacle. f) Reconnect the vacuum harness connector located near the left end of the heater-A/C housing. 68. Position the steering column to the panel bracket and attaching studs. Install the mounting nuts but only tighten them finger tight at this time. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode - Unbalanced Vent Air Flow > Page 6306 69. Bounce the steering wheel lightly in a vertical motion to normalize the alignment. 70. Without influencing the new location of the steering column, tighten the passenger side rearward nut to 12 N.m (105 in. lbs.). 71. Next, tighten the front driver side nut to 12 N.m (105 in. lbs.). 72. Tighten the remaining steering column attaching nuts to 12 N.m (105 in. lbs.). 73. Reconnect the multifunction switch wiring harness. Tighten the assembly using a 7 mm socket to 2 N.m (17 in. lbs.). 74. Reconnect the speed control switch and ignition switch wire harnesses. 75. Install the lower upper steering column shrouds. 76. Install the tilt lever onto the steering column. 77. If the vehicle is equipped with a column shift automatic transmission, install the PRNDL drive cable. Place the gear selector into the Park position. If the indicator needs adjusting, turn the thumb screw on the cable retainer to adjust the cable. 78. If the vehicle is so equipped, reconnect the overdrive lockout switch wire harness connector to the instrument panel wire harness connector located near the instrument panel lower reinforcement. 79. Reconnect the driver side airbag module wire harness connector to the instrument panel wire harness connector located at the instrument panel lower reinforcement. 80. Position the lower reinforcement onto the instrument panel. 81. Install the four screws that secure the lower reinforcement to the instrument panel. Tighten the screws to 2.2 N.m (20 in. lbs.). 82. Position the steering column opening cover to the instrument panel. 83. Align the snap clip retainers on the steering column opening cover with the receptacles in the instrument panel. 84. Press firmly on the steering column opening cover over the snap clip locations until each of the snap clips are fully engaged in their receptacle. 85. Install and tighten the three screws that secure the lower edge of the steering column opening cover to the lower instrument panel reinforcement. Tighten the screws to 2.2 N.m (20 in. lbs.). 86. Position the cowl trim cover onto the cowl. 87. Press the cowl trim cover into place to engage the retaining clips. Then, install and tighten the two retaining screws. 88. Position the front edge of the door sill trim cover over the cowl trim cover and align the tabs. 89. Align door sill trim cover and press into place. 90. Adjust the temperature control cable. Refer the appropriate Service Manual, Group 24 for information regarding Temperature Control Cable adjustment. 91. Connect the battery negative cable and reset the clock on the radio. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode - Unbalanced Vent Air Flow Technical Service Bulletin # 24-20-99A Date: 991217 A/C Bi-Level Mode - Unbalanced Vent Air Flow NUMBER: 24-20-99 Rev. A GROUP: Heating & A/C DATE: Dec. 17, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-20-99, DATED OCT. 8, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL PARTS AND PROCEDURES. SUBJECT: While In Bi-level Mode, Air Flow From Panel Vents Is Less Than That Of The Floor Vents OVERVIEW: This bulletin involves installing a panel-defrost control lever **and a retaining push nut**. MODELS: 1997 - 2000 (AN) Dakota 1998 - 2000 (DN) Durango SYMPTOM/CONDITION: While in bi-level mode, air flow from panel vents is less than that of the floor vents. DIAGNOSIS: While in bi-level mode, there should be an approximately 50% air distribution between the panel vents and the heater outlets. Operate the heater A/C system in panel, bi-level, and heater modes. If the air distribution is good in the heater and panel modes, but when in bi-level mode, air distribution to the heater outlets is greater than the panel outlets, perform the Repair Procedure. PARTS REQUIRED: 1 03847858 Lever, Panel-Defrost Control **1 06031147 Push Nut** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-50-33-91 1.4 Hrs. FAILURE CODE: P8 - New Part Repair Procedure THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. WARNING: REFER TO THE APPROPRIATE SERVICE MANUAL, GROUP 8M-PASSIVE RESTRAINT SYSTEMS, BEFORE ATTEMPTING TO SERVICE THE HEATER-A/C HOUSING ASSEMBLY. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Rotate the steering wheel so that the steering wheel is in an upside down position then, remove the ignition key to lock the steering wheel in this position. 2. Position the front seats in the full rearward position. 3. Disconnect and isolate the battery negative cable. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode - Unbalanced Vent Air Flow > Page 6312 4. Using a trim stick, pry up the door sill trim cover from the door sill on both sides of the vehicle (Figure 1) and separate the cover from the vehicle. 5. Remove the two screws that attach the cowl trim cover to the cowl (Figure 2). 6. Using a trim stick pry the cowl trim cover away from the cowl to disengage the clips. 7. Separate the cowl trim cover from the vehicle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode - Unbalanced Vent Air Flow > Page 6313 8. Remove the three screws that secure the lower edge of the steering column opening cover to the lower instrument panel reinforcement (Figure 3). 9. Using a trim stick, disengage the snap clip retainers from the receptacles in the instrument panel by gently prying the upper edge of the steering column opening cover away from the instrument panel. Pry on the cover just below the instrument cluster bezel on each side of the steering column. 10. Remove the steering column opening cover from the instrument panel. 11. Remove the four screws that secure the lower reinforcement to the instrument panel (Figure 4). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode - Unbalanced Vent Air Flow > Page 6314 12. If the vehicle is equipped with a column shift automatic transmission, put the transmission range selector into Park. Then, remove the PRNDL drive cable from the PRNDL lever (Figure 5). Push the tabs on top of the cable retainer, then squeeze the sides to remove the retainer from the column. 13. Disconnect the driver side airbag module wire harness connector from the instrument panel wire harness near the instrument panel lower reinforcement. 14. If the vehicle is so equipped, disconnect the overdrive lockout switch wire harness connector from the instrument panel wire harness near the instrument panel lower reinforcement. 15. Remove the tilt lever from the steering column. 16. Remove the lower and upper steering column shrouds. 17. Disconnect the multifunction switch, speed control switch, and ignition switch wiring harnesses (Figure 6). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode - Unbalanced Vent Air Flow > Page 6315 18. Remove the steering column mounting nuts (Figure 7) and lower the steering column to the floor. 19. Remove the screw from the center of the headlamp and dash to instrument panel bulkhead wire harness connectors and disconnect the connectors. 20. Disconnect the two body wire harness connectors from the two instrument panel wire harness connectors that are secured to the outboard side of the instrument panel bulkhead connectors. 21. Disconnect the three wire harness connectors (one from the body wire harness and two from the headlamp and dash wire harness) from the three junction block connector receptacles located closest to the dash panel. 22. Disconnect the instrument panel wire harness connector form the stop lamp switch connector receptacle. 23. Remove the park brake release rod from the pedal assembly (Figure 8). 24. Pull the floor carpet back from the front of the floor panel transmission tunnel far enough to access the center support bracket mounting screws. 25. Remove the two screws that secure the center support bracket to the instrument panel. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode - Unbalanced Vent Air Flow > Page 6316 26. Remove the two screws on the left and one screw on the right that secure the instrument panel center support bracket to the Airbag Control Module (ACM) bracket on the floor panel transmission tunnel (Figure 9). 27. Remove the center support bracket from the instrument panel. 28. Disconnect the vacuum harness connector located near the left end of the heater-A/C housing 29. Remove the screw that secures the instrument panel wire harness ground eyelets to the left side of the Airbag Control Module (ACM) mount on the floor panel transmission tunnel. 30. Disconnect the instrument panel wire harness connector from the ACM connector receptacle. 31. Open the glove box. 32. Locate the three screws in the bottom of the glove box bin. Remove only the center screw. 33. Depress the two sides of the glove box bin far enough so that the rubber stop bumpers located on each side of the bin will clear the metal stops located on the bracket on each side of the glove box opening. 34. While holding the sides of the glove box bin depressed, roll the glove box downward until the stop bumpers are beyond the stops, then release the sides of the bin. 35. Grasp the upper outboard corner of the glove box door securely with both hands. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode - Unbalanced Vent Air Flow > Page 6317 36. Pull the door firmly and quickly away from the instrument panel to unsnap the three glove box hinge hooks (Figure 10) from the three hinge pins on the instrument panel (Figure 11). 37. Reaching through the instrument panel glove box opening, perform the following: a) Disconnect the two halves of the radio antenna coaxial cable connector near the center of the lower instrument panel glove box opening. b) Disengage the antenna half of the radio antenna coaxial cable from the retainer clip near the outboard side of the lower instrument panel glove box opening. 38. From under the passenger side of the instrument panel , perform the following: a) If the vehicle is so equipped, disconnect the two instrument panel wire harness connectors from the infinity speaker amplifier connector receptacles on the right cowl side inner panel. b) Remove the nut that secures the instrument panel wire harness radio ground eyelet to the stud on the right cowl side inner panel. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode - Unbalanced Vent Air Flow > Page 6318 39. Loosen the right and left instrument panel cowl side roll-down bracket screws about 6 mm (0.25 in.) (Figure 12). 40. Remove the five screws that secure the top of the instrument panel to the top of the dash panel, removing the center screw last. 41. Pull the lower instrument panel rearward until the right and left cowl side roll-down bracket screws are in the roll-down slot position of both brackets (Figure 13). 42. Roll down the instrument panel and install a temporary hook in the center hole on top of the instrument panel. Secure the other end of the hook to the center hole in the top of the dash panel. The hook should support the instrument panel in its rolled down position about 46 cm (18 in.) from the dash panel. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode - Unbalanced Vent Air Flow > Page 6319 43. Using a trim stick, gently pry the panel-defrost door lever off the panel-defrost door pivot shaft (Figure 14). 44. Slide the panel-defrost door lever off from the panel-defrost door actuator link. 45. Slide the new panel-defrost door lever, p/n 03847858, onto the panel-defrost door actuator link. 46. Snap the panel-defrost door lever onto the panel-defrost door pivot shaft. 47. **Slide push nut p/n 06031147 over the end of the actuator link until the push nut is tight against the panel-defrost door actuator lever (Figure 15).** 48. Push the lower instrument panel forward until the right and left cowl side roll-down bracket screws are in the installed slot position of both brackets. 49. Remove the temporary hook from the instrument panel and roll the instrument panel up to the installed position against the dash panel. 50. Install and tighten the five screws that secure the top of the instrument panel to the top of the dash panel. Tighten the screws to 3.2 N.m (28 in. lbs.). 51. Tighten the right and left instrument panel cowl side roll-down bracket screws. Tighten the screws to 12 N.m (105 in. lbs.). 52. From under the passenger side of the instrument panel, perform the following: Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode - Unbalanced Vent Air Flow > Page 6320 a) If the vehicle is so equipped, reconnect the two instrument panel wire harness connectors to the Infinity speaker amplifier connector receptacles on the right cowl side inner panel. b) Install and tighten the nut that secures the instrument panel wire harness radio ground eyelet to the stud on the right cowl side inner panel. Tighten the nut to 3.9 N.m (35 in. lbs.). 52. Reaching through the instrument panel glove box opening, perform the following: a) Reconnect the two halves of the radio antenna coaxial cable connector near the center of the lower instrument panel glove box opening. b) Engage the antenna half of the radio antenna coaxial cable into the retainer clip near the outboard side of the lower instrument panel glove box opening. 53. Position the glove box to the instrument panel with the bin inserted in the glove box opening far enough so that the rubber stop bumpers, located on each side of the bin, are behind the metal stops located on the bracket on each side of the glove box opening. 54. Starting on the outboard side of the glove box, insert the first glove box hinge hook over the first hinge pin on the instrument panel. 55. Use a slight twisting action on the glove box door to insert the second hinge hook under the second hinge pin. 56. Finally, again using a slight twisting action on the glove box door, insert the last hinge hook under the last hinge pin. 57. Depress the two sides of the glove box bin far enough so that the rubber stop bumpers located on each side of the bin will clear the metal stops located on the bracket on each side of the glove box opening. Then, push the glove box up until the rubber stop bumpers are past the stop bumper brackets. 58. Install and tighten the center screw in the bottom of the glove box bin. Tighten the screw to 2.2 N.m (20 in. lbs.). 59. Close the glove box and then reopen it to check for proper hinge operation. 60. Install and tighten the screw that secures the instrument panel wire harness ground eyelets to the left side of the ACM mount on the floor panel transmission tunnel. Tighten the screw to 3.4 N.m (30 in. lbs.). 61. Reconnect the instrument panel wire harness connector to the ACM connector receptacle. 62. Position the center support bracket to the ACM bracket on the floor panel transmission tunnel. 63. Install and tighten the two screws on the left and the one screw on the right that secure the instrument panel center support bracket to the ACM bracket on the floor panel transmission tunnel. Tighten the screws to 12 N.m (105 in. lbs.). 64. Align the screw holes in the instrument panel with the mounting holes in the center support bracket. 65. Install and tighten the two screws that secure the center support bracket to the instrument panel. Tighten the screws to 12 N.m (105 in. lbs.). 66. Reposition the floor carpet on the front of the floor panel transmission tunnel to conceal the instrument panel center support bracket. 67. From under the driver side of the instrument panel, perform the following. a) Reconnect the headlamp and dash to instrument panel bulkhead wire harness connector Tighten the screw in the center of the connector to 3.5 N.m (31 in. lbs.). b) Reconnect the two body wire harness connectors to the two instrument panel wire harness connectors that are secured to the outboard side of the instrument panel bulkhead connector. c) Reconnect the three wire harness connectors (one from the body wire harness, and two from the headlamp and dash wire harness) to the three junction block connector receptacles located closest to the dash panel. d) Engage the linkage rod end into the lever on the back side of the park brake release handle and snap the plastic retainer clip that secures the rod to the lever over the linkage rod. e) Reconnect the instrument panel wire harness connector to the stop lamp switch connector receptacle. f) Reconnect the vacuum harness connector located near the left end of the heater-A/C housing. 68. Position the steering column to the panel bracket and attaching studs. Install the mounting nuts but only tighten them finger tight at this time. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Assembly: > 24-20-99A > Dec > 99 > A/C Bi-Level Mode - Unbalanced Vent Air Flow > Page 6321 69. Bounce the steering wheel lightly in a vertical motion to normalize the alignment. 70. Without influencing the new location of the steering column, tighten the passenger side rearward nut to 12 N.m (105 in. lbs.). 71. Next, tighten the front driver side nut to 12 N.m (105 in. lbs.). 72. Tighten the remaining steering column attaching nuts to 12 N.m (105 in. lbs.). 73. Reconnect the multifunction switch wiring harness. Tighten the assembly using a 7 mm socket to 2 N.m (17 in. lbs.). 74. Reconnect the speed control switch and ignition switch wire harnesses. 75. Install the lower upper steering column shrouds. 76. Install the tilt lever onto the steering column. 77. If the vehicle is equipped with a column shift automatic transmission, install the PRNDL drive cable. Place the gear selector into the Park position. If the indicator needs adjusting, turn the thumb screw on the cable retainer to adjust the cable. 78. If the vehicle is so equipped, reconnect the overdrive lockout switch wire harness connector to the instrument panel wire harness connector located near the instrument panel lower reinforcement. 79. Reconnect the driver side airbag module wire harness connector to the instrument panel wire harness connector located at the instrument panel lower reinforcement. 80. Position the lower reinforcement onto the instrument panel. 81. Install the four screws that secure the lower reinforcement to the instrument panel. Tighten the screws to 2.2 N.m (20 in. lbs.). 82. Position the steering column opening cover to the instrument panel. 83. Align the snap clip retainers on the steering column opening cover with the receptacles in the instrument panel. 84. Press firmly on the steering column opening cover over the snap clip locations until each of the snap clips are fully engaged in their receptacle. 85. Install and tighten the three screws that secure the lower edge of the steering column opening cover to the lower instrument panel reinforcement. Tighten the screws to 2.2 N.m (20 in. lbs.). 86. Position the cowl trim cover onto the cowl. 87. Press the cowl trim cover into place to engage the retaining clips. Then, install and tighten the two retaining screws. 88. Position the front edge of the door sill trim cover over the cowl trim cover and align the tabs. 89. Align door sill trim cover and press into place. 90. Adjust the temperature control cable. Refer the appropriate Service Manual, Group 24 for information regarding Temperature Control Cable adjustment. 91. Connect the battery negative cable and reset the clock on the radio. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Assembly: > 24-12-97 > Aug > 97 > Heating & A/C - Climate Controls Control Assembly: All Technical Service Bulletins Heating & A/C - Climate Controls NO: 24-12-97 GROUP: Heater & A/C DATE: Aug. 1, 1997 SUBJECT: Climate Controls MODELS: 1997 - 1998 (AN) Dakota DISCUSSION: The 1997 and early 1998 Owner's Manual states that on "Heater Only" systems, turning the mode control knob to the OFF position turns off the blower motor and prevents outside air from coming through any outlet. On the "Air Conditioning" system, turning the mode control knob to the OFF position turns off the blower motor only. These statements listed in the Owner's Manual are reversed. Air conditioning systems utilize a recirculation door that when either in the "OFF" or "MAX A/C" position, the door closes preventing outside air from entering the vehicle. Heater only systems do not contain the recirculation door. On both systems, the blower motor will turn off when the mode control knob has been turned to the OFF position. Do not attempt to repair vehicles with "Heater Only" systems for air entering the vehicle through the heater housing when the mode control knob is in the OFF position. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Assembly: > 24-12-97 > Aug > 97 > Heating & A/C - Climate Controls Control Assembly: All Technical Service Bulletins Heating & A/C - Climate Controls NO: 24-12-97 GROUP: Heater & A/C DATE: Aug. 1, 1997 SUBJECT: Climate Controls MODELS: 1997 - 1998 (AN) Dakota DISCUSSION: The 1997 and early 1998 Owner's Manual states that on "Heater Only" systems, turning the mode control knob to the OFF position turns off the blower motor and prevents outside air from coming through any outlet. On the "Air Conditioning" system, turning the mode control knob to the OFF position turns off the blower motor only. These statements listed in the Owner's Manual are reversed. Air conditioning systems utilize a recirculation door that when either in the "OFF" or "MAX A/C" position, the door closes preventing outside air from entering the vehicle. Heater only systems do not contain the recirculation door. On both systems, the blower motor will turn off when the mode control knob has been turned to the OFF position. Do not attempt to repair vehicles with "Heater Only" systems for air entering the vehicle through the heater housing when the mode control knob is in the OFF position. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Page 6331 Control Assembly: Description and Operation Both the heater and heater-A/C systems use a combination of mechanical, electrical, and vacuum controls. These controls provide the vehicle operator with a number of setting options to help control the climate and comfort within the vehicle. Refer to the owner's manual for more information on the suggested operation and use of these controls. The heater-only or heater-A/C control panel is located to the right of the instrument cluster on the instrument panel. The control panel contains a rotating-type temperature control knob, a rotating-type mode control switch knob, a rotating-type blower motor switch knob, and the Message Center. For more information on the Message Center. The heater-only or heater-A/C control panel cannot be repaired. If faulty or damaged, the entire unit must be replaced. The control knobs are available for service replacement. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Page 6332 Control Assembly: Service and Repair Fig 37 Cluster Bezel Removal/Installation WARNING: On vehicles equipped with Air-Bags, refer to Air Bags and Seat Belts/Air Bags before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is so equipped, turn the ignition switch to the Unlock position, set the parking brake, and place the automatic transmission gear selector lever in the Low position. 3. If the vehicle is so equipped, set the tilt steering wheel in its lowest position. 4. Using a trim stick or another suitable wide fiat-bladed tool, carefully pry around the perimeter of the cluster bezel to disengage the nine snap-clip retainers that secure the bezel to the instrument panel. 5. If the vehicle is so equipped, pull the cluster bezel away from the instrument panel far enough to unplug the wire harness connector from the fog lamp switch. 6. Remove the cluster bezel from the vehicle. Fig 38 Heater A/C Control Removal/Installation 7. Remove the four screws that secure the heater- A/C control to the instrument panel. 8. Pull the heater-A/C control assembly away from the instrument panel far enough to access the connectors. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Page 6333 Fig 39 Heater & A/C Control Connectors 9. Unplug the wire harness connector from the back of the heater-A/C control assembly. 10. Disconnect the wire harness retainer from the side of the heater-A/C control assembly 11. Remove the two stamped nuts that secure the vacuum harness connector and unplug the connector from the back of the heater-A/C control. 12. Release the temperature control cable housing retainer flag and disconnect the cable core from the back of the heater-A/C control. Rotating the heater-A/C control assembly 900 will align the cable core and cable end properly for easy removal. 13. Remove the heater-A/C control from the instrument panel. INSTALLATION 1. Connect the temperature control cable core and cable housing retainer flag to the back of the heater- A/C control. 2. Plug in the vacuum harness connector and install the two stamped nuts to secure the connector to the back of the heater-A/C control. 3. Plug in the wire harness connector to the back of the heater-A/C control, and reinstall the wire harness retainer to the side of the heater-A/C control. 4. Install the heater-A/C control to the instrument panel and secure with four screws. Tighten the screws to 2.2 N.m (20 in. lbs.). 5. If the vehicle is so equipped, plug in the fog lamp switch wire harness connector. 6. Install the instrument cluster bezel. 7. Connect the battery negative cable. 8. Adjust the Temperature Control Cable. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Description and Operation Coupler HVAC: Description and Operation Fig 12 Spring Lock Coupler Disconnect Spring-locking refrigerant line couplers are used to connect refrigerant lines and other components to the refrigerant system. The coupling is held together by a garter spring inside a circular cage. When the coupling halves are connected, the flared end of the female fitting slips behind the garter spring inside the cage of the male fitting. The garter spring and cage prevent the flared end of the female fitting from pulling out of the cage. Secondary clips are installed over the coupling at the factory for added blowoff protection. O-rings are used to seal the coupling. These O-rings are compatible with R-134a refrigerant and must be replaced with O-rings made of the same material. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Description and Operation > Page 6337 Coupler HVAC: Service and Repair Fig 12 Spring Lock Coupler Disconnect WARNING: Review the Service Precautions before leak testing the system. REMOVAL 1. Recover the refrigerant from the refrigerant system. 2. Remove the secondary clip from the coupler. Fit the appropriate spring lock refrigerant line coupler tool from the A/C Tool Kit (Special Tool 6125) to the coupler. 3. Close the tool and push it into the open side of the cage to expand the garter spring and release the female fitting. NOTE: The garter spring may not release if the tool is cocked while pushing it into the cage opening. 4. After the garter spring is expanded, pull the fittings apart within the tool. 5. Remove the tool from the disconnected coupler. 6. Separate the two ends of the coupler. INSTALLATION 1. Check to ensure that the garter spring is in the cage of the male coupler fitting. If the garter spring is missing, install a new spring by pushing it into the cage opening. If the garter spring is damaged, remove it from the cage with a small wire hook (DO NOT use a screwdriver) and install a new garter spring. 2. Clean any dirt or foreign material from both halves of the coupling. 3. Install new O-rings on the male fitting. CAUTION: Use only the specified O-rings as they are made of a special material for the R-134a system. The use of any other O-ring may allow the connection to leak intermittently during vehicle operation. 4. Lubricate the male fitting and O-ring, and the inside of the female fitting with clean R-134a refrigerant oil. Use only refrigerant oil of the type recommended for the compressor in the vehicle. 5. Fit the female fitting to the male fitting and push together until the garter spring snaps over the flared end of the female fitting. 6. Ensure the coupler is fully engaged by pulling back on the lines on either side of the coupler. 7. Install the secondary clip on the coupler. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 24-11-97 > Jul > 97 > A/C Evaporator - Emits Odors Technical Service Bulletin # 24-11-97 Date: 970711 A/C Evaporator - Emits Odors NO: 24-11-97 GROUP: Heater & A/C DATE: Jul. 11, 1997 SUBJECT: A/C Evaporator Odor THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-06-95 REV. A, DATED MAY 26, 1995, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1995 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-96084). THIS IS A COMPLETE REVISION AND NO **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. MODELS: 1992 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1994 - 1998 (AB) Ram Van/Wagon 1992 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1992 - 1993 (AG) Daytona 1992 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1998 (AN) Dakota 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1992 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 1998 (BR) Ram Pickup 1993 - 1995 (ES) Chrysler Voyager (European Market) 1996 - 1998 (GS) Chrysler Voyager (International Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1995 - 1998 (PL) Neon 1997 - 1998 (TJ) Wrangler 1992 - 1998 (XJ) Cherokee 1994 - 1998 (ZG) Grand Cherokee (International Market) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer SYMPTOM/CONDITION: Some vehicle operators may experience a musty odor from the A/C system, primarily at start up in hot and humid climates. This odor may be the result of microbial growth on the evaporator core. During normal A/C system operation, condensation forms in and around the A/C evaporator. When airborne pollutants mix with this condensation, bacteria and fungi growth begins and odor results. DIAGNOSIS: Operate the A/C system, if a musty odor is experienced, perform the Repair Procedure. PARTS REQUIRED: 1 O4897625AA Cleaner, Aerosol Evaporator POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-65-02-93 AA, AC, AG, AJ, AY, PL, TJ, XJ, ZJ 0.7 Hrs. AB, AN, AP, BR, GS, JA, JX, NS 0.6 Hrs. LH 1.5 Hrs. AS, ES 1.0 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 24-11-97 > Jul > 97 > A/C Evaporator - Emits Odors > Page 6346 Repair Procedure This bulletin involves inspecting for leaves or other foreign material in the evaporator and HVAC housing and applying Mopar aerosol evaporator cleaner. NOTE: FOLLOW ALL CAUTIONS AND WARNING SUPPLIED WITH THE AEROSOL EVAPORATOR CLEANER; KEEP OUT OF REACH OF CHILDREN; AVOID CONTACT WITH SKIN OR EYES; WEAR SKIN AND EYE PROTECTION, IF SKIN OR EYE CONTACT OCCURS, WASH SKIN OR FLUSH EYES WITH GENEROUS AMOUNTS OF WATER; AVOID BREATHING VAPORS. 1. Inspect the evaporator and HVAC housing for leaves or other foreign material that may be blocking the air flow through the evaporator. If the build up is excessive replacement of the evaporator may be required. 2. With the parking brake applied and the transmission in Park, start the engine and let idle. Put the temperature control to full hot, blower speed to HIGH, select the PANEL and RE-CIRCULATE modes. Open all windows about 13 mm (1/2 in.). Disable the A/C compressor clutch by disconnecting its wiring connector or the wiring connector to the A/C pressure switch. NOTE: THIS PROCEDURE HEATS THE EVAPORATOR AND CAUSES MOISTURE TO EVAPORATE FASTER. THE SLIGHTLY OPEN WINDOWS ALLOW MOISTURE TO ESCAPE THE VEHICLE WITHOUT LOOSING MUCH HEAT. SOMETIMES, YOU MAY SEE A "FOG" CLOUDING THE WINDOWS. AFTER THIS "FOG" HAS DISAPPEARED CONTINUE TO OPERATE THE HEATER FOR ANOTHER 5 MINUTES. IF THE "FOG" NEVER APPEARED, OPERATE THE HEATER FOR A MINIMUM OF 30 MINUTES. 3. Turn the ignition switch to the OFF position. 4. Gain access to the evaporator cavity to apply the evaporator cleaner by: AB, 1992-93 AN, GS, JA, JX, LH, NS and PL - Remove evaporator fin temperature sensor access grommet. DO NOT REMOVE THE PROBE FROM THE EVAPORATOR. BR, TJ, XJ, ZG, ZJ - Remove blower resistor. For the above vehicles, place a piece of heavy masking tape over the opening in the evaporator housing where the fin temperature sensor access grommet or blower resistor was removed, then punch a small hole for the evaporator cleaner tube to be inserted into. AA, AC, AG, AJ, AP, and AY - Remove the screw attaching the right side floor duct. Use an 1/8 in. drill bit to drill through the bottom of the screw hole, Figure 1. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 24-11-97 > Jul > 97 > A/C Evaporator - Emits Odors > Page 6347 1994-98 AN - Drill an 1/8 in. hole at the mid-point of the rounded corner created by the intersection of the vertical and horizontal surfaces of the HVAC housing, refer to Figure 2. Place tape around the drill bit to prevent the bit from entering the housing more a 1/4 in. AS, ES - Remove the lower right instrument panel. Remove the blower motor cover. Make a template as illustrated below and drill an 1/8 in. hole as shown in Figure 3. Be sure to angle drill as illustrated. Shake evaporator cleaner aerosol can well and insert the application tube in the access hole created in step 3. NOTE: THE APPLICATION TUBE HAS A BLACK MARK AND A RED MARK ON IT INDICATING HOW FAR THE TUBE SHOULD BE INSERTED INTO THE EVAPORATOR CAVITY. THE RED MARK IS FOR AA, AC, AG, AJ, AP, AND AY BODY VEHICLES. THE BLACK MARK IS FOR ALL OTHER VEHICLES. 5. Start the engine and let idle. Set the blower motor to HIGH. 6. Put on goggles and dust mask type breathing protection. 7. Spray the entire contents of the evaporator cleaner into the evaporator cavity. NOTE: A "FOG" MAY BE SEEN ENTERING THE PASSENGER COMPARTMENT WHILE THE EVAPORATOR CLEANER IS BEING SPRAYED. THE EVAPORATOR CLEANER WILL NOT STAIN OR HARM THE VEHICLE INTERIOR, BUT GOGGLES AND BREATHING PROTECTION MUST BE WORN DURING CLEANER APPLICATION. DO NOT BREATH VAPORS! 8. When the can is empty, turn the ignition switch to the OFF position and let the vehicle sit for 20 minutes. This time will allow the cleaner to flow over and coat the evaporator fins and case assembly. 9. Install whatever components that were removed to gain access for application of the cleaner. On AS, ES and 1994-1998 AN, seal the access hole drilled in step 3 NOTE: OWNERS OF NS/GS VEHICLES THAT OPERATE IN CONDITIONS WHERE THE AIR INLET TO THE HVAC HOUSING IS SUBJECT TO FOREIGN MATERIAL, DEBRIS OR OTHER AIRBORNE CONTAMINATES, MAY WANT TO CONSIDER HAVING A MOPAR ACCESSORY CABIN AIR FILTER KIT INSTALLED, P/N 82202509. USE THE INSTRUCTIONS PACKAGED WITH THE KIT TO INSTALL IT. 10. Open all of the vehicle windows about 13 mm (1/2 in.). Start the engine and let idle for a MINIMUM of 30 minutes with the temperature control to full hot, blower speed to HIGH, PANEL and RE-CIRCULATE modes selected. This will dry and cure the evaporator cleaner onto the evaporator coil. 11. Connect the wiring disconnected in step 2 to re-enable the A/C compressor clutch. 12. Verify proper A/C operation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 24-11-97 > Jul > 97 > A/C Evaporator - Emits Odors Technical Service Bulletin # 24-11-97 Date: 970711 A/C Evaporator - Emits Odors NO: 24-11-97 GROUP: Heater & A/C DATE: Jul. 11, 1997 SUBJECT: A/C Evaporator Odor THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-06-95 REV. A, DATED MAY 26, 1995, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1995 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-96084). THIS IS A COMPLETE REVISION AND NO **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. MODELS: 1992 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1994 - 1998 (AB) Ram Van/Wagon 1992 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1992 - 1993 (AG) Daytona 1992 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1998 (AN) Dakota 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1992 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 1998 (BR) Ram Pickup 1993 - 1995 (ES) Chrysler Voyager (European Market) 1996 - 1998 (GS) Chrysler Voyager (International Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1995 - 1998 (PL) Neon 1997 - 1998 (TJ) Wrangler 1992 - 1998 (XJ) Cherokee 1994 - 1998 (ZG) Grand Cherokee (International Market) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer SYMPTOM/CONDITION: Some vehicle operators may experience a musty odor from the A/C system, primarily at start up in hot and humid climates. This odor may be the result of microbial growth on the evaporator core. During normal A/C system operation, condensation forms in and around the A/C evaporator. When airborne pollutants mix with this condensation, bacteria and fungi growth begins and odor results. DIAGNOSIS: Operate the A/C system, if a musty odor is experienced, perform the Repair Procedure. PARTS REQUIRED: 1 O4897625AA Cleaner, Aerosol Evaporator POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-65-02-93 AA, AC, AG, AJ, AY, PL, TJ, XJ, ZJ 0.7 Hrs. AB, AN, AP, BR, GS, JA, JX, NS 0.6 Hrs. LH 1.5 Hrs. AS, ES 1.0 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 24-11-97 > Jul > 97 > A/C Evaporator - Emits Odors > Page 6353 Repair Procedure This bulletin involves inspecting for leaves or other foreign material in the evaporator and HVAC housing and applying Mopar aerosol evaporator cleaner. NOTE: FOLLOW ALL CAUTIONS AND WARNING SUPPLIED WITH THE AEROSOL EVAPORATOR CLEANER; KEEP OUT OF REACH OF CHILDREN; AVOID CONTACT WITH SKIN OR EYES; WEAR SKIN AND EYE PROTECTION, IF SKIN OR EYE CONTACT OCCURS, WASH SKIN OR FLUSH EYES WITH GENEROUS AMOUNTS OF WATER; AVOID BREATHING VAPORS. 1. Inspect the evaporator and HVAC housing for leaves or other foreign material that may be blocking the air flow through the evaporator. If the build up is excessive replacement of the evaporator may be required. 2. With the parking brake applied and the transmission in Park, start the engine and let idle. Put the temperature control to full hot, blower speed to HIGH, select the PANEL and RE-CIRCULATE modes. Open all windows about 13 mm (1/2 in.). Disable the A/C compressor clutch by disconnecting its wiring connector or the wiring connector to the A/C pressure switch. NOTE: THIS PROCEDURE HEATS THE EVAPORATOR AND CAUSES MOISTURE TO EVAPORATE FASTER. THE SLIGHTLY OPEN WINDOWS ALLOW MOISTURE TO ESCAPE THE VEHICLE WITHOUT LOOSING MUCH HEAT. SOMETIMES, YOU MAY SEE A "FOG" CLOUDING THE WINDOWS. AFTER THIS "FOG" HAS DISAPPEARED CONTINUE TO OPERATE THE HEATER FOR ANOTHER 5 MINUTES. IF THE "FOG" NEVER APPEARED, OPERATE THE HEATER FOR A MINIMUM OF 30 MINUTES. 3. Turn the ignition switch to the OFF position. 4. Gain access to the evaporator cavity to apply the evaporator cleaner by: AB, 1992-93 AN, GS, JA, JX, LH, NS and PL - Remove evaporator fin temperature sensor access grommet. DO NOT REMOVE THE PROBE FROM THE EVAPORATOR. BR, TJ, XJ, ZG, ZJ - Remove blower resistor. For the above vehicles, place a piece of heavy masking tape over the opening in the evaporator housing where the fin temperature sensor access grommet or blower resistor was removed, then punch a small hole for the evaporator cleaner tube to be inserted into. AA, AC, AG, AJ, AP, and AY - Remove the screw attaching the right side floor duct. Use an 1/8 in. drill bit to drill through the bottom of the screw hole, Figure 1. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 24-11-97 > Jul > 97 > A/C Evaporator - Emits Odors > Page 6354 1994-98 AN - Drill an 1/8 in. hole at the mid-point of the rounded corner created by the intersection of the vertical and horizontal surfaces of the HVAC housing, refer to Figure 2. Place tape around the drill bit to prevent the bit from entering the housing more a 1/4 in. AS, ES - Remove the lower right instrument panel. Remove the blower motor cover. Make a template as illustrated below and drill an 1/8 in. hole as shown in Figure 3. Be sure to angle drill as illustrated. Shake evaporator cleaner aerosol can well and insert the application tube in the access hole created in step 3. NOTE: THE APPLICATION TUBE HAS A BLACK MARK AND A RED MARK ON IT INDICATING HOW FAR THE TUBE SHOULD BE INSERTED INTO THE EVAPORATOR CAVITY. THE RED MARK IS FOR AA, AC, AG, AJ, AP, AND AY BODY VEHICLES. THE BLACK MARK IS FOR ALL OTHER VEHICLES. 5. Start the engine and let idle. Set the blower motor to HIGH. 6. Put on goggles and dust mask type breathing protection. 7. Spray the entire contents of the evaporator cleaner into the evaporator cavity. NOTE: A "FOG" MAY BE SEEN ENTERING THE PASSENGER COMPARTMENT WHILE THE EVAPORATOR CLEANER IS BEING SPRAYED. THE EVAPORATOR CLEANER WILL NOT STAIN OR HARM THE VEHICLE INTERIOR, BUT GOGGLES AND BREATHING PROTECTION MUST BE WORN DURING CLEANER APPLICATION. DO NOT BREATH VAPORS! 8. When the can is empty, turn the ignition switch to the OFF position and let the vehicle sit for 20 minutes. This time will allow the cleaner to flow over and coat the evaporator fins and case assembly. 9. Install whatever components that were removed to gain access for application of the cleaner. On AS, ES and 1994-1998 AN, seal the access hole drilled in step 3 NOTE: OWNERS OF NS/GS VEHICLES THAT OPERATE IN CONDITIONS WHERE THE AIR INLET TO THE HVAC HOUSING IS SUBJECT TO FOREIGN MATERIAL, DEBRIS OR OTHER AIRBORNE CONTAMINATES, MAY WANT TO CONSIDER HAVING A MOPAR ACCESSORY CABIN AIR FILTER KIT INSTALLED, P/N 82202509. USE THE INSTRUCTIONS PACKAGED WITH THE KIT TO INSTALL IT. 10. Open all of the vehicle windows about 13 mm (1/2 in.). Start the engine and let idle for a MINIMUM of 30 minutes with the temperature control to full hot, blower speed to HIGH, PANEL and RE-CIRCULATE modes selected. This will dry and cure the evaporator cleaner onto the evaporator coil. 11. Connect the wiring disconnected in step 2 to re-enable the A/C compressor clutch. 12. Verify proper A/C operation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid Technical Service Bulletin # 24-006-06 Date: 060810 A/C - Musty Odors When Hot/Humid NUMBER: 24-006-06 GROUP: Heating & A/C DATE: Approval Pending THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-013-05, DATED AUGUST 4, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN ADDITIONAL MODEL, YEAR AND REVISED AB/CS/LX/RS/WK/XK REPAIR PROCEDURE. SUBJECT: A/C Cooling Coil Odor OVERVIEW: This bulletin involves inspecting for leaves and other foreign material, cleaning, and treating the cooling coil and housing. MODELS: 1995-2003 (AB) Ram Van/Wagon 1995-2004 (AN) Dakota 2004 - **2007** (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - **2007** (DR/DH/D1) Ram Pickup 2004 - **2007** (HB) Durango 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2002 - **2007** (KJ) Liberty 1993 - 2004 (LH) 300M/Concorde/LHS/New Yorker/Intrepid/Vision 2005 - **2007** (LX) 300/**Charger**/Magnum 2005 - **2007** (ND) Dakota 2002 (PG) PT Cruiser (International Markets) 1995 - 2005 (PL) Neon/SX 2.0 2001 - **2007** (PT) Chrysler PT Cruiser 2001 - **2007** (RG) Chrysler Voyager (International Markets) 2001 - **2007** (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2002 - 2006 (VA) Sprinter 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - **2007** (WK/WH) Grand Cherokee 2006 - **2007** (XK**/XH)** Commander SYMPTOM/CONDITION: Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6363 Some vehicle operators may experience a musty odor from the A/C system, primarily at start up in hot and humid climates. This odor may be the result of microbial growth on the cooling coil. During normal A/C system operation, condensation forms in and around the NC cooling coil. When airborne pollutants mix with this condensation, bacteria and fungi growth begins and odor results. DIAGNOSIS: If the operator describes, or the technician experiences a musty odor when operating the A/C system, perform the appropriate Repair Procedure based on the vehicle model. PARTS REQUIRED: A/C COOLING COIL CLEANER REQUIREMENTS BY VEHICLE MODEL EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6364 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. AB/CS/LX/RS/WK/XK Vehicle Procedure 1. Open the hood. 2. On LX/RS/**2005 WK/WH (2006 - 2007 WH/WK/XH/XK vehicles skip to step 8) (AB/CS** vehicles proceed to next step), raise the vehicle on a suitable hoist. 3. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 4. On **2005 WK/WH** vehicles (other vehicles proceed to next step), fabricate the cooling coil drain plug as follows (Fig. 1): a. Gather a 457.2 mm (18 in.) long, 9.8 mm (3/8 in.) drive socket extension; a deep 12 mm, 9.8 mm (3/8 in.) drive socket, and a 152.4 mm (6 in.) piece of 15.9 mm (5/8 in.) ID heater hose, p/n HHR00058AA b. Place the socket on the end of the extension. Slide approximately 25.4 mm (1 in.) of the heater hose over the socket. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6365 c. Slip the heater hose over the cooling coil drain tube, located above the right side of the transmission using the socket and extension to reach up between the frame and the exhaust. Leave the hose socket and extension in place (Fig. 2). Proceed to Step # 7. 5. Cap/clamp off the drain tube using a suitable cap/clamp. 6. AB vehicles proceed to Step # 12, other vehicles proceed to next step. 7. On LX/RS/**2005 WK/WH** vehicles (other vehicles proceed to next step), lower the vehicle. 8. Remove passenger side floor mat. 9. Place a protective cover over the carpet and the passenger front seat. 10. On LX/RS/**WH/WK/XH**XK vehicles (other vehicles proceed to next step), remove the glove box to gain access to the blower motor resistor /power module. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Glove Box 11. On LX/**WH/WK/XH/XK vehicles, remove the passenger side instrument panel silencer. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Instrument Panel Silencer. On 2006 - 2007 WH/WK/XH/XK vehicles remove the blower motor and use a shop vacuum to clean the evaporator coil, reinstall the blower motor and skip to step 18. Other vehicles proceed to next step.** 12. Remove the 2 screws securing the blower motor resistor/power module in the NC housing and remove the blower motor resistor/power module. Do not disconnect the electrical connector. 13. On LX/**2005 WK/WH** vehicles (other vehicles proceed to next step), proceed to Step # 18 14. If the vehicle is not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, remove the A/C air filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. If not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, install the air filter door (do not install the air filter at this time). 18. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6366 19. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 20. Connect the assembled applicator tool to the shop compressed air supply line. 21. Insert the applicator tool into the blower resistor/power module opening. 22. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 23. Allow the vehicle sit for a minimum of 30 minutes. 24. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 27. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 25. Remove the cap/clamp from the drain tube. 26. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 27. Fill each empty cleaner bottle with normal tap water. 28. One at a time, screw each bottle of water onto the applicator tool. 29. Insert the applicator tool into the blower resistor opening. 30. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 31. Install the blower motor resistor/power module. 32. Start the engine. 33. Raise all the windows to a slightly open position (about 1/2 inch opening). 34. Set the blower to HIGH. 35. Set the A/C switch to A/C OFF. 36. Set mode switch to PANEL OUTLETS. 37. Set temperature switch to FULL HEAT. 38. Set recirculation switch to RECIRCULATE. 39. Allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the OFF position. 41. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 44. Other vehicles proceed to next step.** 42. Cap/clamp off the drain tube using a suitable cap. 43. On LX/RS/**2005 WH/WK/** vehicles (other vehicles proceed to next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 44. Open all windows in the vehicle. 45. Remove the blower motor resistor/power module. 46. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6367 47. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 48. Allow the vehicle to sit for 30 minutes. 49. Install the blower motor resistor/power module. 50. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 53. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 51. Remove the drain tube cap/clamp. 52. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 53. Start the engine. 54. Raise all the windows to a slightly open position (about 1/2 inch opening). 55. Set the blower to HIGH. 56. Set the A/C switch to A/C OFF. 57. Set mode switch to PANEL OUTLETS. 58. Set temperature switch to FULL HEAT. 59. Set recirculation switch to RECIRCULATE. 60. Allow the engine to run for 20 minutes. 61. Turn the ignition switch to the OFF position. 62. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 63. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 67. Other vehicles proceed to next step.** CAUTION: In the following step be careful not to damage the A/C cooling coil. 64. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 65. AB vehicles proceed to Step # 72, CS vehicles proceed to Step # 68, LX/RS/**2005 WH/WK** vehicles proceed to Step # 66. 66. Lower the vehicle. 67. On **LX/WH/WK/XH/XK** vehicles (RS vehicles proceed to next step), install the right silencer pad. 68. Install the glove box. 69. If the vehicle is not equipped with an A/C air filter, proceed to the next step. If equipped with an A/C filter, remove the air filter door and install the A/C air filter. Replace with a new filter, if necessary. See the parts table for the appropriate part number filter. 70. Remove the carpet and seat protector. 71. Install the floor mat. 72. Close the hood. AN/DN/DR/HB/JR/KJ/LH/ND/PL/PT/TJ/WG/WJ Vehicles Procedure Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6368 1. Open the hood. 2. Disconnect and isolate the negative battery cable. 3. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle on a suitable hoist. 4. On AN/DN/ND - vehicles (other vehicles proceed to the next step), remove the exhaust heat shield covering the cooling coil housing drain. 5. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 6. On AN/DN/DR/HB/KJ vehicles (other vehicles proceed to next step), cap off the drain tube using a suitable cap. When the drain tube is capped off, proceed to Step # 9. 7. On ND vehicles (other vehicles proceed to next step), plug the cooling coil drain using a piece of plastic or a shop towel. When the drain tube is plugged, proceed to Step #9. 8. Clamp off the drain tube. 9. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 10. Remove passenger side floor mat. 11. Place a protective cover over the carpet and the passenger front seat. 12. If applicable, remove the silencer pad from under the instrument panel on the right side to gain access to the blower motor. 13. On LH vehicles (other vehicles proceed to next step), remove the lower right under panel duct and blower motor cover. 14. Disconnect the blower motor wire harness connector and remove the blower motor. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. Open all the windows in the vehicle. NOTE: Technician must use eye protection, rubber gloves, and protective clothing. NOTE: No occupants should be in the vehicle during material application. 18. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 19. Connect the assembled applicator tool to the shop compressed air supply line. 20. Insert the applicator tool into the blower motor opening. Spray all of the cooling coil cleaner onto the cooling coil until the required number of bottles are empty (See table for required number of bottles). 21. Allow the vehicle to sit for a minimum of 30 minutes. 22. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 23. Remove the drain tube clamp/cap/plug. 24. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 25. Fill each empty cleaner bottle with normal tap water. 26. One at a time, screw each bottle of normal tap water onto the applicator tool. 27. Spray all of the normal tap water onto the cooling coil until each bottle is empty. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6369 28. Install the blower motor and connect the blower motor wire harness connector. 29. Connect the negative battery cable. 30. Start the engine. 31. Raise all the windows to a slightly open position (about 1/2 inch opening). 32. Set the blower to HIGH - A/C OFF. 33. Set mode switch to PANEL OUTLETS. 34. Set temperature switch to FULL HEAT. 35. Set recirculation switch to RECIRCULATE. 36. With the engine running, allow the blower to operate for 20 minutes. 37. Turn the ignition switch to the OFF position. 38. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. 39. Install the drain tube clamp/cap/plug. 40. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 41. Open all the windows in the vehicle. 42. Disconnect and isolate the negative battery cable. 43. Disconnect the blower motor wire harness connector and remove the blower motor. 44. Shake an 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 45. Insert the applicator tool into the blower motor opening. Spray the full contents of the bottle on the cooling coil being carefully to cover the entire surface of the cooling coil. 46. Allow the vehicle to sit for 30 minutes. 47. Install the blower motor and connect the blower motor wire harness connector. 48. Connect the negative battery cable. 49. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 50. Remove the drain tube clamp/cap. 51. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 52. Start the engine. 53. Raise all the windows to a slightly open position (about 1/2 inch opening). 54. Set the blower to HIGH - A/C OFF. 55. Set mode switch to PANEL OUTLETS. 56. Set temperature switch to FULL HEAT. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6370 57. Set recirculation switch to RECIRCULATE. 58. With the engine running, allow the blower to operate for 20 minutes. 59. Turn the ignition switch to the OFF position. 60. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 61. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: In the following step be careful not to damage the A/C cooling coil. 62. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 63. On AN/DN/ND - vehicles (other vehicles proceed to the next step), install the exhaust heat shield covering the cooling coil housing drain. 64. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 65. On LH vehicles (other vehicles proceed to next step), install the blower motor cover and lower right under panel duct. 66. Remove the carpet and seat protector. 67. If applicable, install the silencer pad under the right side of the instrument panel. 68. Install floor mat. 69. Close the hood. ST Vehicle Procedure 1. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 2. Remove passenger side floor mat. 3. Place a protective cover over the carpet and the passenger front seat. 4. Remove the joint duct. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Blower Assembly and Resistor, Joint Duct. 5. Inspect and remove any leaves and debris. 6. If necessary, use a shop vacuum to clean the cooling coil. NOTE: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 7. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 8. Connect the assembled applicator tool to the shop compressed air supply line. 9. Insert the applicator tool into the opening created by the joint duct removal. 10. Spray the full contents of 2 bottles of cooling coil cleaner onto the evaporator, moving the tool so that the evaporator is completely covered, until both bottles are empty (16 oz. total). 11. Allow the vehicle to sit for a minimum of 30 minutes. 12. Fill both of the empty cooling coil cleaner bottles with normal tap water. 13. Screw one bottle of water onto the applicator tool. 14. Insert the applicator tool into the opening of the heater/cooler unit at the evaporator. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6371 15. Spray the full contents of water until the bottle is empty. 16. Repeat Step #13 through Step #15 using the second bottle of water. When both bottles of water are empty, proceed to the next step. 17. Install the joint duct. 18. Disconnect the A/C clutch electrical connector at the A/C compressor. 19. Start the engine. 20. Set the blower to HIGH - A/C OFF. 21. Set mode switch to PANEL OUTLETS. 22. Set temperature switch to FULL HEAT. 23. Set recirculation switch to RECIRCULATE. 24. Open windows slightly (about 1/2 inch opening). 25. With the engine running, allow the blower to operate for 20 minutes. 26. Turn the engine off. 27. Turn the ignition switch ON, do not start the engine, to allow blower motor operation. 28. Fully open all windows. 29. Remove the outer glove box and the inner glove box. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, 23C Body Interior, Instrument Panel CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 30. Shake the 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 31. Insert the applicator tool into the recirculation inlet (behind glove box opening). Spray the full contents of the bottle in the airstream until the bottle is empty. 32. Start the engine. 33. Set the blower to HIGH. 34. Set the A/C switch to A/C OFF. 35. Set mode switch to PANEL OUTLETS. 36. Set temperature switch to FULL HEAT. 37. Set recirculation switch to RECIRCULATE. 38. Open windows slightly (about 1/2 inch opening). 39. With the engine running, allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the off position. 41. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 42. Connect the A/C compressor clutch electrical connector at the compressor. 43. Open the right side panel outlet vent. 44. Install inner glove box. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6372 45. Install outer glove box. 46. Remove the carpet and seat protector. 47. Install floor mat. VA Vehicle Procedure 1. Raise the vehicle on a suitable hoist. 2. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 3. Clamp off the drain tube using a suitable clamp. 4. Lower the vehicle. 5. Remove the HVAC filter cover and HVAC filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 6. Inspect and remove any leaves and debris. 7. If necessary, use a shop vacuum to clean the cooling coil. 8. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 9. Screw the bottle of cooling coil cleaner (pin 05170022AA) onto the applicator tool. 10. Connect the assembled applicator tool to the shop compressed air supply line. 11. Insert the applicator tool into the HVAC filter opening. 12. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 13. Allow the vehicle sit for a minimum of 30 minutes. 14. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 15. Remove the clamp from the drain tube. 16. Lower the vehicle. 17. Fill each empty cleaner bottle with normal tap water. 18. One at a time, screw each bottle of water onto the applicator tool. 19. Insert the applicator tool into the HVAC filter opening. 20. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 21. Install the HVAC filter cover (do not install the HVAC filter at this time). 22. Start the engine. 23. Raise all the windows to a slightly open position (about 1/2 inch opening). 24. Set the blower to HIGH. 25. Set the A/C switch to NC OFF. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6373 26. Set mode switch to PANEL OUTLETS. 27. Set temperature switch to FULL HEAT. 28. Set recirculation switch to RECIRCULATE. 29. With the engine running, allow the blower to operate for 20 minutes. 30. Turn the ignition switch to the OFF position. 31. Raise the vehicle on a suitable hoist. 32. Clamp off the drain tube using a suitable clamp. 33. Lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 34. Open all windows in the vehicle. 35. Remove the HVAC filter cover. 36. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 37. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 38. Allow the vehicle to sit for 30 minutes. 39. Install the HVAC filter. Replace with a new filter, p/n 05103600AA, if necessary. 40. Install the HVAC filter cover. 41. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 42. Remove the drain tube clamp. 43. Lower the vehicle. 44. Start the engine. 45. Raise all the windows to a slightly open position (about 1/2 inch opening). 46. Set the blower to HIGH. 47. Set the A/C switch to A/C OFF. 48. Set mode switch to PANEL OUTLETS. 49. Set temperature switch to FULL HEAT. 50. Set recirculation switch to RECIRCULATE. 51. With the engine running, allow the blower motor to operate for 20 minutes. 52. Turn the ignition switch to the OFF position. 53. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 54. Raise the vehicle on a suitable hoist. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6374 CAUTION: In the following step be careful not to damage the A/C cooling coil. 55. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 56. Lower the vehicle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid Technical Service Bulletin # 24-006-06 Date: 060810 A/C - Musty Odors When Hot/Humid NUMBER: 24-006-06 GROUP: Heating & A/C DATE: Approval Pending THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-013-05, DATED AUGUST 4, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN ADDITIONAL MODEL, YEAR AND REVISED AB/CS/LX/RS/WK/XK REPAIR PROCEDURE. SUBJECT: A/C Cooling Coil Odor OVERVIEW: This bulletin involves inspecting for leaves and other foreign material, cleaning, and treating the cooling coil and housing. MODELS: 1995-2003 (AB) Ram Van/Wagon 1995-2004 (AN) Dakota 2004 - **2007** (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - **2007** (DR/DH/D1) Ram Pickup 2004 - **2007** (HB) Durango 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2002 - **2007** (KJ) Liberty 1993 - 2004 (LH) 300M/Concorde/LHS/New Yorker/Intrepid/Vision 2005 - **2007** (LX) 300/**Charger**/Magnum 2005 - **2007** (ND) Dakota 2002 (PG) PT Cruiser (International Markets) 1995 - 2005 (PL) Neon/SX 2.0 2001 - **2007** (PT) Chrysler PT Cruiser 2001 - **2007** (RG) Chrysler Voyager (International Markets) 2001 - **2007** (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2002 - 2006 (VA) Sprinter 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - **2007** (WK/WH) Grand Cherokee 2006 - **2007** (XK**/XH)** Commander SYMPTOM/CONDITION: Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6380 Some vehicle operators may experience a musty odor from the A/C system, primarily at start up in hot and humid climates. This odor may be the result of microbial growth on the cooling coil. During normal A/C system operation, condensation forms in and around the NC cooling coil. When airborne pollutants mix with this condensation, bacteria and fungi growth begins and odor results. DIAGNOSIS: If the operator describes, or the technician experiences a musty odor when operating the A/C system, perform the appropriate Repair Procedure based on the vehicle model. PARTS REQUIRED: A/C COOLING COIL CLEANER REQUIREMENTS BY VEHICLE MODEL EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6381 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. AB/CS/LX/RS/WK/XK Vehicle Procedure 1. Open the hood. 2. On LX/RS/**2005 WK/WH (2006 - 2007 WH/WK/XH/XK vehicles skip to step 8) (AB/CS** vehicles proceed to next step), raise the vehicle on a suitable hoist. 3. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 4. On **2005 WK/WH** vehicles (other vehicles proceed to next step), fabricate the cooling coil drain plug as follows (Fig. 1): a. Gather a 457.2 mm (18 in.) long, 9.8 mm (3/8 in.) drive socket extension; a deep 12 mm, 9.8 mm (3/8 in.) drive socket, and a 152.4 mm (6 in.) piece of 15.9 mm (5/8 in.) ID heater hose, p/n HHR00058AA b. Place the socket on the end of the extension. Slide approximately 25.4 mm (1 in.) of the heater hose over the socket. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6382 c. Slip the heater hose over the cooling coil drain tube, located above the right side of the transmission using the socket and extension to reach up between the frame and the exhaust. Leave the hose socket and extension in place (Fig. 2). Proceed to Step # 7. 5. Cap/clamp off the drain tube using a suitable cap/clamp. 6. AB vehicles proceed to Step # 12, other vehicles proceed to next step. 7. On LX/RS/**2005 WK/WH** vehicles (other vehicles proceed to next step), lower the vehicle. 8. Remove passenger side floor mat. 9. Place a protective cover over the carpet and the passenger front seat. 10. On LX/RS/**WH/WK/XH**XK vehicles (other vehicles proceed to next step), remove the glove box to gain access to the blower motor resistor /power module. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Glove Box 11. On LX/**WH/WK/XH/XK vehicles, remove the passenger side instrument panel silencer. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Instrument Panel Silencer. On 2006 - 2007 WH/WK/XH/XK vehicles remove the blower motor and use a shop vacuum to clean the evaporator coil, reinstall the blower motor and skip to step 18. Other vehicles proceed to next step.** 12. Remove the 2 screws securing the blower motor resistor/power module in the NC housing and remove the blower motor resistor/power module. Do not disconnect the electrical connector. 13. On LX/**2005 WK/WH** vehicles (other vehicles proceed to next step), proceed to Step # 18 14. If the vehicle is not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, remove the A/C air filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. If not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, install the air filter door (do not install the air filter at this time). 18. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6383 19. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 20. Connect the assembled applicator tool to the shop compressed air supply line. 21. Insert the applicator tool into the blower resistor/power module opening. 22. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 23. Allow the vehicle sit for a minimum of 30 minutes. 24. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 27. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 25. Remove the cap/clamp from the drain tube. 26. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 27. Fill each empty cleaner bottle with normal tap water. 28. One at a time, screw each bottle of water onto the applicator tool. 29. Insert the applicator tool into the blower resistor opening. 30. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 31. Install the blower motor resistor/power module. 32. Start the engine. 33. Raise all the windows to a slightly open position (about 1/2 inch opening). 34. Set the blower to HIGH. 35. Set the A/C switch to A/C OFF. 36. Set mode switch to PANEL OUTLETS. 37. Set temperature switch to FULL HEAT. 38. Set recirculation switch to RECIRCULATE. 39. Allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the OFF position. 41. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 44. Other vehicles proceed to next step.** 42. Cap/clamp off the drain tube using a suitable cap. 43. On LX/RS/**2005 WH/WK/** vehicles (other vehicles proceed to next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 44. Open all windows in the vehicle. 45. Remove the blower motor resistor/power module. 46. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6384 47. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 48. Allow the vehicle to sit for 30 minutes. 49. Install the blower motor resistor/power module. 50. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 53. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 51. Remove the drain tube cap/clamp. 52. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 53. Start the engine. 54. Raise all the windows to a slightly open position (about 1/2 inch opening). 55. Set the blower to HIGH. 56. Set the A/C switch to A/C OFF. 57. Set mode switch to PANEL OUTLETS. 58. Set temperature switch to FULL HEAT. 59. Set recirculation switch to RECIRCULATE. 60. Allow the engine to run for 20 minutes. 61. Turn the ignition switch to the OFF position. 62. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 63. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 67. Other vehicles proceed to next step.** CAUTION: In the following step be careful not to damage the A/C cooling coil. 64. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 65. AB vehicles proceed to Step # 72, CS vehicles proceed to Step # 68, LX/RS/**2005 WH/WK** vehicles proceed to Step # 66. 66. Lower the vehicle. 67. On **LX/WH/WK/XH/XK** vehicles (RS vehicles proceed to next step), install the right silencer pad. 68. Install the glove box. 69. If the vehicle is not equipped with an A/C air filter, proceed to the next step. If equipped with an A/C filter, remove the air filter door and install the A/C air filter. Replace with a new filter, if necessary. See the parts table for the appropriate part number filter. 70. Remove the carpet and seat protector. 71. Install the floor mat. 72. Close the hood. AN/DN/DR/HB/JR/KJ/LH/ND/PL/PT/TJ/WG/WJ Vehicles Procedure Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6385 1. Open the hood. 2. Disconnect and isolate the negative battery cable. 3. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle on a suitable hoist. 4. On AN/DN/ND - vehicles (other vehicles proceed to the next step), remove the exhaust heat shield covering the cooling coil housing drain. 5. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 6. On AN/DN/DR/HB/KJ vehicles (other vehicles proceed to next step), cap off the drain tube using a suitable cap. When the drain tube is capped off, proceed to Step # 9. 7. On ND vehicles (other vehicles proceed to next step), plug the cooling coil drain using a piece of plastic or a shop towel. When the drain tube is plugged, proceed to Step #9. 8. Clamp off the drain tube. 9. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 10. Remove passenger side floor mat. 11. Place a protective cover over the carpet and the passenger front seat. 12. If applicable, remove the silencer pad from under the instrument panel on the right side to gain access to the blower motor. 13. On LH vehicles (other vehicles proceed to next step), remove the lower right under panel duct and blower motor cover. 14. Disconnect the blower motor wire harness connector and remove the blower motor. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. Open all the windows in the vehicle. NOTE: Technician must use eye protection, rubber gloves, and protective clothing. NOTE: No occupants should be in the vehicle during material application. 18. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 19. Connect the assembled applicator tool to the shop compressed air supply line. 20. Insert the applicator tool into the blower motor opening. Spray all of the cooling coil cleaner onto the cooling coil until the required number of bottles are empty (See table for required number of bottles). 21. Allow the vehicle to sit for a minimum of 30 minutes. 22. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 23. Remove the drain tube clamp/cap/plug. 24. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 25. Fill each empty cleaner bottle with normal tap water. 26. One at a time, screw each bottle of normal tap water onto the applicator tool. 27. Spray all of the normal tap water onto the cooling coil until each bottle is empty. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6386 28. Install the blower motor and connect the blower motor wire harness connector. 29. Connect the negative battery cable. 30. Start the engine. 31. Raise all the windows to a slightly open position (about 1/2 inch opening). 32. Set the blower to HIGH - A/C OFF. 33. Set mode switch to PANEL OUTLETS. 34. Set temperature switch to FULL HEAT. 35. Set recirculation switch to RECIRCULATE. 36. With the engine running, allow the blower to operate for 20 minutes. 37. Turn the ignition switch to the OFF position. 38. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. 39. Install the drain tube clamp/cap/plug. 40. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 41. Open all the windows in the vehicle. 42. Disconnect and isolate the negative battery cable. 43. Disconnect the blower motor wire harness connector and remove the blower motor. 44. Shake an 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 45. Insert the applicator tool into the blower motor opening. Spray the full contents of the bottle on the cooling coil being carefully to cover the entire surface of the cooling coil. 46. Allow the vehicle to sit for 30 minutes. 47. Install the blower motor and connect the blower motor wire harness connector. 48. Connect the negative battery cable. 49. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 50. Remove the drain tube clamp/cap. 51. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 52. Start the engine. 53. Raise all the windows to a slightly open position (about 1/2 inch opening). 54. Set the blower to HIGH - A/C OFF. 55. Set mode switch to PANEL OUTLETS. 56. Set temperature switch to FULL HEAT. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6387 57. Set recirculation switch to RECIRCULATE. 58. With the engine running, allow the blower to operate for 20 minutes. 59. Turn the ignition switch to the OFF position. 60. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 61. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: In the following step be careful not to damage the A/C cooling coil. 62. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 63. On AN/DN/ND - vehicles (other vehicles proceed to the next step), install the exhaust heat shield covering the cooling coil housing drain. 64. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 65. On LH vehicles (other vehicles proceed to next step), install the blower motor cover and lower right under panel duct. 66. Remove the carpet and seat protector. 67. If applicable, install the silencer pad under the right side of the instrument panel. 68. Install floor mat. 69. Close the hood. ST Vehicle Procedure 1. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 2. Remove passenger side floor mat. 3. Place a protective cover over the carpet and the passenger front seat. 4. Remove the joint duct. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Blower Assembly and Resistor, Joint Duct. 5. Inspect and remove any leaves and debris. 6. If necessary, use a shop vacuum to clean the cooling coil. NOTE: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 7. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 8. Connect the assembled applicator tool to the shop compressed air supply line. 9. Insert the applicator tool into the opening created by the joint duct removal. 10. Spray the full contents of 2 bottles of cooling coil cleaner onto the evaporator, moving the tool so that the evaporator is completely covered, until both bottles are empty (16 oz. total). 11. Allow the vehicle to sit for a minimum of 30 minutes. 12. Fill both of the empty cooling coil cleaner bottles with normal tap water. 13. Screw one bottle of water onto the applicator tool. 14. Insert the applicator tool into the opening of the heater/cooler unit at the evaporator. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6388 15. Spray the full contents of water until the bottle is empty. 16. Repeat Step #13 through Step #15 using the second bottle of water. When both bottles of water are empty, proceed to the next step. 17. Install the joint duct. 18. Disconnect the A/C clutch electrical connector at the A/C compressor. 19. Start the engine. 20. Set the blower to HIGH - A/C OFF. 21. Set mode switch to PANEL OUTLETS. 22. Set temperature switch to FULL HEAT. 23. Set recirculation switch to RECIRCULATE. 24. Open windows slightly (about 1/2 inch opening). 25. With the engine running, allow the blower to operate for 20 minutes. 26. Turn the engine off. 27. Turn the ignition switch ON, do not start the engine, to allow blower motor operation. 28. Fully open all windows. 29. Remove the outer glove box and the inner glove box. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, 23C Body Interior, Instrument Panel CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 30. Shake the 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 31. Insert the applicator tool into the recirculation inlet (behind glove box opening). Spray the full contents of the bottle in the airstream until the bottle is empty. 32. Start the engine. 33. Set the blower to HIGH. 34. Set the A/C switch to A/C OFF. 35. Set mode switch to PANEL OUTLETS. 36. Set temperature switch to FULL HEAT. 37. Set recirculation switch to RECIRCULATE. 38. Open windows slightly (about 1/2 inch opening). 39. With the engine running, allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the off position. 41. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 42. Connect the A/C compressor clutch electrical connector at the compressor. 43. Open the right side panel outlet vent. 44. Install inner glove box. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6389 45. Install outer glove box. 46. Remove the carpet and seat protector. 47. Install floor mat. VA Vehicle Procedure 1. Raise the vehicle on a suitable hoist. 2. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 3. Clamp off the drain tube using a suitable clamp. 4. Lower the vehicle. 5. Remove the HVAC filter cover and HVAC filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 6. Inspect and remove any leaves and debris. 7. If necessary, use a shop vacuum to clean the cooling coil. 8. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 9. Screw the bottle of cooling coil cleaner (pin 05170022AA) onto the applicator tool. 10. Connect the assembled applicator tool to the shop compressed air supply line. 11. Insert the applicator tool into the HVAC filter opening. 12. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 13. Allow the vehicle sit for a minimum of 30 minutes. 14. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 15. Remove the clamp from the drain tube. 16. Lower the vehicle. 17. Fill each empty cleaner bottle with normal tap water. 18. One at a time, screw each bottle of water onto the applicator tool. 19. Insert the applicator tool into the HVAC filter opening. 20. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 21. Install the HVAC filter cover (do not install the HVAC filter at this time). 22. Start the engine. 23. Raise all the windows to a slightly open position (about 1/2 inch opening). 24. Set the blower to HIGH. 25. Set the A/C switch to NC OFF. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6390 26. Set mode switch to PANEL OUTLETS. 27. Set temperature switch to FULL HEAT. 28. Set recirculation switch to RECIRCULATE. 29. With the engine running, allow the blower to operate for 20 minutes. 30. Turn the ignition switch to the OFF position. 31. Raise the vehicle on a suitable hoist. 32. Clamp off the drain tube using a suitable clamp. 33. Lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 34. Open all windows in the vehicle. 35. Remove the HVAC filter cover. 36. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 37. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 38. Allow the vehicle to sit for 30 minutes. 39. Install the HVAC filter. Replace with a new filter, p/n 05103600AA, if necessary. 40. Install the HVAC filter cover. 41. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 42. Remove the drain tube clamp. 43. Lower the vehicle. 44. Start the engine. 45. Raise all the windows to a slightly open position (about 1/2 inch opening). 46. Set the blower to HIGH. 47. Set the A/C switch to A/C OFF. 48. Set mode switch to PANEL OUTLETS. 49. Set temperature switch to FULL HEAT. 50. Set recirculation switch to RECIRCULATE. 51. With the engine running, allow the blower motor to operate for 20 minutes. 52. Turn the ignition switch to the OFF position. 53. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 54. Raise the vehicle on a suitable hoist. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6391 CAUTION: In the following step be careful not to damage the A/C cooling coil. 55. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 56. Lower the vehicle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 6392 Evaporator Core: Specifications Refrigerant Oil Capacity 60 ml (2 oz) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 6393 Evaporator Core: Description and Operation The evaporator coil is located in the heater-A/C housing, under the instrument panel. Refrigerant enters the evaporator as a low-temperature, low-pressure liquid. As air passes over the fins of the evaporator, the humidity in the air condenses on the fins, and the heat from the air is absorbed by the refrigerant. Heat absorption causes the refrigerant to become a low-pressure gas before it leaves the evaporator. The evaporator coil cannot be repaired and, if faulty or damaged. it must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 6394 Evaporator Core: Service and Repair Fig 65 Evaporator Coil Removal/Installation WARNING: On vehicles equipped with Air-Bags, failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. REMOVAL 1. Disconnect and isolate the battery negative cable, 2. Remove the instrument panel assembly from the vehicle. 3. Remove the heater-A/C housing. Refer to: "Housing Assembly HVAC : Service and Repair" See: Housing Assembly HVAC/Service and Repair 4. Remove the heater-A/C housing cover. 5. Lift the evaporator coil out of the heater-A/C housing. INSTALLATION 1. Insert the evaporator coil into the bottom of the heater-A/C housing. 2. Install the heater-A/C housing cover. Refer to: "Housing Assembly HVAC : Service and Repair" See: Housing Assembly HVAC/Service and Repair 3. Reinstall the heater-A/C housing. 4. Reinstall the instrument panel assembly in the vehicle. 5. Connect the battery negative cable. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Description and Operation Expansion Block/Orifice Tube: Description and Operation FIXED ORIFICE TUBE The fixed orifice tube is located in the outlet line of the condenser. It is accessed by disconnecting the refrigerant line coupler at the condenser outlet line. The inlet and outlet ends of the tube have a screen to filter the refrigerant. O-rings on the tube body prevent the refrigerant from bypassing the fixed orifice. The fixed orifice tube is used to meter the flow of liquid refrigerant into the evaporator coil. The fixed orifice tube cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Description and Operation > Page 6398 Expansion Block/Orifice Tube: Service and Repair Fig 31 Fixed Orifice Tube Removal/Installation WARNING: Review the Service Precautions before performing the following operation. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. 3. Disconnect the liquid line refrigerant line coupler at the condenser outlet tube. See A/C Coupler for the procedures. Install plugs in, or tape over all of the open refrigerant fittings. 4. Remove the fixed orifice tube from the condenser outlet tube using a pair of needle nose pliers. Note the orientation of the fixed orifice tube for correct reinstallation. INSTALLATION 1. Insert the fixed orifice tube in the liquid line. Be certain that it is properly oriented. 2. Remove the tape or plugs from all of the refrigerant fittings. Install the liquid line to the condenser outlet tube. See A/C Coupler for the procedures. 3. Evacuate and charge the refrigerant system. 4. Connect the battery negative cable. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and Operation Heater Core: Description and Operation The heater core is located in the heater-A/C housing, under the instrument panel. It is a heat exchanger made of rows of tubes and fins. Engine coolant is circulated through heater hoses to the heater core at all times. As the coolant flows through the heater core, heat removed from the engine is transferred to the heater core fins and tubes. Air directed through the heater core picks up the heat from the heater core fins. The blend air door allows control of the heater output air temperature by controlling how much of the air flowing through the heater-A/C housing is directed through the heater core. The blower motor speed controls the amount of air flowing through the heater-A/C housing. The heater core cannot be repaired and, if faulty or damaged. it must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and Operation > Page 6402 Heater Core: Service and Repair Fig 64 Heater Core Removal/Installation WARNING: On vehicles equipped with Air-Bags, failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel assembly from the vehicle. Refer to: "Instrument Panel, Gauges and Warning Indicators : Instrument Panel : Service and Repair" See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair 3. Remove the heater-A/C housing.Refer to: "Housing Assembly HVAC : Service and Repair" See: Housing Assembly HVAC/Service and Repair 4. Remove the heater-A/C housing cover. 5. Lift the heater core out of the heater-A/C housing. INSTALLATION 1. Insert the heater core into the bottom of the heater-A/C housing. 2. Install the heater-A/C housing cover. 3. Reinstall the heater-A/C housing. 4. Reinstall the instrument panel assembly in the vehicle. 5. Connect the battery negative cable. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Description and Operation High Pressure Safety Valve HVAC: Description and Operation HIGH PRESSURE RELIEF VALVE The high pressure relief valve is located on the compressor manifold. The valve is used to prevent excessive system pressure. The valve vents the system when a pressure of 3445 to 4135 kPa (500 to 600 psi) and above, is reached. This prevents damage to the compressor and other system components due to condenser air flow being restricted or an overcharge of refrigerant. The valve closes with a minimum pressure of 2756 kPa (400 psi). The high pressure relief valve vents only enough refrigerant to reduce system pressure, then re-seats itself. The majority of the refrigerant is conserved in the system. If the valve vents refrigerant, it does not mean the valve is faulty. The valve is only serviced as part of the compressor assembly, and must not be removed or otherwise disturbed. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation Hose/Line HVAC: Description and Operation REFRIGERANT LINE The refrigerant lines are used to carry the refrigerant between the various air conditioning system components. A barrier hose design is used for the air conditioning system on this vehicle. The ends of the refrigerant hoses are made from lightweight aluminum, and use braze-less fittings. The refrigerant lines and hoses cannot be repaired and, if faulty or damaged, they must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Liquid Hose/Line Replacement Hose/Line HVAC: Service and Repair A/C Liquid Hose/Line Replacement Fig 28 Liquid Line Removal/Installation WARNING: Review the Service Precautions before performing the following operation. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. 3. Remove the engine air filter housing. 4. If the vehicle is so equipped, remove the nuts that secure the vehicle speed control servo mounting bracket to the studs on the cowl plenum panel and move the servo far enough to access the liquid line to evaporator coupler. 5. Disconnect the refrigerant line couplers at the condenser and the evaporator. See Refrigerant A/C Coupler for the procedures. Install plugs in, or tape over all of the open refrigerant fittings. 6. Disengage the two clips that secure the liquid line to the inner fender shield. 7. Remove the liquid line from the vehicle. INSTALLATION 1. Install the liquid line in the two clips on the inner fender shield. 2. Remove the tape or plugs from all of the refrigerant fittings, and install the refrigerant lines to the condenser and the evaporator. See Refrigerant A/C Coupler for the procedures. 3. If the vehicle is so equipped, reinstall the vehicle speed control servo mounting bracket to the studs on the cowl plenum panel. 4. Reinstall the engine air filter housing. 5. Connect the battery negative cable. 6. Evacuate and charge the refrigerant system. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Liquid Hose/Line Replacement > Page 6411 Hose/Line HVAC: Service and Repair Suction and Discharge Line Fig 14 Suction And Discharge Line Removal/Installation -- Typical WARNING: Review the Service Precautions before performing the following operation. REMOVAL 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 cut-off switch. 4. Disconnect the refrigerant line couplers at the condenser and the accumulator. See A/C Coupler for the procedures. Install plugs in, or tape over all of the open refrigerant fittings. 5. Remove the fastener that secures the refrigerant line support bracket near the compressor. 6. Remove the screw that secures the refrigerant line manifold to the compressor. Install plugs in, or tape over all of the open refrigerant fittings. 7. Remove the suction and discharge line from the vehicle. INSTALLATION 1. Remove the tape or plugs from all of the refrigerant fittings, and install the A/C Couplers to the condenser and the accumulator. 2. Install the refrigerant line manifold to the compressor. Tighten the mounting screw to 22 N.m (200 m. lbs.). 3. Install the compressor on the mounting bracket. Tighten the mounting screws to 27 N.m (20 ft. lbs.). 4. Install the fastener that secures the refrigerant line support bracket near the compressor. 5. Plug in the wire harness connector to the high pressure cut-off switch. 6. Connect the battery negative cable. 7. Evacuate and charge the refrigerant system. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Cover Removal and Installation Housing Assembly HVAC: Service and Repair Heater-A/C Housing Cover Removal and Installation WARNING: On vehicles equipped with Air-Bags, failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel assembly. Refer to: "Instrument Panel, Gauges and Wiring Indicators : Instrument Panel : Service and Repair" See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair 3. Remove the heater-A/C housing. 4. Place the heater-A/C housing on a bench, with the heater-A/C housing cover face down. Then proceed as follows: a. Remove the two screws that secure the heater-A/C housing cover to the top of the blower motor housing cover. b. If the vehicle is so equipped, unplug the two vacuum harness connectors from the recirculation air door actuator. c. Unplug the vacuum harness connector from the panel-defrost door actuator. d. Remove the floor duct as described in this group. Fig 52 Heater-A/C Housing Floor Outlet Screws e. Remove the two screws that secure the heater-A/C housing cover to the lower housing near the floor outlet. 5. Turn the heater-A/C housing over on the bench, with the heater-A/C housing cover face up. Then proceed as follows: a. Disengage the vacuum harness retainer from the hole near the left end of the heater-A/C housing cover. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Cover Removal and Installation > Page 6416 Fig 53 Blend-air Door Lever Removal/Installation b. Remove the vacuum harness from the molded clips on the heater-A/C housing cover. c. Remove the thirteen screws that secure the perimeter of the heater-A/C housing cover to the heater-A/C housing. d. Remove the nut that secures the blend-air door lever to the blend-air door pivot shaft and remove the lever. e. Carefully pry off the push nut that secures the heater-A/C housing cover to the heater-A/C housing post. Fig 54 Panel-defrost Door Lever Removal f. Using a trim stick or another suitable wide-bladed flat tool, gently pry the panel-defrost door pivot shaft. 6. Pull up on the heater-A/C housing cover around the perimeter to separate the cover sealant from the heater-A/C housing. 7. Remove the heater-A/C housing cover from the heater-A/C housing. INSTALLATION Fig 55 Heater-A/C Housing Cover Sealant Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Cover Removal and Installation > Page 6417 1. Before installing the heater-A/C housing cover, be certain that the heater-A/C housing cover sealant is in place and in good condition. 2. Position the heater-A/C housing cover on the heater-A/C housing. Be certain that all of the floor-defrost, panel-defrost, blend-air, and recirculation air (if the vehicle is so equipped) door pivots are properly positioned. 3. Install the push nut that secures the heater-A/C housing cover to the heater-A/C housing post. 4. Install the thirteen screws that secure the perimeter of the heater-A/C housing. Tighten the screws enough to seat the cover sealant to the housing. 5. Snap the panel-defrost door lever to the blend-air door pivot shaft and secure it to the shaft with the nut. 7. Install the vacuum harness retainer into the hole near the left end of the heater-A/C housing cover. 8. Route the vacuum harness through the molded clips on the heater-A/C housing cover. 9. Turn the heater-A/C housing cover face up. Then proceed as follows: a. Install the two screws that secure the heater-A/C housing cover to the lower housing near the floor outlet. Tighten the screws enough to seat the cover sealant to the housing. b. Install the floor duct as described in this group. c. Plug in the vacuum harness connector to the panel-defrost door actuator. d. If the vehicle is so equipped, plug in the two vacuum harness connectors to the recirculation air door actuator. e. Install the two screws that secure the heater-A/C housing cover to the top of the blower motor housing cover. Tighten the screws enough to seat the cover sealant to the housing. 10. Reinstall the heater-A/C housing. 11. Reinstall the instrument panel assembly. Refer to: "Instrument Panel, Gauges and Wiring Indicators : Instrument Panel : Service and Repair" See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair 12. Connect the negative battery cable. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Cover Removal and Installation > Page 6418 Housing Assembly HVAC: Service and Repair Heater - A/C Housing Removal and Installation Fig 49 Heater-A/C Housing Removal/Installation WARNING: On vehicles equipped with Air-Bags, failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel assembly. Refer to: "Body and Frame : Interior Moulding/Trim : Dashboard/Instrument Panel : Service and Repair" See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 3. If the vehicle is so equipped, recover the refrigerant from the refrigerant system. Refer to: "Heating and Air Conditioning : Service and Repair" See: Service and Repair 4. If the vehicle is so equipped, disconnect the liquid line and the accumulator from the evaporator tubes. Install plugs in, or tape over all of the open refrigerant fittings. 5. Drain the cooling system and disconnect the heater hoses from the heater core tubes. Refer to: "Engine, Cooling and Exhaust : Cooling System : Service and Repair" See: Engine, Cooling and Exhaust/Cooling System/Service and Repair 6. Remove the four nuts that secure the heater- A/C housing mounting studs on the engine compartment side of the dash panel. 7. Remove the nut that secures the heater-A/C housing mounting brace to the stud on the passenger compartment side of the dash panel. 8. Remove the heater-A/C housing from the vehicle. INSTALLATION 1. Position the heater-A/C housing to the dash panel. Be certain that the condensate drain tube is positioned in the dash panel drain hole. 2. Install the nut that secures the heater-A/C housing mounting brace to the stud on the passenger compartment side of the dash panel. Tighten the mounting brace nut to 11 N.m (95 in. lbs.). 3. Install the four nuts that secure the heater-A/C housing mounting studs on the engine compartment side of the dash panel. Tighten the heater-A/C mounting nuts to 7 N.m (60 in. lbs.). 4. Connect the heater hoses to the heater core tubes and fill the cooling system. 5. If the vehicle is so equipped, unplug or remove the tape from all of the open refrigerant fittings. Connect the liquid line and the accumulator to the evaporator tubes. 6. If the vehicle is so equipped, evacuate and charge the refrigerant system. 7. Reinstall the instrument panel assembly. 8. Connect the battery negative cable. 9. Start the vehicle and check for proper operation of the heating and air conditioning systems. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater-A/C Housing Cover Removal and Installation > Page 6419 Housing Assembly HVAC: Service and Repair Heater-A/C Housing Plenum Adapter Removal and Installation Fig 50 Heater-A/C Housing Plenum Adapter Removal/Installation WARNING: On vehicles equipped with Air-Bags, failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel assembly. Refer to: "Instrument Panel, Gauges and Wiring Indicators : Instrument Panel : Service and Repair" See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair 3. Remove the heater-A/C housing. 4. Remove the two screws that secure the heater-A/C housing plenum adapter to the plenum panel. 5. Remove the plenum adapter from the plenum panel. INSTALLATION 1. Position the heater-A/C housing plenum adapter to the plenum panel. Be certain that the snap features on each side of the adapter are fully engaged with the hole in the cowl plenum panel. This must be a water tight connection to prevent leaks. 2. Install the two screws that secure the plenum adapter to the plenum panel. Tighten the mounting screws to 3 N.m (24 in. lbs.). 3. Reinstall the heater-A/C housing. 4. Reinstall the instrument panel assembly. Refer to: "Instrument Panel, Gauges and Wiring Indicators : Instrument Panel : Service and Repair" See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair 5. Connect the battery negative cable. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Refrigerant Capacity 0.907 kg (32 oz) Refrigerant Oil Capacity - A/C System = 230 ml (7.75 oz) - Accumulator = 120 ml (4 oz) - Condenser = 30 ml (1 oz) - Evaporator = 60 ml (2 oz) - Compressor = Drain and measure the oil from the old compressor. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 6424 Refrigerant: Fluid Type Specifications Hydrofluorocarbon (HFC), ................................................................................................................... ............................................... R-134a liquefied gas Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 6425 Refrigerant: Description and Operation REFRIGERANT The R-134a refrigerant used in this air conditioning system is a non-toxic, non-flammable, clear, and colorless liquefied gas. R-134a refrigerant is not compatible with R-12 refrigerant in an air conditioning system. Even a small amount of R-12 added to a R-134a refrigerant system, will cause compressor failure, refrigerant oil sludge, or poor air conditioning system performance. The refrigerant system service ports have been designed to ensure that the system is not accidentally filled with the wrong refrigerant (R-12). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Total System ........................................................................................................................................ ........................................................... 230 ml 7.75 oz. Accumulator ......................................................................................................................................... ............................................................ 120 ml 4.0 oz. Condenser ........................................................................................................................................... ................................................................ 30 ml 1.0 oz. Evaporator ........................................................................................................................................... ............................................................... 60 ml 2.0 oz. Compressor ............................................................................................................................................. Drain and measure the oil from the old compressor Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 6430 Refrigerant Oil: Fluid Type Specifications Synthetic-based, Polyalkylene Glycol .................................................................................................. ......................................................................... SP-20 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 6431 Refrigerant Oil: Service and Repair Refrigerant Oil Capacities Refrigerant Oil Level When an air conditioning system is assembled at the factory, all components (except the compressor are refrigerant oil free. After the system has been charged and operated, the oil in the compressor is dispersed throughout the refrigerant system. The accumulator, evaporator, condenser, and compressor will each retain a significant amount of oil. It is important to have the correct amount of oil in the refrigerant system. This will ensure proper lubrication of the compressor. Too little oil will result in damage to the compressor. Too much oil will reduce the cooling capacity of the system. It will not be necessary to check the oil level in the compressor or to add oil, unless there has been an oil loss. This may be due to a rupture or leak from a refrigerant line, a compressor shaft seal, an evaporator, or a condenser. If a rupture occurs, add 30 ml (1 ounce) of oil to the system after the repair has been made. Oil loss at a leak point will be evident by the presence of a wet, shiny surface around the leak. Refrigerant oil must be added when a accumulator, evaporator, or condenser are replaced. See the Refrigerant Oil Capacities chart. When a compressor is replaced, the oil must be drained from the old compressor and measured. Drain all the oil from the new compressor, then fill the new compressor with the same amount of oil that was drained out of the old compressor. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations High Pressure Sensor / Switch: Locations Fig 25 High Pressure Cut-off Switch -- Typical HIGH PRESSURE CUT-OFF SWITCH The high pressure cut-off switch is located on the discharge line near the compressor. Fig 29 Low Pressure Cycling Clutch Switch Removal/Installation LOW PRESSURE CYCLING CLUTCH SWITCH The low pressure cycling clutch switch is mounted on the accumulator. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 6436 High Pressure Sensor / Switch: Description and Operation Fig 25 High Pressure Cut-off Switch -- Typical HIGH PRESSURE CUT-OFF SWITCH The high pressure cut-off switch is located on the discharge line near the compressor. This switch is connected in series between the low pressure clutch cycling switch and the Powertrain Control Module (PCM). This switch prevents compressor operation when the discharge line pressure approaches high levels. When the discharge line pressure rises above 3100 to 3375 kPa (450 to 490 psi) the switch contacts open and interrupt the A/C request signal circuit to the PCM. The PCM responds by de-energizing the compressor clutch relay, which will cause the compressor clutch to disengage. The switch will close again when the pressure drops to 1860 to 2275 kPa (270 to 330 psi). The high pressure cut-off switch is a factory-calibrated unit. The switch cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Fig 29 Low Pressure Cycling Clutch Switch Removal/Installation LOW PRESSURE CYCLING CLUTCH SWITCH The low pressure cycling clutch switch is mounted on top of the accumulator. The switch is connected in series with the high pressure cut-off switch in the A/C request signal circuit, between the heater-A/C mode control switch and the Powertrain Control Module (PCM). The switch contacts open and close causing the PCM to turn the compressor clutch on and off. This regulates the system pressure and controls evaporator temperature. Controlling evaporator temperature prevents condensate water on the evaporator fins from freezing and obstructing air conditioning system air flow. The switch contacts are normally open when the suction pressure is approximately 172 kPa (25 psi) or lower. The switch will close when the suction pressure rises to approximately 296 kPa (43 psi) or above. Lower ambient temperatures, below approximately -1~C (30~F) during cold weather, will also open the switch contacts. This is due to the pressure/temperature relationship of the refrigerant in the system. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 6437 The low pressure cycling clutch switch is a factory-calibrated unit. This switch cannot be adjusted or repaired. If faulty or damaged, the switch must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 6438 High Pressure Sensor / Switch: Testing and Inspection Fig 25 High Pressure Cut-off Switch -- Typical HIGH PRESSURE CUT-OFF SWITCH 1. Verify that the refrigerant system is properly charged. 2. Unplug the high pressure switch wire harness connector and test for continuity between the switch terminals. There should be continuity If OK, refer to the wiring diagrams and repair the circuits as required. If not OK, replace the faulty switch. Fig 29 Low Pressure Cycling Clutch Switch Removal/Installation NOTE: Verify that the refrigerant system has the correct refrigerant charge. LOW PRESSURE CYCLING CLUTCH SWITCH 1. Unplug the low pressure cycling clutch switch wire harness connector from the switch on the accumulator, and install a jumper wire between the two connector cavities. 2. Connect a manifold gauge set to the refrigerant system service ports. 3. Place the heater-A/C mode control switch knob in any A/C position and start the engine. 4. Check the continuity between the two terminals of the low pressure switch. There should be continuity with a suction pressure reading of 296 kPa (43 psi) or above, and no continuity with a suction pressure reading of 172 kPa (25 psi) or below. If OK, test and repair the compressor clutch control circuit as required. If not OK, replace the faulty switch. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 6439 High Pressure Sensor / Switch: Service and Repair Fig 25 High Pressure Cut-off Switch -- Typical HIGH PRESSURE CUT-OFF SWITCH Removal 1. Disconnect and isolate the battery negative cable. 2. Unplug the wire harness connector from the switch. 3. Unscrew the switch from the discharge line fitting. Installation 1. Install and tighten the switch. 2. Unplug the wire harness connector into the switch. 3. Connect the battery negative cable. Fig 29 Low Pressure Cycling Clutch Switch Removal/Installation LOW PRESSURE CYCLING CLUTCH SWITCH 1. Disconnect and isolate the battery negative cable. 2. Unplug the wire harness connector from the low pressure cycling clutch switch near the top of the accumulator. 3. Unscrew the switch from the fitting on the accumulator. 4. Reverse the removal procedures to install. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations Low Pressure Sensor / Switch: Locations Fig 25 High Pressure Cut-off Switch -- Typical HIGH PRESSURE CUT-OFF SWITCH The high pressure cut-off switch is located on the discharge line near the compressor. Fig 29 Low Pressure Cycling Clutch Switch Removal/Installation LOW PRESSURE CYCLING CLUTCH SWITCH The low pressure cycling clutch switch is mounted on the accumulator. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 6443 Low Pressure Sensor / Switch: Description and Operation Fig 25 High Pressure Cut-off Switch -- Typical HIGH PRESSURE CUT-OFF SWITCH The high pressure cut-off switch is located on the discharge line near the compressor. This switch is connected in series between the low pressure clutch cycling switch and the Powertrain Control Module (PCM). This switch prevents compressor operation when the discharge line pressure approaches high levels. When the discharge line pressure rises above 3100 to 3375 kPa (450 to 490 psi) the switch contacts open and interrupt the A/C request signal circuit to the PCM. The PCM responds by de-energizing the compressor clutch relay, which will cause the compressor clutch to disengage. The switch will close again when the pressure drops to 1860 to 2275 kPa (270 to 330 psi). The high pressure cut-off switch is a factory-calibrated unit. The switch cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Fig 29 Low Pressure Cycling Clutch Switch Removal/Installation LOW PRESSURE CYCLING CLUTCH SWITCH The low pressure cycling clutch switch is mounted on top of the accumulator. The switch is connected in series with the high pressure cut-off switch in the A/C request signal circuit, between the heater-A/C mode control switch and the Powertrain Control Module (PCM). The switch contacts open and close causing the PCM to turn the compressor clutch on and off. This regulates the system pressure and controls evaporator temperature. Controlling evaporator temperature prevents condensate water on the evaporator fins from freezing and obstructing air conditioning system air flow. The switch contacts are normally open when the suction pressure is approximately 172 kPa (25 psi) or lower. The switch will close when the suction pressure rises to approximately 296 kPa (43 psi) or above. Lower ambient temperatures, below approximately -1~C (30~F) during cold weather, will also open the switch contacts. This is due to the pressure/temperature relationship of the refrigerant in the system. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 6444 The low pressure cycling clutch switch is a factory-calibrated unit. This switch cannot be adjusted or repaired. If faulty or damaged, the switch must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 6445 Low Pressure Sensor / Switch: Testing and Inspection Fig 25 High Pressure Cut-off Switch -- Typical HIGH PRESSURE CUT-OFF SWITCH 1. Verify that the refrigerant system is properly charged. 2. Unplug the high pressure switch wire harness connector and test for continuity between the switch terminals. There should be continuity If OK, refer to the wiring diagrams and repair the circuits as required. If not OK, replace the faulty switch. Fig 29 Low Pressure Cycling Clutch Switch Removal/Installation NOTE: Verify that the refrigerant system has the correct refrigerant charge. LOW PRESSURE CYCLING CLUTCH SWITCH 1. Unplug the low pressure cycling clutch switch wire harness connector from the switch on the accumulator, and install a jumper wire between the two connector cavities. 2. Connect a manifold gauge set to the refrigerant system service ports. 3. Place the heater-A/C mode control switch knob in any A/C position and start the engine. 4. Check the continuity between the two terminals of the low pressure switch. There should be continuity with a suction pressure reading of 296 kPa (43 psi) or above, and no continuity with a suction pressure reading of 172 kPa (25 psi) or below. If OK, test and repair the compressor clutch control circuit as required. If not OK, replace the faulty switch. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 6446 Low Pressure Sensor / Switch: Service and Repair Fig 25 High Pressure Cut-off Switch -- Typical HIGH PRESSURE CUT-OFF SWITCH Removal 1. Disconnect and isolate the battery negative cable. 2. Unplug the wire harness connector from the switch. 3. Unscrew the switch from the discharge line fitting. Installation 1. Install and tighten the switch. 2. Unplug the wire harness connector into the switch. 3. Connect the battery negative cable. Fig 29 Low Pressure Cycling Clutch Switch Removal/Installation LOW PRESSURE CYCLING CLUTCH SWITCH 1. Disconnect and isolate the battery negative cable. 2. Unplug the wire harness connector from the low pressure cycling clutch switch near the top of the accumulator. 3. Unscrew the switch from the fitting on the accumulator. 4. Reverse the removal procedures to install. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations Blower Motor Relay: Locations Fig 40 Power Distribution Center The blower motor relay is located in the PDC in the engine compartment. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 6451 Blower Motor Relay: Description and Operation Blower Motor Relay Fig 40 Power Distribution Center The blower motor relay is a International Standards Organization (ISO)-type relay. The relay is a electromechanical device that switches battery current from a fuse in the Power Distribution Center (PDC) to the blower motor, whenever the ignition switch is in the On position. This arrangement reduces the amount of battery current that must flow through the ignition switch. When the ignition switch is in the On position, the relay is energized by a fused battery feed signal to the relay coil. The relay control circuit is protected by a fuse located in the junction block. When the relay is de-energized, the blower motor receives no battery feed. See the Diagnosis and Testing section of this group for more information on the operation of the relay. The blower motor relay is located in the PDC in the engine compartment. The relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 6452 Blower Motor Relay: Testing and Inspection Blower Motor Relay Fig 40 Power Distribution Center RELAY TEST Remove the blower motor relay from its wire harness connector as described to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK. go to Step 2. If not OK, replace the faulty relay 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 +/- 5 ohms. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, see the Relay Circuit Test procedure. If not OK, replace the faulty relay. RELAY CIRCUIT TEST 1. The relay common feed terminal cavity (30) is connected to battery voltage and should be hot at all times. If OK, go to Step 2. If not OK, repair the open circuit to the fuse in the PDC as required. 2. The relay normally closed terminal cavity (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3. 3. The relay normally open terminal cavity (87) is connected to the blower motor. When the relay is energized, terminal 87 is connected to terminal 30 and provides full battery current to the blower motor. There should be continuity between this cavity and the blower motor relay output circuit cavity of the blower motor wire harness connector at all times. If OK, go to Step 4. If not OK, repair the open circuit to the blower motor as required. 4. The coil battery terminal cavity (86) is connected to the electromagnet in the relay It is energized when the ignition switch is in the On position. Check for battery voltage at the cavity for relay terminal 86 with the ignition switch in the On position. If OK, go to Step 5. If not OK, repair the open circuit to the ignition switch through the fuse in the junction block as required. 5. The coil ground terminal cavity (85) is connected to ground. This terminal supplies the ground for the relay electromagnetic coil. There should be continuity between the cavity for relay terminal 85 and a good ground at all times. If not OK, repair the open circuit as required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 6453 Blower Motor Relay: Service and Repair Fig 40 Power Distribution Center 1. Disconnect and isolate the battery negative cable. 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC for blower motor relay identification and location. 4. Unplug the blower motor clutch relay from the PDC. 5. Install the blower motor relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 6. Install the PDC cover. 7. Connect the battery negative cable. 8. Test the relay operation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Component Locations Compressor Clutch Relay: Component Locations Power Distribution Center Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Component Locations > Page 6458 Power Distribution Fig 27 Power Distribution Center Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Component Locations > Page 6459 Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 6460 Compressor Clutch Relay: Description and Operation Fig 27 Power Distribution Center The compressor clutch relay is a International Standards Organization (ISO) micro-relay The terminal designations and functions are the same as a conventional ISO relay However, the micro-relay terminal orientation (footprint) is different, the current capacity is lower and the relay case dimensions are smaller than on the conventional ISO relay. The compressor clutch relay is a electromechanical device that switches current to the compressor clutch coil when the Powertrain Control Module (PCM) grounds the coil side of the relay The PCM responds to inputs from the heater-A/C mode control switch, the low pressure cycling clutch switch, and the high pressure cut-off switch. The compressor clutch relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the PDC label for relay identification and location. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 6461 Compressor Clutch Relay: Testing and Inspection Compressor Clutch Relay RELAY TEST The compressor clutch relay is located in the Power Distribution Center (PDC). Refer to the PDC label for relay identification and location. Remove the relay from the PDC to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2. If not OK, replace the faulty relay. 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 +/-5 ohms. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, SEE the Relay Circuit Test. If not OK, replace the faulty relay. RELAY CIRCUIT TEST 1. The relay common feed terminal cavity (30) is connected to fused battery feed. There should be battery voltage at the cavity for relay terminal 30 at all times. If OK, go to Step 2. If not OK, repair the open circuit to the 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 Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 6462 Compressor Clutch Relay: Service and Repair Fig 27 Power Distribution Center 1. Disconnect and isolate the battery negative cable. 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC for compressor clutch relay identification and location. 4. Unplug the compressor clutch relay from the PDC. 5. Install the compressor clutch relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 6. Install the PDC cover. 7. Connect the battery negative cable. 8. Test the relay operation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Description and Operation Ambient Temperature Sensor / Switch HVAC: Description and Operation CIRCUIT OPERATION The ambient temperature sensor is a variable resistor. Circuit G31 supplies voltage from the overhead console to the sensor. Circuit G32 is the signal return from the sensor to the overhead console. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Description and Operation > Page 6467 Ambient Temperature Sensor / Switch HVAC: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Ambient Temperature Sensor Remove/Install 2. Locate the ambient temperature sensor, on the radiator yoke behind the grille. 3. Unplug the sensor wire harness connector. 4. Remove the screw that secures the ambient temperature sensor to the radiator yoke. 5. Remove the ambient temperature sensor. 6. Reverse the removal procedures to install. Tighten the ambient temperature sensor mounting screw to 5.6 N.m (50 in lbs.). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Description and Operation Blower Motor Switch: Description and Operation The heater-only or heater-A/C blower motor is controlled by a rotary switch mounted in the heater-A/C control panel. The switch allows for the selection of four blower motor speeds and an Off position, but will only operate with the ignition switch in the On position, and the heater-A/C mode control switch in any position except Off. The blower motor switch is connected in series with the blower motor ground path through the heater-A/C mode control switch. The blower motor switch directs this ground path to the blower motor through the blower motor resistor wires, or directly to the blower motor, as required to achieve the selected blower motor speed. The blower motor switch cannot be repaired and, if faulty or damaged, it must be replaced. The switch is serviced only as a part of the heater-only or heater-A/C control assembly. The blower motor switch knob is serviced separately. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Description and Operation > Page 6471 Blower Motor Switch: Testing and Inspection The blower motor switch is only serviced as a part of the heater-only or heater-A/C control assembly. 1. Turn the ignition switch to the Off position. Remove the heater-A/C control from the instrument panel. Check for continuity between the ground circuit cavity of the control wire harness connector and a good ground. There should be continuity. If OK, go to Step 2. If not OK, repair the open circuit to ground as required. 2. With the heater-A/C control wire harness connector unplugged, place the mode control switch knob in any position except the Off position. Check for continuity between the ground circuit terminal and each of the blower motor driver circuit terminals of the control as you move the blower switch to each of the four speed positions. There should be continuity at each driver circuit terminal in only one blower motor switch speed position. If OK, test and repair the blower driver circuits between the control connector and the blower motor resistor as required. If not OK, replace the faulty heater-A/C control unit. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations High Pressure Sensor / Switch: Locations Fig 25 High Pressure Cut-off Switch -- Typical HIGH PRESSURE CUT-OFF SWITCH The high pressure cut-off switch is located on the discharge line near the compressor. Fig 29 Low Pressure Cycling Clutch Switch Removal/Installation LOW PRESSURE CYCLING CLUTCH SWITCH The low pressure cycling clutch switch is mounted on the accumulator. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 6476 High Pressure Sensor / Switch: Description and Operation Fig 25 High Pressure Cut-off Switch -- Typical HIGH PRESSURE CUT-OFF SWITCH The high pressure cut-off switch is located on the discharge line near the compressor. This switch is connected in series between the low pressure clutch cycling switch and the Powertrain Control Module (PCM). This switch prevents compressor operation when the discharge line pressure approaches high levels. When the discharge line pressure rises above 3100 to 3375 kPa (450 to 490 psi) the switch contacts open and interrupt the A/C request signal circuit to the PCM. The PCM responds by de-energizing the compressor clutch relay, which will cause the compressor clutch to disengage. The switch will close again when the pressure drops to 1860 to 2275 kPa (270 to 330 psi). The high pressure cut-off switch is a factory-calibrated unit. The switch cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Fig 29 Low Pressure Cycling Clutch Switch Removal/Installation LOW PRESSURE CYCLING CLUTCH SWITCH The low pressure cycling clutch switch is mounted on top of the accumulator. The switch is connected in series with the high pressure cut-off switch in the A/C request signal circuit, between the heater-A/C mode control switch and the Powertrain Control Module (PCM). The switch contacts open and close causing the PCM to turn the compressor clutch on and off. This regulates the system pressure and controls evaporator temperature. Controlling evaporator temperature prevents condensate water on the evaporator fins from freezing and obstructing air conditioning system air flow. The switch contacts are normally open when the suction pressure is approximately 172 kPa (25 psi) or lower. The switch will close when the suction pressure rises to approximately 296 kPa (43 psi) or above. Lower ambient temperatures, below approximately -1~C (30~F) during cold weather, will also open the switch contacts. This is due to the pressure/temperature relationship of the refrigerant in the system. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 6477 The low pressure cycling clutch switch is a factory-calibrated unit. This switch cannot be adjusted or repaired. If faulty or damaged, the switch must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 6478 High Pressure Sensor / Switch: Testing and Inspection Fig 25 High Pressure Cut-off Switch -- Typical HIGH PRESSURE CUT-OFF SWITCH 1. Verify that the refrigerant system is properly charged. 2. Unplug the high pressure switch wire harness connector and test for continuity between the switch terminals. There should be continuity If OK, refer to the wiring diagrams and repair the circuits as required. If not OK, replace the faulty switch. Fig 29 Low Pressure Cycling Clutch Switch Removal/Installation NOTE: Verify that the refrigerant system has the correct refrigerant charge. LOW PRESSURE CYCLING CLUTCH SWITCH 1. Unplug the low pressure cycling clutch switch wire harness connector from the switch on the accumulator, and install a jumper wire between the two connector cavities. 2. Connect a manifold gauge set to the refrigerant system service ports. 3. Place the heater-A/C mode control switch knob in any A/C position and start the engine. 4. Check the continuity between the two terminals of the low pressure switch. There should be continuity with a suction pressure reading of 296 kPa (43 psi) or above, and no continuity with a suction pressure reading of 172 kPa (25 psi) or below. If OK, test and repair the compressor clutch control circuit as required. If not OK, replace the faulty switch. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 6479 High Pressure Sensor / Switch: Service and Repair Fig 25 High Pressure Cut-off Switch -- Typical HIGH PRESSURE CUT-OFF SWITCH Removal 1. Disconnect and isolate the battery negative cable. 2. Unplug the wire harness connector from the switch. 3. Unscrew the switch from the discharge line fitting. Installation 1. Install and tighten the switch. 2. Unplug the wire harness connector into the switch. 3. Connect the battery negative cable. Fig 29 Low Pressure Cycling Clutch Switch Removal/Installation LOW PRESSURE CYCLING CLUTCH SWITCH 1. Disconnect and isolate the battery negative cable. 2. Unplug the wire harness connector from the low pressure cycling clutch switch near the top of the accumulator. 3. Unscrew the switch from the fitting on the accumulator. 4. Reverse the removal procedures to install. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations Low Pressure Sensor / Switch: Locations Fig 25 High Pressure Cut-off Switch -- Typical HIGH PRESSURE CUT-OFF SWITCH The high pressure cut-off switch is located on the discharge line near the compressor. Fig 29 Low Pressure Cycling Clutch Switch Removal/Installation LOW PRESSURE CYCLING CLUTCH SWITCH The low pressure cycling clutch switch is mounted on the accumulator. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 6483 Low Pressure Sensor / Switch: Description and Operation Fig 25 High Pressure Cut-off Switch -- Typical HIGH PRESSURE CUT-OFF SWITCH The high pressure cut-off switch is located on the discharge line near the compressor. This switch is connected in series between the low pressure clutch cycling switch and the Powertrain Control Module (PCM). This switch prevents compressor operation when the discharge line pressure approaches high levels. When the discharge line pressure rises above 3100 to 3375 kPa (450 to 490 psi) the switch contacts open and interrupt the A/C request signal circuit to the PCM. The PCM responds by de-energizing the compressor clutch relay, which will cause the compressor clutch to disengage. The switch will close again when the pressure drops to 1860 to 2275 kPa (270 to 330 psi). The high pressure cut-off switch is a factory-calibrated unit. The switch cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Fig 29 Low Pressure Cycling Clutch Switch Removal/Installation LOW PRESSURE CYCLING CLUTCH SWITCH The low pressure cycling clutch switch is mounted on top of the accumulator. The switch is connected in series with the high pressure cut-off switch in the A/C request signal circuit, between the heater-A/C mode control switch and the Powertrain Control Module (PCM). The switch contacts open and close causing the PCM to turn the compressor clutch on and off. This regulates the system pressure and controls evaporator temperature. Controlling evaporator temperature prevents condensate water on the evaporator fins from freezing and obstructing air conditioning system air flow. The switch contacts are normally open when the suction pressure is approximately 172 kPa (25 psi) or lower. The switch will close when the suction pressure rises to approximately 296 kPa (43 psi) or above. Lower ambient temperatures, below approximately -1~C (30~F) during cold weather, will also open the switch contacts. This is due to the pressure/temperature relationship of the refrigerant in the system. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 6484 The low pressure cycling clutch switch is a factory-calibrated unit. This switch cannot be adjusted or repaired. If faulty or damaged, the switch must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 6485 Low Pressure Sensor / Switch: Testing and Inspection Fig 25 High Pressure Cut-off Switch -- Typical HIGH PRESSURE CUT-OFF SWITCH 1. Verify that the refrigerant system is properly charged. 2. Unplug the high pressure switch wire harness connector and test for continuity between the switch terminals. There should be continuity If OK, refer to the wiring diagrams and repair the circuits as required. If not OK, replace the faulty switch. Fig 29 Low Pressure Cycling Clutch Switch Removal/Installation NOTE: Verify that the refrigerant system has the correct refrigerant charge. LOW PRESSURE CYCLING CLUTCH SWITCH 1. Unplug the low pressure cycling clutch switch wire harness connector from the switch on the accumulator, and install a jumper wire between the two connector cavities. 2. Connect a manifold gauge set to the refrigerant system service ports. 3. Place the heater-A/C mode control switch knob in any A/C position and start the engine. 4. Check the continuity between the two terminals of the low pressure switch. There should be continuity with a suction pressure reading of 296 kPa (43 psi) or above, and no continuity with a suction pressure reading of 172 kPa (25 psi) or below. If OK, test and repair the compressor clutch control circuit as required. If not OK, replace the faulty switch. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 6486 Low Pressure Sensor / Switch: Service and Repair Fig 25 High Pressure Cut-off Switch -- Typical HIGH PRESSURE CUT-OFF SWITCH Removal 1. Disconnect and isolate the battery negative cable. 2. Unplug the wire harness connector from the switch. 3. Unscrew the switch from the discharge line fitting. Installation 1. Install and tighten the switch. 2. Unplug the wire harness connector into the switch. 3. Connect the battery negative cable. Fig 29 Low Pressure Cycling Clutch Switch Removal/Installation LOW PRESSURE CYCLING CLUTCH SWITCH 1. Disconnect and isolate the battery negative cable. 2. Unplug the wire harness connector from the low pressure cycling clutch switch near the top of the accumulator. 3. Unscrew the switch from the fitting on the accumulator. 4. Reverse the removal procedures to install. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Description and Operation Service Port HVAC: Description and Operation The refrigerant system service ports are used to charge,recover/recycle, evacuate, and test the air conditioning refrigerant system. Unique service port fitting sizes are used on the R-134a system, to ensure that the refrigerant system is not accidentally contaminated by the use of the wrong refrigerant (R-12), or refrigerant system service equipment. The high pressure service port is located on the compressor manifold or plumbing, near the front of the engine compartment. The low pressure service port is located on the suction line, near the front of the engine compartment. After servicing the refrigerant system, always reinstall the service port caps. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Vacuum Check Valve HVAC > Component Information > Locations Fig 33 Vacuum Supply Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Vacuum Check Valve HVAC > Component Information > Locations > Page 6493 Vacuum Check Valve HVAC: Description and Operation Fig 33 Vacuum Supply A one-way vacuum check valve is installed in the accessory vacuum supply line near the vacuum fitting on the power brake booster. This check valve helps to maintain the system vacuum needed to retain the selected heater-A/C mode settings by preventing the engine from bleeding down system vacuum through the intake manifold during extended heavy engine load (low engine vacuum) operation. The vacuum check valve cannot be repaired and, if faulty, it must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Vacuum Check Valve HVAC > Component Information > Locations > Page 6494 Vacuum Check Valve HVAC: Service and Repair Fig 33 Vacuum Supply 1. Unplug the vacuum supply line at the power brake booster. 2. Note the orientation of the check valve in the vacuum supply line for correct reinstallation. 3. Unplug the vacuum check valve from the vacuum supply line fittings. 4. Reverse the removal procedures to install. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Description and Operation Vacuum Reservoir HVAC: Description and Operation The vacuum reservoir is mounted to the underside of the cowl plenum cover/grille panel in the right cowl plenum area. Vacuum stored in the reservoir is used to operate the vacuum-controlled vehicle accessories during periods of low engine vacuum, such as when the vehicle is climbing a steep grade or under other high engine load operating conditions. The vacuum reservoir cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Description and Operation > Page 6498 Vacuum Reservoir HVAC: Service and Repair Fig 34 Cowl Plenum Cover/Grille Panel Weatherstrip 1. Disconnect and isolate the battery negative cable. 2. Remove the windshield wiper arms as described in Wiper and Washer Systems. 3. Remove the weatherstrip along the front edge of cowl plenum cover/grille panel and the cowl plenum panel. Fig 35 Cowl Plenum Cover/Grille Panel Removal/Installation 4. Remove the four plastic nuts that secure the cowl plenum cover/grille panel to the studs on the cowl top panel near the base of the windshield. 5. Remove the two plastic rivets that secure each side of the cowl plenum cover/grille panel to the cowl plenum panel and the cowl top panel. 6. Lift the cowl plenum cover/grille panel from the vehicle far enough to access the windshield washer and vacuum plumbing near the right end of the cowl plenum. 7. Disconnect the windshield washer supply hose at the in-line connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Description and Operation > Page 6499 Fig 36 Vacuum Reservoir 8. Disconnect the vacuum supply hose from the vacuum reservoir, which is secured under the right end of the cowl plenum cover/grille panel. 9. Remove the cowl plenum cover/grille panel from the vehicle. 10. Remove the three screws that secure the reservoir to the right side of the cowl plenum cover/ grille panel. 11. Remove the vacuum reservoir. 12. Reverse the removal procedures to install. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Arming and Disarming The airbag system is a sensitive, complex electromechanical unit. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components you must first disconnect and isolate the battery negative (ground) cable. Then wait two minutes for the system capacitor to discharge before further system service. This is the only sure way to disable the airbag system. Failure to do this could result in accidental air-bag deployment and possible personal injury. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Recalls: > NHTSA97V080000 > May > 97 > Recall 97V080000: Unexpected Air Bag Deployment Air Bag: Recalls Recall 97V080000: Unexpected Air Bag Deployment The electrical circuit design allows the potential for an inadvertent air bag deployment upon vehicle ignition shut down. Unexpected air bag deployment can result in occupant injury. Dealers will replace the air bag electronic control module with a newly designed module. Owner notification began during July 1997. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chrysler at 1-800-853-1403. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-800-424-9393. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag: > 19-009-01 > Oct > 01 > Driver Airbag - Trim Cover Service Air Bag: All Technical Service Bulletins Driver Airbag - Trim Cover Service NUMBER: 19-009-01 GROUP: Steering DATE: Oct. 26, 2001 SUBJECT: Driver Airbag Trim Cover Service MODELS: 1999 - 2002 (AB) Ram Van 1997 - 2002 (AN) Dakota 1997 - 2002 (BE/BR) Ram Truck 1998 - 2002 (DN) Durango 2002 (DR) Ram Truck 2001 - 2002 (JR) Sebring/Sebring Convertible/Stratus 1998 - 2002 (LH) LHS/300M/Concorde/Intrepid 2001 (PT) Chrysler PT Cruiser 2001 - 2002 (RG) Chrysler Voyager (International Markets) 2001 - 2002 (RS) Town & Country/Voyager/Caravan 2000 - 2001 (R1) Dakota (International Markets) 1997 - 2002 (TJ) Wrangler 2001 - 2002 (WG) Grand Cherokee (International Markets) 1999 - 2002 (WJ) Grand Cherokee 1997 - 2002 (XJ) Cherokee 1997 - 1998 (ZG) Grand Cherokee (International Markets) 1997 - 1998 (ZJ) Grand Cherokee DISCUSSION: Driver airbag trim covers/horn switches for the above vehicles are serviceable and as such, when applicable, must be used instead of replacing the airbag module assembly. Airbag module assemblies returned for trim cover and serviceable horn switch issues, are subject to charge back. In most cases, the service manuals show driver airbag replacement procedures in the Restraints section of Group 8. Several MOPAR driver airbag cover packages include instruction sheets. Because of the long list of part numbers involved they are not listed here, please consult the MOPAR parts catalog for the correct part number(s). WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag: > 19-009-01 > Oct > 01 > Driver Airbag - Trim Cover Service > Page 6518 WARNING: THE HORN SWITCH IS INTEGRAL TO THE DRIVER AIRBAG UNIT. ONLY DAIMLERCHRYSLER-TRAINED AND AUTHORIZED DEALER SERVICE TECHNICIANS SHOULD PERFORM SERVICE OF THIS UNIT. FAILURE TO TAKE THE PROPER PRECAUTIONS OR TO FOLLOW THE PROPER PROCEDURES COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES. WARNING: USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE DRIVER AIRBAG, OR BECOMING ENTRAPPED BETWEEN THE DRIVER AIRBAG CUSHION AND THE DRIVER AIRBAG TRIM COVER. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. WARNING: THE DRIVER AIRBAG TRIM COVER MUST NEVER BE PAINTED. REPLACEMENT TRIM COVERS ARE SERVICED IN THE ORIGINAL COLORS. PAINT MAY CHANGE THE WAY IN WHICH THE MATERIAL OF THE TRIM COVER RESPONDS TO AN AIRBAG DEPLOYMENT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. The following can be used for all airbag trim cover replacements: TIME ALLOWANCE: FAILURE CODE: POLICY: Reimbursable within the provisions of the warranty. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag: > 08-010-01 > May > 01 > Airbag/Clock Spring - Service Air Bag: All Technical Service Bulletins Airbag/Clock Spring - Service NUMBER: 08-010-01 GROUP: Electrical DATE: May 25, 2001 SUBJECT: Airbag/Clock Spring Service MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2002 (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1988 - 1993 (AG) Daytona 1988 - 1995 (AJ) Lebaron Coupe/Convertible 1990 (AL) Horizon/Omni 1988 - 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1994 - 2002 (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2002 (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - 2002 (DN) Durango 2002 (DR) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2002 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 (KJ) Liberty 1993 - 2002 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2002 (PL) Neon 1997 - 2002 (PR) Prowler 2002 (PG) PT Cruiser (International Markets) 2001 - 2002 (PT) PT Cruiser 2001 - 2002 (RG) Chrysler Voyager (International Markets) 2001 - 2002 (RS) Town & Country/Caravan/Voyager 1996 - 2002 (SR) Viper 2001 - 2002 (ST) Sebring Coupe/Stratus Coupe 1997 - 2002 (TJ) Wrangler 2001 - 2002 (WG) Grand Cherokee (International Markets) 1999 - 2002 (WJ) Grand Cherokee 1995 - 2001 (XJ) Cherokee 1995 - 1998 (ZG) Grand Cherokee (International Markets) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Airbag When servicing any airbag system, it is essential to follow the proper Service Manual and/or Diagnostic Manual procedures for diagnosing, testing, and replacing of any component. When diagnosing any airbag squib circuit Diagnostic Trouble Code (DTC) with a DRBIII(R), the use of the Airbag Load Tool (Special Tool 8310 and 8443) is required. The Airbag Load Tool, used in conjunction with the DRBIII(R) are used to isolate and test components and wiring for failure. Only replace the component or wiring that has failed. This will reduce unnecessary cost to the customer or DaimlerChrysler. NOTE: AIRBAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN ANOTHER COMPONENT HAS FAILED. USE OF THE DRBIII(R) AND AIRBAG LOAD TOOL WILL DETERMINE IF THE AIRBAG HAS FAILED AND REPLACEMENT IS NEEDED. NOTE: Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag: > 08-010-01 > May > 01 > Airbag/Clock Spring - Service > Page 6523 TECHNICIANS SHOULD RECORD ALL STORED AND ACTIVE AIRBAG SYSTEM FAULT CODES ON THE REPAIR ORDER. Clock Springs Recent analysis of returned clock springs have indicated that prior service may have contributed to the clock spring's failure. ^ Do not use silicone or any other lubricant spray on or near the clock spring. Lubricants are often used in the clock spring area of the steering column to eliminate noise. Lubricants may have an adverse effect on the clock spring. ^ Clock spring centering. Any repair that may disrupt the positioning of the steering wheel with the front wheels will require that the clock spring be centered. This includes clock spring replacement, steering column service, HVAC service, steering gear service, and front suspension crossmember service. Refer to the appropriate Service Manual for the clock spring centering procedure. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag: > NHTSA97V080000 > May > 97 > Recall 97V080000: Unexpected Air Bag Deployment Air Bag: All Technical Service Bulletins Recall 97V080000: Unexpected Air Bag Deployment The electrical circuit design allows the potential for an inadvertent air bag deployment upon vehicle ignition shut down. Unexpected air bag deployment can result in occupant injury. Dealers will replace the air bag electronic control module with a newly designed module. Owner notification began during July 1997. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chrysler at 1-800-853-1403. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-800-424-9393. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag: > 19-009-01 > Oct > 01 > Driver Airbag - Trim Cover Service Air Bag: All Technical Service Bulletins Driver Airbag - Trim Cover Service NUMBER: 19-009-01 GROUP: Steering DATE: Oct. 26, 2001 SUBJECT: Driver Airbag Trim Cover Service MODELS: 1999 - 2002 (AB) Ram Van 1997 - 2002 (AN) Dakota 1997 - 2002 (BE/BR) Ram Truck 1998 - 2002 (DN) Durango 2002 (DR) Ram Truck 2001 - 2002 (JR) Sebring/Sebring Convertible/Stratus 1998 - 2002 (LH) LHS/300M/Concorde/Intrepid 2001 (PT) Chrysler PT Cruiser 2001 - 2002 (RG) Chrysler Voyager (International Markets) 2001 - 2002 (RS) Town & Country/Voyager/Caravan 2000 - 2001 (R1) Dakota (International Markets) 1997 - 2002 (TJ) Wrangler 2001 - 2002 (WG) Grand Cherokee (International Markets) 1999 - 2002 (WJ) Grand Cherokee 1997 - 2002 (XJ) Cherokee 1997 - 1998 (ZG) Grand Cherokee (International Markets) 1997 - 1998 (ZJ) Grand Cherokee DISCUSSION: Driver airbag trim covers/horn switches for the above vehicles are serviceable and as such, when applicable, must be used instead of replacing the airbag module assembly. Airbag module assemblies returned for trim cover and serviceable horn switch issues, are subject to charge back. In most cases, the service manuals show driver airbag replacement procedures in the Restraints section of Group 8. Several MOPAR driver airbag cover packages include instruction sheets. Because of the long list of part numbers involved they are not listed here, please consult the MOPAR parts catalog for the correct part number(s). WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag: > 19-009-01 > Oct > 01 > Driver Airbag - Trim Cover Service > Page 6533 WARNING: THE HORN SWITCH IS INTEGRAL TO THE DRIVER AIRBAG UNIT. ONLY DAIMLERCHRYSLER-TRAINED AND AUTHORIZED DEALER SERVICE TECHNICIANS SHOULD PERFORM SERVICE OF THIS UNIT. FAILURE TO TAKE THE PROPER PRECAUTIONS OR TO FOLLOW THE PROPER PROCEDURES COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES. WARNING: USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE DRIVER AIRBAG, OR BECOMING ENTRAPPED BETWEEN THE DRIVER AIRBAG CUSHION AND THE DRIVER AIRBAG TRIM COVER. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. WARNING: THE DRIVER AIRBAG TRIM COVER MUST NEVER BE PAINTED. REPLACEMENT TRIM COVERS ARE SERVICED IN THE ORIGINAL COLORS. PAINT MAY CHANGE THE WAY IN WHICH THE MATERIAL OF THE TRIM COVER RESPONDS TO AN AIRBAG DEPLOYMENT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. The following can be used for all airbag trim cover replacements: TIME ALLOWANCE: FAILURE CODE: POLICY: Reimbursable within the provisions of the warranty. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag: > 08-010-01 > May > 01 > Airbag/Clock Spring - Service Air Bag: All Technical Service Bulletins Airbag/Clock Spring - Service NUMBER: 08-010-01 GROUP: Electrical DATE: May 25, 2001 SUBJECT: Airbag/Clock Spring Service MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2002 (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1988 - 1993 (AG) Daytona 1988 - 1995 (AJ) Lebaron Coupe/Convertible 1990 (AL) Horizon/Omni 1988 - 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1994 - 2002 (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2002 (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - 2002 (DN) Durango 2002 (DR) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2002 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 (KJ) Liberty 1993 - 2002 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2002 (PL) Neon 1997 - 2002 (PR) Prowler 2002 (PG) PT Cruiser (International Markets) 2001 - 2002 (PT) PT Cruiser 2001 - 2002 (RG) Chrysler Voyager (International Markets) 2001 - 2002 (RS) Town & Country/Caravan/Voyager 1996 - 2002 (SR) Viper 2001 - 2002 (ST) Sebring Coupe/Stratus Coupe 1997 - 2002 (TJ) Wrangler 2001 - 2002 (WG) Grand Cherokee (International Markets) 1999 - 2002 (WJ) Grand Cherokee 1995 - 2001 (XJ) Cherokee 1995 - 1998 (ZG) Grand Cherokee (International Markets) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Airbag When servicing any airbag system, it is essential to follow the proper Service Manual and/or Diagnostic Manual procedures for diagnosing, testing, and replacing of any component. When diagnosing any airbag squib circuit Diagnostic Trouble Code (DTC) with a DRBIII(R), the use of the Airbag Load Tool (Special Tool 8310 and 8443) is required. The Airbag Load Tool, used in conjunction with the DRBIII(R) are used to isolate and test components and wiring for failure. Only replace the component or wiring that has failed. This will reduce unnecessary cost to the customer or DaimlerChrysler. NOTE: AIRBAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN ANOTHER COMPONENT HAS FAILED. USE OF THE DRBIII(R) AND AIRBAG LOAD TOOL WILL DETERMINE IF THE AIRBAG HAS FAILED AND REPLACEMENT IS NEEDED. NOTE: Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag: > 08-010-01 > May > 01 > Airbag/Clock Spring - Service > Page 6538 TECHNICIANS SHOULD RECORD ALL STORED AND ACTIVE AIRBAG SYSTEM FAULT CODES ON THE REPAIR ORDER. Clock Springs Recent analysis of returned clock springs have indicated that prior service may have contributed to the clock spring's failure. ^ Do not use silicone or any other lubricant spray on or near the clock spring. Lubricants are often used in the clock spring area of the steering column to eliminate noise. Lubricants may have an adverse effect on the clock spring. ^ Clock spring centering. Any repair that may disrupt the positioning of the steering wheel with the front wheels will require that the clock spring be centered. This includes clock spring replacement, steering column service, HVAC service, steering gear service, and front suspension crossmember service. Refer to the appropriate Service Manual for the clock spring centering procedure. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Driver's Side Airbag Air Bag: Description and Operation Driver's Side Airbag DESCRIPTION The airbag module protective trim cover is the most visible part of the driver side airbag system. The module is mounted directly to the steering wheel. Located under the airbag module 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 inflator are attached and sealed. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. OPERATION The inflator assembly is mounted to the back of the airbag module. The inflator seals the hole in the airbag cushion so it can discharge the gas it produces directly into the cushion when supplied with the proper electrical signal. 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. Upon airbag deployment, this cover will split at a predetermined breakout line. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Driver's Side Airbag > Page 6541 Air Bag: Description and Operation Passenger's Side Airbag DESCRIPTION The airbag door on the instrument panel above the glove box is the most visible part of the passenger side airbag system. Located under the airbag door are the airbag cushion and its supporting components. The airbag module includes a housing to which the cushion and inflator are attached and sealed. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. OPERATION The inflator assembly is mounted to the back of the airbag module. The inflator seals the hole in the airbag cushion so it can discharge the gas it produces directly into the cushion when supplied with the proper electrical signal. The airbag door is secured to the airbag module and the instrument panel base, and has predetermined breakout lines concealed beneath its decorative cover. Upon airbag deployment, the airbag door will split at the breakout lines and the door will pivot out of the way. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Driver's Side Airbag > Page 6542 Air Bag: Description and Operation Storage An airbag module must be stored in its original, special container until used for service. Also, it must be stored in a clean, dry environment; away from sources of extreme heat, sparks, and high electrical energy. Always place or store an airbag module on a surface with its trim cover or airbag side facing up, to minimize movement in case of an accidental deployment. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Side Airbag Module Replacement Air Bag: Service and Repair Driver Side Airbag Module Replacement WARNING: ^ THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIR BAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ^ WHEN REMOVING A DEPLOYED AIRBAG MODULE, RUBBER GLOVES, EYE PROTECTION, AND A LONG-SLEEVED SHIRT SHOULD BE WORN. THERE MAY BE DEPOSITS ON THE AIRBAG MODULE AND OTHER INTERIOR SURFACES. IN LARGE DOSES, THESE DEPOSITS MAY CAUSE IRRITATION TO THE SKIN AND EYES. 1. Disconnect and isolate the battery negative cable. If the airbag module has not been deployed, wait two minutes for the system capacitor to discharge before further service. 2. From the underside of the steering wheel, remove the two screws that secure the driver side airbag module to the steering wheel. 3. Pull the airbag module away from the steering wheel far enough to unplug the airbag module and horn switch wire harness connectors from the back of the airbag module. 4. Remove the airbag module from the steering wheel. 5. If the airbag has been deployed, see Service and Repair/Deployed. 6. When installing the airbag module, connect the clockspring wire harness connector to the module by pressing straight in on the connector. Be certain that the connector is fully engaged by observing the latching clip arms on the top of the connector. 7. Install the two airbag module mounting screws and tighten to 10.2 N.m (90 in. lbs.). 8. Do not connect the battery negative cable at this time. See Testing and Inspection/Procedures. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Side Airbag Module Replacement > Page 6545 Air Bag: Service and Repair Driver Side Airbag Module Trim Cover Replacement WARNING: ^ THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ^ THE HORN SWITCH IS INTEGRAL TO THE AIRBAG MODULE TRIM COVER. SERVICE OF THIS COMPONENT SHOULD BE PERFORMED ONLY BY CHRYSLER-TRAINED AND AUTHORIZED DEALER SERVICE TECHNICIANS. FAILURE TO TAKE THE PROPER PRECAUTIONS OR TO FOLLOW THE PROPER PROCEDURES COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. If the airbag module has not been deployed, wait two minutes for the system capacitor to discharge before further service. 2. Remove the driver side airbag module. 3. Remove the four nuts that secure the upper and lower trim cover retainers to the studs on the airbag housing. 4. Remove the upper and lower trim cover retainers from the airbag housing studs. 5. Remove the horn switch ground wire eyelet from the airbag housing stud. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Side Airbag Module Replacement > Page 6546 6. Disengage the six trim cover locking blocks from the lip around the outside edge of the airbag housing and remove the housing from the cover. 7. When installing the trim cover and horn switch, be certain that the locking blocks are fully engaged on the lip of the airbag housing. 8. When installing the upper and lower trim cover retainers, be certain that the tabs on each retainer are engaged in the retainer slots of the trim cover. 9. Install and tighten the trim cover retainer nuts to 10 N.m (90 in. lbs.). 10. Reverse the remaining removal procedures to complete the installation, but do not connect the battery negative cable at this time. See Testing and Inspection/Procedures for the proper procedures. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Side Airbag Module Replacement > Page 6547 Air Bag: Service and Repair Passenger Side Airbag Door Replacement The passenger side airbag door for this model is only serviced as a part of the instrument panel top cover assembly. if the airbag door is faulty or damaged, the instrument panel top cover must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Side Airbag Module Replacement > Page 6548 Air Bag: Service and Repair Passenger Side Airbag Module Replacement 1. Disconnect and isolate the battery negative cable. If the airbag module has not been deployed, wait two minutes for the system capacitor to discharge before further service. 2. Remove the instrument panel top cover. 3. Apply masking tape over the passenger side airbag module vents located on each end of the module. The tape will help to prevent any foreign material from entering the module through the vents during disassembly and reassembly. WARNING: USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE PASSENGER SIDE AIRBAG MODULE, OR BECOMING ENTRAPPED BETWEEN THE INSTRUMENT PANEL TOP COVER AND THE PASSENGER SIDE AIRBAG MODULE. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. 4. Use a center punch to drive out the mandrels from the four rivets that secure the airbag module to the upper airbag door flange and bracket on the instrument panel top cover. 5. Use a pair of rivet cutters or a large pair of side cutters to cut the rims or heads off of the four rivets. WARNING: DO NOT USE A DRILL TO REMOVE THE RIVETS. SPARKS CREATED WHEN DRILLING COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALSO, METAL SHAVINGS CREATED WHEN DRILLING COULD ENTER THE PASSENGER SIDE AIRBAG MODULE AND RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Side Airbag Module Replacement > Page 6549 6. Remove the passenger side airbag module from the upper airbag door flange and bracket on the instrument panel top cover. 7. When installing the passenger side airbag module, use only the correct rivets that are specified in the Chrysler Mopar Parts Catalog, or that are supplied in the service package with the new airbag module and/or the new instrument panel top cover. 8. Remove the tape applied in Step 3 from the passenger side airbag module vents. 9. When reinstalling the instrument panel top cover, be certain that the airbag module wire harness connector latches are fully engaged. 10. Reverse the remaining removal procedures to complete the installation. 11. Do not connect the battery negative cable at this time. See Testing and Inspection/Procedures for the proper procedures. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module Technical Service Bulletin # 731 Date: 970701 Recall - Airbag Control Module No. 731 July, 1997 To: All Dealers Subject: Safety Recall # 731 -- Airbag Control Module Models: ^ 1997 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Belvidere Assembly Plant ("D" in the 11th VIN Position) Through September 3, 1996 (MDH 090317) ^ 1997 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Toluca Assembly Plant ("T" in the 11th VIN Position) Through September 9, 1996 (MDH 090906) ^ 1997 Model Year Dodge Dakota (AN) Vehicles Built Through September 5, 1996 (MDH 090521) ^ 1997 Model Year Jeep Wrangler (TJ) Vehicles Built Through September 3, 1996 (MDH 090319) ^ 1997 Model Year Jeep Grand Cherokee (ZJ) Vehicles Built Through September 3, 1996 (MDH 090312) ^ 1996 Model Year Dodge Viper GTS Coupe (SR) Vehicles Built Through September 30, 1996 (MDH 093014) The airbags on the above listed vehicles, may inadvertently deploy during a three (3) second period after the ignition key has been turned to the off position, which could injure a vehicle occupant. To correct this condition, the airbag control module (ACM) must be replaced. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory, and should perform this recall on vehicles in for service as determined by using DIAL System Function 70. Details of this service action are explained in the following sections. Service Procedure Videotape No videotape of the service procedure for this recall will be provided. Dealer Notification & Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53, 70 and VIP All involved vehicles will be entered to DIAL System Functions 53, 70 and VIP at the time of recall implementation for dealer inquiry as needed. Parts Important: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 6558 Each involved dealer, to whom vehicles in the recall were invoiced (or the current dealer at the same street address), will receive enough of each ACM Package to service about 25% of those vehicles. Each package contains one (1) ACM. Refer to the table above for the appropriate package application: Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for the service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Service Procedure For Neon (PL) Vehicles: 1. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. For Manual Transmission Equipped Vehicles: Remove the shifter knob fastener and remove the shifter knob. 3. Remove the front two (2) center console attaching screws located near the cup holders (Figure 1). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 6559 4. Remove the two (2) screws at the bottom of the storage bin (Figure 2). 5. Remove the bolt access covers and the two lower console bracket bolts on each side of the console bin. 6. Raise the park brake hand lever as high as possible. 7. Remove the center console assembly. WARNING: The auto adjusting feature of the park brake lever assembly contains a clock spring loaded to approximately 20 lbs. DO NOT release the auto adjuster lock out device before installing the cables into the equalizer. Keep hands out of auto adjuster sector and pawl area. Failure to observe caution in handling this mechanism could lead to serious injury. 8. Lower the park brake handle. 9. Grasp the park brake lever output cable by hand and pull upward until a 3/16" drill bit can be inserted into the handle and sector gear mechanism (Figure 3). This will remove the tension from the park brake cables. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 6560 10. Remove both rear park brake cables from the park brake cable equalizer (Figure 4). 11. Disconnect the brake warning light electrical connector from the park brake lever switch. 12. Remove the two park brake lever attaching nuts and remove the park brake lever assembly. 13. Disconnect the ACM wiring connector (Figure 5): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 14. Remove the remaining three (3) nuts that secure the ACM mounting bracket to the floor, disconnect the two (2) park brake lever switch wire harness clips from the ACM bracket and then remove the ACM and bracket assembly. 15. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 16. Loosely install the three (3) ACM attaching nuts. 17. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 6561 18. Install the park brake lever assembly. 19. Tighten the four (4) ACM nuts and the remaining park brake lever nut to 115 in-lbs (12.5 N.m). 20. Connect the park brake lever switch electrical connector and attach the wiring clips to the ACM bracket. 21. Install both rear park brake cables into the equalizer. 22. Pull the park brake lever handle all the way up. 23. Firmly grasp the park brake lever locking pin (drill bit) and quickly remove it from the mechanism. 24. Cycle the park brake lever once to position the park brake cables. 25. Make sure that the park brake lever is fully raised and then install the center console assembly. 26. Install the front two (2) center console attaching screws located near the cup holders (Figure 1). 27. Install the two (2) screws at the bottom of the storage bin (Figure 2). 28. Install the two (2) outer lower console bracket bolts on each side of the storage bin and then install the bolt covers. 29. For Manual Transmission Equipped Vehicles: Install the shifter knob and fastener. 30. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 31. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 32. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. Service Procedure For Dakota (AN) Vehicles: 1. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Pull back the floor carpet from the area around the center instrument panel support. 3. Remove the two (2) front center support bracket screws (Figure 6). 4. Remove the two (2) left side and one (1) right side support bracket screws (Figure 6). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 6562 5. Remove the support bracket. 6. Remove the ground eyelet screw from the left side of the ACM bracket. 7. Disconnect the ACM wiring connector (Figure 7): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 8. Remove the three (3) screws that secure the ACM mounting bracket to the floor pan transmission tunnel (Figure 8). 9. Remove the ACM and bracket assembly. 10. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 11. Tighten the three (3) ACM to floorpan transmission tunnel attaching screws to 105 in-lbs (11.8 N.m). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 6563 12. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. 13. Install the ground eyelet screw to the left side of the ACM bracket. 14. Install the center instrument panel support bracket. 15. Install the two (2) left side and one (1) right side support bracket screws (Figure 6). Tighten the bracket screws to 105 in-lbs (11.8 N.m). 16. Install the two (2) front center support bracket screws (Figure 6). Tighten the bracket screws to 105 in-lbs (11.8 N.m). 17. Reinstall the floor carpet around the center instrument panel support. 18. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 19. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 20. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. Service Procedure For Wrangler (TJ) Vehicles: 1. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Pull back the floor carpet from the area under the heater-A/C housing floor duct and forward of the center floor console. 3. For vehicles equipped with ABS: Remove the ABS acceleration sensor from its mounting bracket and set aside (Figure 9). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 6564 4. Remove the four (4) screws that secure the ACM mounting bracket to the floor pan transmission tunnel (Figure 10). 5. Disconnect the ACM wiring connector (Figure 11): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 6. Slide the ACM and bracket assembly out from under the heater-A/C housing floor duct and remove it from the vehicle. 7. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 8. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. 9. Tighten the four (4) ACM to floorpan transmission tunnel attaching screws to 95 in-lbs (10.7 N.m) (Figure 10). 10. For vehicles equipped with ABS: Reinstall the ABS acceleration sensor (Figure 9). Tighten the sensor mounting bolts to 40 in-lbs (4.5 N.m). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 6565 11. Reinstall the floor carpet under the heater-A/C floor duct. 12. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 13. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 14. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. Service Procedure For Grand Cherokee (ZJ) Vehicles: 1. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Remove the transmission shift lever handle by pulling straight up firmly and quickly. 3. Pry up the transmission shift indicator bezel with a trim stick (Figure 12). 4. Lift the bezel far enough to remove the lamp socket from the bezel and then remove the transmission shift indicator bezel from the console. 5. Pry up the transfer case shift indicator bezel with a trim stick (Figure 12). 6. Lift the bezel far enough to remove the lamp socket from the bezel and then remove the transfer case bezel from the console. 7. Remove the console attaching screws and then remove the console (Figure 12). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 6566 8. Disconnect the ACM wiring connector (Figure 13): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 9. Remove the four (4) screws that secure the ACM mounting bracket to the floor transmission tunnel (Figure 14). 10. Remove the ACM and bracket assembly. 11. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 12. Tighten the four (4) ACM attaching screws to 95 in-lbs (10.7 N.m). 13. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. 14. Install the console and secure it with the attaching screws (Figure 12). 15. Install the lamp socket into the transfer case shift bezel and then install the bezel into the console (Figure 12). 16. Install the lamp socket into the transmission shift indicator bezel and then install the bezel into the console (Figure 12). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 6567 17. Install the transmission shift lever handle. 18. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 19. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 20. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. Service Procedure For Viper GTS Coupe (SR) Vehicles: 1. Remove the left rear wheel and tire assembly. 2. Remove the left rear wheel well inner splash shield. 3. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 4. Remove the instrument panel center bezel and then disconnect the rear window defogger switch, the power window switches and the lighter (Figure 15). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 6568 5. Remove the right and left knee blockers (Figure 16). 6. Remove the headlamp switch knob by inserting a paper clip in the hole under the knob and pushing gently to release the lock clip (Figure 16). 7. Remove the tilt steering handle. 8. Remove the upper steering column shroud. 9. Remove the instrument panel bezel (Figure 16). NOTE: Be careful not to break the headlamp switch lock tab when removing the I/P bezel. 10. Remove the two (2) radio mounting screws. 11. Remove the radio and disconnect the wire connector, coaxial cable and antenna cable. 12. Remove the radio from the vehicle. 13. Remove the HVAC control module. Only disconnect the vacuum and electrical connectors. Do not disconnect the cable. Set the control module aside. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 6569 14. Reach through the radio opening and disconnect the ACM wiring connector (Figure 17): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 15. Remove the three (3) nuts that secure the ACM mounting bracket to the floor pan transmission tunnel (Figure 18). 16. Slide the ACM and bracket assembly out through the radio opening. 17. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 18. Tighten the three (3) ACM to floorpan transmission tunnel attaching screws to 95 in-lbs (10.7 N.m). 19. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. 20. Connect the HVAC control head electrical and vacuum connectors. Install the HVAC control module. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 6570 21. Connect the radio wire connector, coaxial cable and antenna cable. 22. Install the radio into the instrument panel and tighten the two (2) mounting screws. 23. Install the instrument panel bezel (Figure 16). NOTE: Be careful when installing the I/P bezel. Do not break the headlamp switch lock tab. 24. Install the headlamp switch knob (Figure 16). 25. Install the upper steering column cover. 26. Install the tilt steering handle. 27. Install the right and left knee blockers (Figure 16). 28. Connect the rear window defogger switch, the power window switches and the lighter and then install the instrument panel center bezel (Figure 15). 29. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 30. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 31. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. 32. Install the left rear wheel well inner splash shield. 33. Install the left rear wheel and tire assembly. Completion Reporting and Reimbursement / Parts Return Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. Parts Return Initially, a small number of ACM and bracket assemblies are required to be returned to the Warranty Material Return Center. When an adequate number of returned parts have been accumulated, Parts Return Documents will no longer be generated and parts are to be discarded. Note: See the Warranty Administration Manual, Recall Claim Processing Section for complete recall claim processing and material return instructions. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 6571 CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Dealer Service Instructions IMPORTANT Safety Recall # 731 -- Airbag Control Module ^ Effective immediately, this recall (# 731) cancels and supercedes Recall # 683 -- Airbag Control Module for 1997 Jeep Wrangler (TJ) vehicles. ^ This service requirement applies only to: ^ 1997 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Belvidere Assembly Plant ("D" in the 11th VIN Position) Through September 3, 1996 (MDH 090317) ^ 1997 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Toluca Assembly Plant ("T" in the 11th VIN Position) Through September 9, 1996 (MDH 090906) ^ 1997 Model Year Dodge Dakota (AN) Vehicles Built Through September 5, 1996 (MDH 090521) ^ 1997 Model Year Jeep Wrangler (TJ) Vehicles Built Through September 3, 1996 (MDH 090319) ^ 1997 Model Year Jeep Grand Cherokee (ZJ) Vehicles Built Through September 3, 1996 (MDH 090312) ^ 1996 Model Year Dodge Viper GTS Coupe (SR) Vehicles Built Through September 30, 1996 (MDH 093014) ^ The airbags on the above listed vehicles, may inadvertently deploy during a three (3) second period after the ignition key has been turned to the off position. To correct this condition, the airbag control module (ACM) must be replaced. Parts Packages: ^ Each involved dealer, to whom vehicles in the recall were invoiced, will receive enough ACM Packages to service about 25% of those vehicles. Owner Letter SAFETY RECALL TO REPLACE YOUR VEHICLE'S AIRBAG CONTROL MODULE Dear Chrysler Vehicle Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Chrysler Corporation has determined that a defect which relates to motor vehicle safety exists in some 1997 Plymouth and Dodge Neon; Dodge Dakota; Jeep Grand Cherokee and Wrangler; and 1996 Dodge Viper GTS Coupe vehicles. The problem is... The airbags on your vehicle (identified on the enclosed form), may inadvertently deploy during a three (3) second period after the ignition key has been turned to the off position, which could injure a vehicle occupant. What Chrysler and your dealer will do... Chrysler will repair your (vehicle) free of charge (parts and labor). To do this, your dealer will replace the airbag control module. The work will take about one hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do to ensure your safety... ^ Simply contact your dealer right away to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to the dealer. If you need help... Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 6572 If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-853-1403. A representative will assist you in getting your vehicle repaired. If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590, or call the Toll Free Auto Safety Hotline at 1-800-424-9393. (Washington, D.C. area residents may call 366-0123.) We're sorry for any inconvenience, but we are sincerely concerned about your safety. Thanks for your attention to this important matter. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module Technical Service Bulletin # 731 Date: 970701 Recall - Airbag Control Module No. 731 July, 1997 To: All Dealers Subject: Safety Recall # 731 -- Airbag Control Module Models: ^ 1997 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Belvidere Assembly Plant ("D" in the 11th VIN Position) Through September 3, 1996 (MDH 090317) ^ 1997 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Toluca Assembly Plant ("T" in the 11th VIN Position) Through September 9, 1996 (MDH 090906) ^ 1997 Model Year Dodge Dakota (AN) Vehicles Built Through September 5, 1996 (MDH 090521) ^ 1997 Model Year Jeep Wrangler (TJ) Vehicles Built Through September 3, 1996 (MDH 090319) ^ 1997 Model Year Jeep Grand Cherokee (ZJ) Vehicles Built Through September 3, 1996 (MDH 090312) ^ 1996 Model Year Dodge Viper GTS Coupe (SR) Vehicles Built Through September 30, 1996 (MDH 093014) The airbags on the above listed vehicles, may inadvertently deploy during a three (3) second period after the ignition key has been turned to the off position, which could injure a vehicle occupant. To correct this condition, the airbag control module (ACM) must be replaced. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory, and should perform this recall on vehicles in for service as determined by using DIAL System Function 70. Details of this service action are explained in the following sections. Service Procedure Videotape No videotape of the service procedure for this recall will be provided. Dealer Notification & Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53, 70 and VIP All involved vehicles will be entered to DIAL System Functions 53, 70 and VIP at the time of recall implementation for dealer inquiry as needed. Parts Important: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 6578 Each involved dealer, to whom vehicles in the recall were invoiced (or the current dealer at the same street address), will receive enough of each ACM Package to service about 25% of those vehicles. Each package contains one (1) ACM. Refer to the table above for the appropriate package application: Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for the service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Service Procedure For Neon (PL) Vehicles: 1. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. For Manual Transmission Equipped Vehicles: Remove the shifter knob fastener and remove the shifter knob. 3. Remove the front two (2) center console attaching screws located near the cup holders (Figure 1). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 6579 4. Remove the two (2) screws at the bottom of the storage bin (Figure 2). 5. Remove the bolt access covers and the two lower console bracket bolts on each side of the console bin. 6. Raise the park brake hand lever as high as possible. 7. Remove the center console assembly. WARNING: The auto adjusting feature of the park brake lever assembly contains a clock spring loaded to approximately 20 lbs. DO NOT release the auto adjuster lock out device before installing the cables into the equalizer. Keep hands out of auto adjuster sector and pawl area. Failure to observe caution in handling this mechanism could lead to serious injury. 8. Lower the park brake handle. 9. Grasp the park brake lever output cable by hand and pull upward until a 3/16" drill bit can be inserted into the handle and sector gear mechanism (Figure 3). This will remove the tension from the park brake cables. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 6580 10. Remove both rear park brake cables from the park brake cable equalizer (Figure 4). 11. Disconnect the brake warning light electrical connector from the park brake lever switch. 12. Remove the two park brake lever attaching nuts and remove the park brake lever assembly. 13. Disconnect the ACM wiring connector (Figure 5): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 14. Remove the remaining three (3) nuts that secure the ACM mounting bracket to the floor, disconnect the two (2) park brake lever switch wire harness clips from the ACM bracket and then remove the ACM and bracket assembly. 15. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 16. Loosely install the three (3) ACM attaching nuts. 17. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 6581 18. Install the park brake lever assembly. 19. Tighten the four (4) ACM nuts and the remaining park brake lever nut to 115 in-lbs (12.5 N.m). 20. Connect the park brake lever switch electrical connector and attach the wiring clips to the ACM bracket. 21. Install both rear park brake cables into the equalizer. 22. Pull the park brake lever handle all the way up. 23. Firmly grasp the park brake lever locking pin (drill bit) and quickly remove it from the mechanism. 24. Cycle the park brake lever once to position the park brake cables. 25. Make sure that the park brake lever is fully raised and then install the center console assembly. 26. Install the front two (2) center console attaching screws located near the cup holders (Figure 1). 27. Install the two (2) screws at the bottom of the storage bin (Figure 2). 28. Install the two (2) outer lower console bracket bolts on each side of the storage bin and then install the bolt covers. 29. For Manual Transmission Equipped Vehicles: Install the shifter knob and fastener. 30. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 31. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 32. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. Service Procedure For Dakota (AN) Vehicles: 1. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Pull back the floor carpet from the area around the center instrument panel support. 3. Remove the two (2) front center support bracket screws (Figure 6). 4. Remove the two (2) left side and one (1) right side support bracket screws (Figure 6). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 6582 5. Remove the support bracket. 6. Remove the ground eyelet screw from the left side of the ACM bracket. 7. Disconnect the ACM wiring connector (Figure 7): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 8. Remove the three (3) screws that secure the ACM mounting bracket to the floor pan transmission tunnel (Figure 8). 9. Remove the ACM and bracket assembly. 10. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 11. Tighten the three (3) ACM to floorpan transmission tunnel attaching screws to 105 in-lbs (11.8 N.m). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 6583 12. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. 13. Install the ground eyelet screw to the left side of the ACM bracket. 14. Install the center instrument panel support bracket. 15. Install the two (2) left side and one (1) right side support bracket screws (Figure 6). Tighten the bracket screws to 105 in-lbs (11.8 N.m). 16. Install the two (2) front center support bracket screws (Figure 6). Tighten the bracket screws to 105 in-lbs (11.8 N.m). 17. Reinstall the floor carpet around the center instrument panel support. 18. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 19. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 20. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. Service Procedure For Wrangler (TJ) Vehicles: 1. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Pull back the floor carpet from the area under the heater-A/C housing floor duct and forward of the center floor console. 3. For vehicles equipped with ABS: Remove the ABS acceleration sensor from its mounting bracket and set aside (Figure 9). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 6584 4. Remove the four (4) screws that secure the ACM mounting bracket to the floor pan transmission tunnel (Figure 10). 5. Disconnect the ACM wiring connector (Figure 11): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 6. Slide the ACM and bracket assembly out from under the heater-A/C housing floor duct and remove it from the vehicle. 7. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 8. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. 9. Tighten the four (4) ACM to floorpan transmission tunnel attaching screws to 95 in-lbs (10.7 N.m) (Figure 10). 10. For vehicles equipped with ABS: Reinstall the ABS acceleration sensor (Figure 9). Tighten the sensor mounting bolts to 40 in-lbs (4.5 N.m). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 6585 11. Reinstall the floor carpet under the heater-A/C floor duct. 12. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 13. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 14. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. Service Procedure For Grand Cherokee (ZJ) Vehicles: 1. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Remove the transmission shift lever handle by pulling straight up firmly and quickly. 3. Pry up the transmission shift indicator bezel with a trim stick (Figure 12). 4. Lift the bezel far enough to remove the lamp socket from the bezel and then remove the transmission shift indicator bezel from the console. 5. Pry up the transfer case shift indicator bezel with a trim stick (Figure 12). 6. Lift the bezel far enough to remove the lamp socket from the bezel and then remove the transfer case bezel from the console. 7. Remove the console attaching screws and then remove the console (Figure 12). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 6586 8. Disconnect the ACM wiring connector (Figure 13): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 9. Remove the four (4) screws that secure the ACM mounting bracket to the floor transmission tunnel (Figure 14). 10. Remove the ACM and bracket assembly. 11. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 12. Tighten the four (4) ACM attaching screws to 95 in-lbs (10.7 N.m). 13. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. 14. Install the console and secure it with the attaching screws (Figure 12). 15. Install the lamp socket into the transfer case shift bezel and then install the bezel into the console (Figure 12). 16. Install the lamp socket into the transmission shift indicator bezel and then install the bezel into the console (Figure 12). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 6587 17. Install the transmission shift lever handle. 18. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 19. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 20. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. Service Procedure For Viper GTS Coupe (SR) Vehicles: 1. Remove the left rear wheel and tire assembly. 2. Remove the left rear wheel well inner splash shield. 3. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 4. Remove the instrument panel center bezel and then disconnect the rear window defogger switch, the power window switches and the lighter (Figure 15). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 6588 5. Remove the right and left knee blockers (Figure 16). 6. Remove the headlamp switch knob by inserting a paper clip in the hole under the knob and pushing gently to release the lock clip (Figure 16). 7. Remove the tilt steering handle. 8. Remove the upper steering column shroud. 9. Remove the instrument panel bezel (Figure 16). NOTE: Be careful not to break the headlamp switch lock tab when removing the I/P bezel. 10. Remove the two (2) radio mounting screws. 11. Remove the radio and disconnect the wire connector, coaxial cable and antenna cable. 12. Remove the radio from the vehicle. 13. Remove the HVAC control module. Only disconnect the vacuum and electrical connectors. Do not disconnect the cable. Set the control module aside. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 6589 14. Reach through the radio opening and disconnect the ACM wiring connector (Figure 17): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 15. Remove the three (3) nuts that secure the ACM mounting bracket to the floor pan transmission tunnel (Figure 18). 16. Slide the ACM and bracket assembly out through the radio opening. 17. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 18. Tighten the three (3) ACM to floorpan transmission tunnel attaching screws to 95 in-lbs (10.7 N.m). 19. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. 20. Connect the HVAC control head electrical and vacuum connectors. Install the HVAC control module. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 6590 21. Connect the radio wire connector, coaxial cable and antenna cable. 22. Install the radio into the instrument panel and tighten the two (2) mounting screws. 23. Install the instrument panel bezel (Figure 16). NOTE: Be careful when installing the I/P bezel. Do not break the headlamp switch lock tab. 24. Install the headlamp switch knob (Figure 16). 25. Install the upper steering column cover. 26. Install the tilt steering handle. 27. Install the right and left knee blockers (Figure 16). 28. Connect the rear window defogger switch, the power window switches and the lighter and then install the instrument panel center bezel (Figure 15). 29. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 30. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 31. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. 32. Install the left rear wheel well inner splash shield. 33. Install the left rear wheel and tire assembly. Completion Reporting and Reimbursement / Parts Return Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. Parts Return Initially, a small number of ACM and bracket assemblies are required to be returned to the Warranty Material Return Center. When an adequate number of returned parts have been accumulated, Parts Return Documents will no longer be generated and parts are to be discarded. Note: See the Warranty Administration Manual, Recall Claim Processing Section for complete recall claim processing and material return instructions. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 6591 CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Dealer Service Instructions IMPORTANT Safety Recall # 731 -- Airbag Control Module ^ Effective immediately, this recall (# 731) cancels and supercedes Recall # 683 -- Airbag Control Module for 1997 Jeep Wrangler (TJ) vehicles. ^ This service requirement applies only to: ^ 1997 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Belvidere Assembly Plant ("D" in the 11th VIN Position) Through September 3, 1996 (MDH 090317) ^ 1997 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Toluca Assembly Plant ("T" in the 11th VIN Position) Through September 9, 1996 (MDH 090906) ^ 1997 Model Year Dodge Dakota (AN) Vehicles Built Through September 5, 1996 (MDH 090521) ^ 1997 Model Year Jeep Wrangler (TJ) Vehicles Built Through September 3, 1996 (MDH 090319) ^ 1997 Model Year Jeep Grand Cherokee (ZJ) Vehicles Built Through September 3, 1996 (MDH 090312) ^ 1996 Model Year Dodge Viper GTS Coupe (SR) Vehicles Built Through September 30, 1996 (MDH 093014) ^ The airbags on the above listed vehicles, may inadvertently deploy during a three (3) second period after the ignition key has been turned to the off position. To correct this condition, the airbag control module (ACM) must be replaced. Parts Packages: ^ Each involved dealer, to whom vehicles in the recall were invoiced, will receive enough ACM Packages to service about 25% of those vehicles. Owner Letter SAFETY RECALL TO REPLACE YOUR VEHICLE'S AIRBAG CONTROL MODULE Dear Chrysler Vehicle Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Chrysler Corporation has determined that a defect which relates to motor vehicle safety exists in some 1997 Plymouth and Dodge Neon; Dodge Dakota; Jeep Grand Cherokee and Wrangler; and 1996 Dodge Viper GTS Coupe vehicles. The problem is... The airbags on your vehicle (identified on the enclosed form), may inadvertently deploy during a three (3) second period after the ignition key has been turned to the off position, which could injure a vehicle occupant. What Chrysler and your dealer will do... Chrysler will repair your (vehicle) free of charge (parts and labor). To do this, your dealer will replace the airbag control module. The work will take about one hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do to ensure your safety... ^ Simply contact your dealer right away to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to the dealer. If you need help... Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 6592 If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-853-1403. A representative will assist you in getting your vehicle repaired. If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590, or call the Toll Free Auto Safety Hotline at 1-800-424-9393. (Washington, D.C. area residents may call 366-0123.) We're sorry for any inconvenience, but we are sincerely concerned about your safety. Thanks for your attention to this important matter. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 6593 Module Locations Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions Air Bag Control Module: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6596 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 Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6597 Electrostatic Discharge Symbol All Electrostatic Discharge (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, especially 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. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6598 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6599 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6600 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6601 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6602 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6603 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6604 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6605 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. 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. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6606 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6607 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6608 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6609 Air Bag Control Module: Diagnostic Aids 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 in 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 and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6610 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. 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 every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. 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 fuse circuit. 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 the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6611 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools 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 - This instrument is 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 vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. 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 non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6612 ABCM Connector Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6613 Airbag System Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Page 6614 Air Bag Control Module: Description and Operation DESCRIPTION The Airbag Control Module (ACM) contains the impact sensor, and a microprocessor that monitors the impact sensor and the airbag system electrical circuits to determine the system readiness. The ACM contains On-Board Diagnostics (OBD), and will send an airbag lamp-on message to the instrument cluster on the Chrysler Collision Detection (CCD) data bus to light the airbag indicator lamp in the instrument cluster when a monitored airbag system fault occurs. OPERATION The ACM also contains an energy-storage capacitor. This capacitor stores enough electrical energy to deploy the airbags for up to one second following a battery disconnect or failure during an impact. The purpose of the capacitor is to provide airbag system protection in a severe secondary impact, if the initial impact has damaged or disconnected the battery, but was not severe enough to deploy the airbags. The ACM cannot be repaired and, if damaged or faulty, it must be replaced. CIRCUIT OPERATION Two circuits provide battery voltage to the Airbag Control Module (ACM); F14 and F24. Circuits F14 and F24 are connected to separate bus bars in the junction block. Different circuits from the Power Distribution Center (PDC) and the ignition switch supply battery voltage to the junction block bus bars. Circuit F24 supplies battery voltage to the ACM only when the ignition switch is in the RUN position. Circuit F14 circuit powers the ACM when the ignition switch is in either the START or RUN position. The ACM is case grounded and has an external dedicated ground, circuit Z2. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Testing and Inspection > Helpful Information Air Bag Control Module: Testing and Inspection Helpful Information - Check the 10 Amp fuses in the junction block Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Testing and Inspection > Helpful Information > Page 6617 Air Bag Control Module: Testing and Inspection Module Testing Refer to Powertrain Management/Computers and Control Systems/Body Control Module/Testing and Inspection. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Testing and Inspection > Page 6618 Air Bag Control Module: Service and Repair WARNING: ^ The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components you must first disconnect and isolate the battery negative (ground) cable. Then wait two minutes for the system capacitor to discharge before further system service. This is the only sure way to disable the airbag system. Failure to do this could result in accidental air bag 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. 1. Disconnect and isolate the battery negative cable. if the airbag has not been deployed, wait two minutes for the system capacitor to discharge before further service. 2. Remove the instrument panel center support bracket. 3. Remove the screw that secures the instrument panel wire harness ground eyelet to the left side of the floor pan transmission tunnel. 4. Unplug the Airbag Control Module (ACM) wire harness connector. To unplug the connector, first pull the two white locks out about 3 mm (0.125 in.) from each side of the connector. Then squeeze the two connector latch tabs between the thumb and fore-finger, while pulling the connector out from the ACM. NOTE: Always remove and replace the airbag control module and its mounting bracket as a unit. Replacement modules include a replacement mounting bracket. Do not transfer the module to another mounting bracket. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Testing and Inspection > Page 6619 5. Remove the three screws that secure the ACM mounting bracket to the floor pan transmission tunnel. 6. Remove the ACM and mounting bracket as a unit. 7. When installing the ACM, position the unit with the arrow on the ACM housing pointing forward. 8. Attach the ACM to the floor pan transmission tunnel with the four mounting screws. Tighten the mounting screws to 11.8 N.m (105 in. lbs.). 9. Plug in the wire harness connector to the ACM. Be certain that the connector latches are fully engaged and that the connector locks are pushed in. 10. Reverse the remaining removal procedures to complete the installation. 11. Do not connect the battery negative cable at this time. See Testing and Inspection/Procedures for the proper procedures. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches Air Bag Deactivation Switch: Technical Service Bulletins Air Bag - On/Off Switches NUMBER: 08-025-01 GROUP: Electrical DATE: Nov. 23, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-037-99, DATED NOVEMBER 12, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1999 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-00004). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS, PARTS, AND 2001 MODEL YEAR PROCEDURES. NOTE: THIS BULLETIN DOES NOT APPLY TO DIAMLERCHRYSLER CANADA DEALERS. SUBJECT: Airbag On-Off Switches MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - **2001** (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) Lebaron Coupe/Convertible 1994 - **2001** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - **2001** (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - **2001** (DN) Durango 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus **2001** (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 1993 - **2001** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - **2001** (PL) Neon 1997 (PR) Prowler **2001 (PT) PT Cruiser** **2001** (RS) Town & Country/Caravan/Voyager Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6624 1996 - 1997 (SR) Viper **2001 - 2002 (ST) Sebring Coupe/Stratus Coupe** 1997 - 2001** (TJ) Wrangler 1999 - **2001** (WJ) Grand Cherokee 1997 - **2001** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. NOTE: **SOME 2001 MODEL YEAR PACKAGES (AN/AN84/DN/JR/LH/PL/PT/RS/TJ) REQUIRE OCCUPANT RESTRAINT CONTROLLER (ORC) CONFIGURATION USING THE DRB III(R) AS DETAILED IN EACH VEHICLE SPECIFIC PACKAGE.** DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. NOTE: FOR SOME 2000 MODEL YEAR APPLICATIONS (AB/AN/AN84/DN/JA/NS) **AND SOME 2001 CARRYOVER APPLICATIONS (AB/BR/WJ/XJ)**, A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05013528AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT IS ORANGE, AND MUST BE PRESENTED TO THE CUSTOMER IN PLACE OF THE YELLOW ONE, P/N 05013517AA, THAT WILL COME IN THE AIRBAG KIT. **FOR SOME 2001 MODEL YEAR APPLICATIONS (WITH J1850 BUS, AN/AN84/DN/JR/LH/PL(PT/RS/TJ) A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05016025AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT MUST BE PRESENTED TO THE CUSTOMER AFTER INSTALLATION.** Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6625 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6626 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6627 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6628 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6629 PARTS REQUIRED: NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have~ 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available in the "Forms Folder" under "TSB/Recall" tab of MDS2 and printed on your dealership letterhead. keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6630 Air Bag Deactivation Switch: Technical Service Bulletins Air Bag System - ON-OFF Switch Availibility NO: 08-17-98 Rev. C GROUP: Electrical DATE: Dec. 30, 1998 SUBJECT: Airbag On-Off Switches THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-17-98 Rev. B DATED SEPTEMBER 18, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL MODELS HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: **1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan** 1995 - **1999** (AB) Ram Van/Wagon **1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon** 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/Convertible 1994 -**1999** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan/Voyager **1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue** 1994 - **1999** (BR) Ram Pickup **1995 - 1996 (B7) Stealth** 1998 - **1999** (DN) Durango **1995 - 1999 (FJ) Avenger/Sebring/Talon** 1995 - **1999** (JA) Breeze/Cirrus/Stratus 1996 - **1999** (JX) Sebring Convertible 1993 -**1999** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - **1999** (NS) Town & Country/Caravan/ Voyager 1995 - **1999** (PL) Neon 1996 - 1997 (SR) Viper 1997 - **1999** (TJ) Wrangler 1997 - **1999** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. Other applicable passenger vehicles will be announced as soon as the switches are available. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6631 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6632 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6633 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6634 PARTS REQUIRED: Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6635 NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have. 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available on T.I.L. and printed on your dealership letterhead. Keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6636 POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Safety Switch/Connector > Component Information > Description and Operation Air Bag Safety Switch/Connector: Description and Operation CIRCUIT OPERATION The passengers side airbag uses a pressure switch to measure the pressure of the propellant used to help inflate the airbag. Circuits R50 and R51 connect between the passengers side airbag and the Airbag Control Module (ACM). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Airbag/Clock Spring - Service Clockspring Assembly / Spiral Cable: Technical Service Bulletins Airbag/Clock Spring - Service NUMBER: 08-010-01 GROUP: Electrical DATE: May 25, 2001 SUBJECT: Airbag/Clock Spring Service MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2002 (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1988 - 1993 (AG) Daytona 1988 - 1995 (AJ) Lebaron Coupe/Convertible 1990 (AL) Horizon/Omni 1988 - 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1994 - 2002 (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2002 (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - 2002 (DN) Durango 2002 (DR) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2002 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 (KJ) Liberty 1993 - 2002 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2002 (PL) Neon 1997 - 2002 (PR) Prowler 2002 (PG) PT Cruiser (International Markets) 2001 - 2002 (PT) PT Cruiser 2001 - 2002 (RG) Chrysler Voyager (International Markets) 2001 - 2002 (RS) Town & Country/Caravan/Voyager 1996 - 2002 (SR) Viper 2001 - 2002 (ST) Sebring Coupe/Stratus Coupe 1997 - 2002 (TJ) Wrangler 2001 - 2002 (WG) Grand Cherokee (International Markets) 1999 - 2002 (WJ) Grand Cherokee 1995 - 2001 (XJ) Cherokee 1995 - 1998 (ZG) Grand Cherokee (International Markets) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Airbag When servicing any airbag system, it is essential to follow the proper Service Manual and/or Diagnostic Manual procedures for diagnosing, testing, and replacing of any component. When diagnosing any airbag squib circuit Diagnostic Trouble Code (DTC) with a DRBIII(R), the use of the Airbag Load Tool (Special Tool 8310 and 8443) is required. The Airbag Load Tool, used in conjunction with the DRBIII(R) are used to isolate and test components and wiring for failure. Only replace the component or wiring that has failed. This will reduce unnecessary cost to the customer or DaimlerChrysler. NOTE: AIRBAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN ANOTHER COMPONENT HAS FAILED. USE OF THE DRBIII(R) AND AIRBAG LOAD TOOL WILL DETERMINE IF THE AIRBAG HAS FAILED AND REPLACEMENT IS NEEDED. NOTE: Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Airbag/Clock Spring - Service > Page 6644 TECHNICIANS SHOULD RECORD ALL STORED AND ACTIVE AIRBAG SYSTEM FAULT CODES ON THE REPAIR ORDER. Clock Springs Recent analysis of returned clock springs have indicated that prior service may have contributed to the clock spring's failure. ^ Do not use silicone or any other lubricant spray on or near the clock spring. Lubricants are often used in the clock spring area of the steering column to eliminate noise. Lubricants may have an adverse effect on the clock spring. ^ Clock spring centering. Any repair that may disrupt the positioning of the steering wheel with the front wheels will require that the clock spring be centered. This includes clock spring replacement, steering column service, HVAC service, steering gear service, and front suspension crossmember service. Refer to the appropriate Service Manual for the clock spring centering procedure. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 6645 Clockspring Assembly / Spiral Cable: Description and Operation DESCRIPTION The clockspring is mounted on the steering column behind the steering wheel. This assembly consists of a plastic housing which contains a flat, ribbon-like, electrically conductive tape that winds and unwinds with the steering wheel rotation. OPERATION The clockspring is used to maintain a continuous electrical circuit between the wire harness and the driver side airbag module, the horn switch, and the vehicle speed control switches on vehicles that are so equipped. The clockspring must be properly centered when it is installed on the steering column following any service removal, or it will be damaged. See Clockspring Assembly/Spiral Cable/Adjustments for more information. The clockspring cannot be repaired. If the clockspring is faulty, damaged, or if the airbag has been deployed, the clockspring must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 6646 Clockspring Assembly / Spiral Cable: Adjustments CLOCKSPRING CENTERING If the rotating tape within the clockspring is not positioned properly in relation to the steering wheel and the front wheels, the clockspring may fail during use. The clockspring must be centered if it is not known to be properly positioned, or if the front wheels were moved from the straight-ahead position with the clockspring removed during any service procedure. WARNING: THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Turn the steering wheel until the front wheels are in the straight-ahead position before starting the centering procedure. 2. Disconnect and isolate the battery negative cable. If the airbag has not been deployed, wait two minutes for the system capacitor to discharge before further service. 3. Remove the airbag module. 4. If the vehicle is so equipped, unplug the wire harness connectors for the vehicle speed control switches. 5. Remove the steering wheel with a steering wheel puller (Special Tool C-3428B). 6. Depress the two plastic clockspring auto-locking tabs. 7. Keeping the locking mechanism disengaged, rotate the clockspring rotor clockwise to the end of its travel. Do not apply excessive torque. 8. From the end of the clockwise travel, rotate the rotor two and one-half turns counterclockwise. The horn wire harness should end up at the top, and the airbag wire harness at the bottom. 9. The front wheels should still be in the straight-ahead position. Install the steering wheel being certain to fit the flats on the hub of the steering wheel onto the formations on the inside of the clockspring. Pull the wire harnesses from the clockspring through the upper and lower holes in the steering wheel hub. Tighten the steering wheel nut to 61 N.m (45 ft. lbs.). Be certain not to pinch any of the wiring between the steering wheel and the nut. 10. If the vehicle is so equipped, plug in the vehicle speed control switch wire harness connectors. 11. Install the airbag module. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Page 6647 Clockspring Assembly / Spiral Cable: Service and Repair WARNING: The airbag system is a sensitive, complex electromechanical unit. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components you must first disconnect and isolate the battery negative (ground) cable. Then wait two minutes for the system capacitor to discharge before further system service. This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. 1. Turn the steering wheel until the front wheels are in the straight-ahead position before starting the procedure. 2. Disconnect and isolate the battery negative cable. If the airbag has not been deployed, wait two minutes for the system capacitor to discharge before further service. 3. Remove the driver side airbag module. 4. If the vehicle is so equipped, unplug the wire harness connectors for the vehicle speed control switches. 5. Remove the steering wheel with a steering wheel puller (Special Tool C-3428B). 6. Remove the upper and lower steering column shrouds to gain access to the clockspring wire harness connectors. 7. Unplug the wire harness connectors from the clockspring. 8. Remove the steering column opening cover and knee blocker. 9. Remove the lower fixed column shroud. 10. Unplug the wire harness connector between the clockspring and the instrument panel wire harness, located on the lower instrument panel reinforcement underneath the steering column. 11. To remove the clockspring, lift the locating fingers of the clockspring assembly from the steering column as necessary. The clockspring cannot be repaired. It must be replaced if faulty, or if the air-bag has been deployed. 12. When installing the clockspring, snap the clockspring onto the steering column. If the clock-spring is not properly positioned, see Adjustments before installing the steering wheel. 13. Plug the clockspring wire harness connector into the instrument panel wire harness. Be certain that the wire harness locator clips are properly seated on the outside of the wiring trough and that the connector latches are fully engaged. 14. Reinstall the steering column shrouds. Be certain that the clockspring wire harness is inside the shrouds. 15. The front wheels should still be in the straight-ahead position. Install the steering wheel being certain to fit the flats on the hub of the steering wheel onto the formations on the inside of the clockspring. Pull the wire harnesses from the clock-spring through the upper and lower holes in the steering wheel hub. Tighten the steering wheel nut to 61 N.m (45 ft. lbs.). Be certain not to pinch the wiring between the steering wheel and the nut. 16. If the vehicle is so equipped, plug in the vehicle speed control switch wire harness connectors. 17. Install the airbag module. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Diagnostic Connector, Air Bag > Component Information > Description and Operation Diagnostic Connector: Description and Operation CIRCUIT OPERATION The DRB scan tool connects to the data link connector. A twisted pair of wires, circuits D1 and D2, send and transmit data between the Airbag Control Module (ACM) and the DRB scan tool. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Description and Operation Impact Sensor: Description and Operation DESCRIPTION Airbag Control Module Remove/Install The impact sensor provides verification of the direction and severity of an impact. One impact sensor is used. It is located inside the Airbag Control Module (ACM), which is secured to a bracket on the floor pan transmission tunnel inside the vehicle. OPERATION The impact sensor is an accelerometer that senses the rate of deceleration. The microprocessor in the ACM monitors the impact sensor signal. A pre-programmed decision algorithm in the microprocessor determines when the deceleration rate indicates an impact is severe enough to require airbag system protection. When the programmed conditions are met, the ACM sends an electrical signal to deploy the airbag system components. The impact sensor is calibrated for the specific vehicle. The sensor is only serviced as a unit with the ACM. The sensor cannot be repaired or adjusted and, if faulty or damaged, the ACM unit must be replaced. CIRCUIT OPERATION The Airbag system uses a sensor internal to the Airbag Control Module (ACM) to detect impact. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Technical Service Bulletins > Customer Interest for Malfunction Lamp / Indicator: > 08-26-97 > Jul > 97 > Airbag Warning Lamp - Stays Dimly Illuminated Malfunction Lamp / Indicator: Customer Interest Airbag Warning Lamp - Stays Dimly Illuminated NO: 08-26-97 GROUP: Electrical EFFECTIVE DATE: Jul. 23, 1997 SUBJECT: Airbag Warning Lamp Stays Dimly Illuminated MODELS: 1997 (AN) Dakota SYMPTOM/CONDITION: Airbag warning lamp stays dimly illuminated with the ignition key in the RUN position when no Diagnostic Trouble Codes (DTC) are recorded in the Airbag Control Module's (ACM) memory. NOTE: REFER TO THE 1997 DAKOTA BODY DIAGNOSTIC PROCEDURES MANUAL (PUBLICATION NO. 81-699-96034), SECTION 3 FOR INFORMATION REGARDING AIRBAG SYSTEM DIAGNOSIS FOR AIRBAG WARNING LAMPS THAT REMAIN ILLUMINATED WITH NORMAL INTENSITY. DIAGNOSIS: Turn the ignition key to the RUN position. Monitor the airbag warning lamp. The warning lamp will normally illuminate for a few seconds as a warning lamp test feature then go out. If the warning lamp illuminates normally for a few seconds, then goes dim, perform the following Repair Procedure. NOTE: IT MAY REQUIRE ALMOST TOTAL DARKNESS INSIDE THE VEHICLE TO BE ABLE TO IDENTIFY IF THE AIRBAG WARNING LAMP IS DIMLY LIT. PARTS REQUIRED: AR (1) 56009103 Instrument Cluster, High Line With Tachometer, 120 mph AR (1) 56009104 Instrument Cluster, Low Line, 120 mph AR (1) 56009105 Instrument Cluster, High Line With Tachometer, 200 kph AR (1) 56009106 Instrument Cluster, Low Line, 200 kph REPAIR PROCEDURE: This bulletin involves replacing the instrument cluster with a revised cluster. 1. Record the radio station presets. 2. Disconnect and isolate the battery negative cable. 3. Turn the ignition switch to the UNLOCK position, set the parking brake, and if the vehicle is so equipped, place the automatic transmission gear selector into the LOW position. 4. If the vehicle is so equipped, set the tilt steering wheel to its lowest position. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Technical Service Bulletins > Customer Interest for Malfunction Lamp / Indicator: > 08-26-97 > Jul > 97 > Airbag Warning Lamp - Stays Dimly Illuminated > Page 6662 5. Using a trim stick or another suitable wide flat-bladed tool, carefully pry around the perimeter of the cluster bezel to disengage the nine snap-clip retainers that secure the bezel to the instrument panel (Figure 1). 6. Pull the cluster bezel away from the instrument panel far enough to unplug the wire harness connector from the fog lamp switch or fog lamp switch wire connector locator plug. 7. Remove the cluster bezel from the vehicle. 8. Remove the four screws that secure the instrument cluster to the instrument panel (Figure 2). 9. On automatic transmission equipped vehicles, pull the cluster rearward far enough to remove the two screws that secure the automatic transmission gear selector indicator to the back of the cluster housing. Pull the gear selector indicator out of the cluster housing. 10. Remove the instrument cluster from the instrument panel. 11. If the vehicle is so equipped, attach the gear selector indicator to the new instrument cluster (see Parts Required section) with two screws. 12. Install the new instrument cluster (see Parts Required section) into the instrument panel and attach the cluster with four screws. Tighten the instrument cluster mounting screws to 2.2 Nm (20 in. lbs.). NOTE: THE INSTRUMENT CLUSTER HAS TWO SELF-DOCKING WIRE HARNESS CONNECTORS THAT WILL BE AUTOMATICALLY ALIGNED WITH AND CONNECTED TO THE INSTRUMENT PANEL WIRE HARNESS WHEN THE CLUSTER IS INSTALLED IN THE INSTRUMENT PANEL. 13. Attach the wire harness connector to the fog lamp switch on the instrument cluster bezel or the fog lamp switch wire connector locator plug. 14. Install the instrument cluster bezel to the instrument panel by carefully inserting the nine snap-clips into place. 15. If the vehicle is so equipped, return the tilt steering wheel to its original position and place the gear selector into the PARK position. Place the ignition key in the LOCK position. 16. Connect the battery negative cable, set the radio stations to the values recorded in step one and reset the clock. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Technical Service Bulletins > Customer Interest for Malfunction Lamp / Indicator: > 08-26-97 > Jul > 97 > Airbag Warning Lamp - Stays Dimly Illuminated > Page 6663 Labor Operation No: 08-45-10-90 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Malfunction Lamp / Indicator: > 08-26-97 > Jul > 97 > Airbag Warning Lamp - Stays Dimly Illuminated Malfunction Lamp / Indicator: All Technical Service Bulletins Airbag Warning Lamp - Stays Dimly Illuminated NO: 08-26-97 GROUP: Electrical EFFECTIVE DATE: Jul. 23, 1997 SUBJECT: Airbag Warning Lamp Stays Dimly Illuminated MODELS: 1997 (AN) Dakota SYMPTOM/CONDITION: Airbag warning lamp stays dimly illuminated with the ignition key in the RUN position when no Diagnostic Trouble Codes (DTC) are recorded in the Airbag Control Module's (ACM) memory. NOTE: REFER TO THE 1997 DAKOTA BODY DIAGNOSTIC PROCEDURES MANUAL (PUBLICATION NO. 81-699-96034), SECTION 3 FOR INFORMATION REGARDING AIRBAG SYSTEM DIAGNOSIS FOR AIRBAG WARNING LAMPS THAT REMAIN ILLUMINATED WITH NORMAL INTENSITY. DIAGNOSIS: Turn the ignition key to the RUN position. Monitor the airbag warning lamp. The warning lamp will normally illuminate for a few seconds as a warning lamp test feature then go out. If the warning lamp illuminates normally for a few seconds, then goes dim, perform the following Repair Procedure. NOTE: IT MAY REQUIRE ALMOST TOTAL DARKNESS INSIDE THE VEHICLE TO BE ABLE TO IDENTIFY IF THE AIRBAG WARNING LAMP IS DIMLY LIT. PARTS REQUIRED: AR (1) 56009103 Instrument Cluster, High Line With Tachometer, 120 mph AR (1) 56009104 Instrument Cluster, Low Line, 120 mph AR (1) 56009105 Instrument Cluster, High Line With Tachometer, 200 kph AR (1) 56009106 Instrument Cluster, Low Line, 200 kph REPAIR PROCEDURE: This bulletin involves replacing the instrument cluster with a revised cluster. 1. Record the radio station presets. 2. Disconnect and isolate the battery negative cable. 3. Turn the ignition switch to the UNLOCK position, set the parking brake, and if the vehicle is so equipped, place the automatic transmission gear selector into the LOW position. 4. If the vehicle is so equipped, set the tilt steering wheel to its lowest position. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Malfunction Lamp / Indicator: > 08-26-97 > Jul > 97 > Airbag Warning Lamp - Stays Dimly Illuminated > Page 6669 5. Using a trim stick or another suitable wide flat-bladed tool, carefully pry around the perimeter of the cluster bezel to disengage the nine snap-clip retainers that secure the bezel to the instrument panel (Figure 1). 6. Pull the cluster bezel away from the instrument panel far enough to unplug the wire harness connector from the fog lamp switch or fog lamp switch wire connector locator plug. 7. Remove the cluster bezel from the vehicle. 8. Remove the four screws that secure the instrument cluster to the instrument panel (Figure 2). 9. On automatic transmission equipped vehicles, pull the cluster rearward far enough to remove the two screws that secure the automatic transmission gear selector indicator to the back of the cluster housing. Pull the gear selector indicator out of the cluster housing. 10. Remove the instrument cluster from the instrument panel. 11. If the vehicle is so equipped, attach the gear selector indicator to the new instrument cluster (see Parts Required section) with two screws. 12. Install the new instrument cluster (see Parts Required section) into the instrument panel and attach the cluster with four screws. Tighten the instrument cluster mounting screws to 2.2 Nm (20 in. lbs.). NOTE: THE INSTRUMENT CLUSTER HAS TWO SELF-DOCKING WIRE HARNESS CONNECTORS THAT WILL BE AUTOMATICALLY ALIGNED WITH AND CONNECTED TO THE INSTRUMENT PANEL WIRE HARNESS WHEN THE CLUSTER IS INSTALLED IN THE INSTRUMENT PANEL. 13. Attach the wire harness connector to the fog lamp switch on the instrument cluster bezel or the fog lamp switch wire connector locator plug. 14. Install the instrument cluster bezel to the instrument panel by carefully inserting the nine snap-clips into place. 15. If the vehicle is so equipped, return the tilt steering wheel to its original position and place the gear selector into the PARK position. Place the ignition key in the LOCK position. 16. Connect the battery negative cable, set the radio stations to the values recorded in step one and reset the clock. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Malfunction Lamp / Indicator: > 08-26-97 > Jul > 97 > Airbag Warning Lamp - Stays Dimly Illuminated > Page 6670 Labor Operation No: 08-45-10-90 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Technical Service Bulletins > Page 6671 Malfunction Lamp / Indicator: Description and Operation SYSTEM OPERATION The airbag indicator lamp gives an indication when the airbag system is faulty or inoperative. The lamp is controlled by the instrument cluster circuitry based upon messages received from the Airbag Control Module (ACM) on the Chrysler Collision Detection (CCD) data bus. The lamp is turned on by the ACM for about seven seconds when the ignition switch is turned to the On position as a bulb test. The ACM continually monitors the airbag system circuits and sensors to decide whether the system is in good operating condition. The ACM then sends the proper message to the instrument cluster on the CCD data bus to turn the lamp on or off. If the ACM turns the lamp on after the bulb test, it indicates the ACM has detected a system malfunction and/or that the airbag system has become inoperative. A lamp-on message does not mean that either or both airbags will not deploy upon an impact, only that they might not deploy, depending upon the nature of the detected malfunction. Each time the instrument cluster circuitry receives a lamp-on message from the ACM, it will light the lamp for three seconds or the duration of the airbag system malfunction, whichever is longer. The airbag indicator lamp also has a lamp backup feature. About twenty seconds after the ignition switch is turned to the On position, if an inoperative airbag warning lamp circuit was detected during the bulb test sequence, the instrument cluster circuitry will flash the seat belt reminder lamp on and off for about thirty seconds. If the seat belt reminder lamp stays on after flashing for thirty seconds, or comes on at any time other than about twenty seconds after the initial ignition-on sequence, it indicates an airbag system fault has been detected and that the airbag indicator lamp is inoperative. CIRCUIT OPERATION The airbag warning lamp illuminates when the Airbag Control Module (ACM) provides ground for the lamp on circuit R41. Illumination of the Airbag warning lamp is controlled by the Central Timer Module (CTM) and the CCD Bus. When the Airbag Control Module (ACM) detects a problem in the system it sends a signal on the CCD Bus to the CTM. The CTM process the signal and illuminates the AIRBAG lamp in the instrument cluster. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Technical Service Bulletins > Page 6672 Malfunction Lamp / Indicator: Testing and Inspection The diagnosis found here addresses an inoperative lamp condition. If the airbag indicator lamp stays on with the ignition switch in the On position, or comes on and stays on while driving, refer to Air Bag Systems for diagnosis. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. The airbag indicator lamp has a lamp backup feature. Twenty seconds after the ignition switch is turned to the On position, if the instrument cluster circuitry has detected an inoperative airbag warning lamp circuit it will flash the seat belt reminder lamp on and off for thirty seconds. Once the instrument cluster circuitry has detected an inoperative airbag warning lamp circuit, if a lamp-on message is received from the Airbag Control Module ( ACM) on the Chrysler Collision Detection (CCD) data bus, the seat belt reminder lamp will remain on for the duration of the airbag system malfunction. If the airbag indicator lamp fails to light when the ignition switch is turned to the On position, and the seat belt reminder lamp flashes following its normal display function (about seven seconds after the ignition switch is turned to the On position), diagnosis of the airbag system and/or the CCD data bus should be performed with a DRB scan tool as described in the proper Diagnostic Procedures. For diagnosis of the airbag lamp and the instrument cluster circuitry, see Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Instrument Cluster. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time Child Seat: Technical Service Bulletins Child Seat - Tether Anchor Part Numbers & Labor Time NUMBER: 23-008-00 Rev. B GROUP: Body DATE: Nov. 24, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. A, DATED JULY 7, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND PARTS. SUBJECT: Child Seat Tether Anchors MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 2000 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1993 (AJ) Lebaron Coupe 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2000 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1990 - 1994 (BD) Laser/Talon 1994 - 2001 (BR/BE) Ram Truck 1989 - 1992 (B2) Colt/Summit 1992 - 1995 (B3) Colt Vista 1989 (B5) Conquest 1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada) 1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon 1993 - 1994 (B9) Colt/Summit 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 JA Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GTS **2000 (TJ) Wrangler** 1999 - 2000 (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1993 - 1998 (WJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND LABOR OPERATION NUMBERS NECESSARY TO INSTALL A CHILD SEAT TETHER ANCHOR. DAIMLERCHRYSLER WILL REIMBURSE YOU FOR THE ANCHORS AND LABOR TO INSTALL THEM. THIS IS BEING DONE IN THE INTEREST OF CUSTOMER SATISFACTION. REFER TO GLOBAL WARRANTY ADMINISTRATION BULLETIN # D-99-23 FOR COMPLETE REIMBURSEMENT INSTRUCTIONS. DISCUSSION: User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model Year, and in light trucks in the 2001 Model Year. Tether straps improve the performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit for a Kid" Program, owners of earlier products are expected to approach dealers for the free provision and installation of the anchor hardware. DaimlerChrysler Corporation is offering child seat tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary parts and a detailed instruction sheet. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 6677 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 6678 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 6679 PARTS REQUIRED: POLICY: Customer Satisfaction Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 6680 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 6681 TIME ALLOWANCE: FAILURE CODE: Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module Technical Service Bulletin # 731 Date: 970701 Recall - Airbag Control Module No. 731 July, 1997 To: All Dealers Subject: Safety Recall # 731 -- Airbag Control Module Models: ^ 1997 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Belvidere Assembly Plant ("D" in the 11th VIN Position) Through September 3, 1996 (MDH 090317) ^ 1997 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Toluca Assembly Plant ("T" in the 11th VIN Position) Through September 9, 1996 (MDH 090906) ^ 1997 Model Year Dodge Dakota (AN) Vehicles Built Through September 5, 1996 (MDH 090521) ^ 1997 Model Year Jeep Wrangler (TJ) Vehicles Built Through September 3, 1996 (MDH 090319) ^ 1997 Model Year Jeep Grand Cherokee (ZJ) Vehicles Built Through September 3, 1996 (MDH 090312) ^ 1996 Model Year Dodge Viper GTS Coupe (SR) Vehicles Built Through September 30, 1996 (MDH 093014) The airbags on the above listed vehicles, may inadvertently deploy during a three (3) second period after the ignition key has been turned to the off position, which could injure a vehicle occupant. To correct this condition, the airbag control module (ACM) must be replaced. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory, and should perform this recall on vehicles in for service as determined by using DIAL System Function 70. Details of this service action are explained in the following sections. Service Procedure Videotape No videotape of the service procedure for this recall will be provided. Dealer Notification & Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53, 70 and VIP All involved vehicles will be entered to DIAL System Functions 53, 70 and VIP at the time of recall implementation for dealer inquiry as needed. Parts Important: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 6691 Each involved dealer, to whom vehicles in the recall were invoiced (or the current dealer at the same street address), will receive enough of each ACM Package to service about 25% of those vehicles. Each package contains one (1) ACM. Refer to the table above for the appropriate package application: Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for the service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Service Procedure For Neon (PL) Vehicles: 1. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. For Manual Transmission Equipped Vehicles: Remove the shifter knob fastener and remove the shifter knob. 3. Remove the front two (2) center console attaching screws located near the cup holders (Figure 1). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 6692 4. Remove the two (2) screws at the bottom of the storage bin (Figure 2). 5. Remove the bolt access covers and the two lower console bracket bolts on each side of the console bin. 6. Raise the park brake hand lever as high as possible. 7. Remove the center console assembly. WARNING: The auto adjusting feature of the park brake lever assembly contains a clock spring loaded to approximately 20 lbs. DO NOT release the auto adjuster lock out device before installing the cables into the equalizer. Keep hands out of auto adjuster sector and pawl area. Failure to observe caution in handling this mechanism could lead to serious injury. 8. Lower the park brake handle. 9. Grasp the park brake lever output cable by hand and pull upward until a 3/16" drill bit can be inserted into the handle and sector gear mechanism (Figure 3). This will remove the tension from the park brake cables. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 6693 10. Remove both rear park brake cables from the park brake cable equalizer (Figure 4). 11. Disconnect the brake warning light electrical connector from the park brake lever switch. 12. Remove the two park brake lever attaching nuts and remove the park brake lever assembly. 13. Disconnect the ACM wiring connector (Figure 5): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 14. Remove the remaining three (3) nuts that secure the ACM mounting bracket to the floor, disconnect the two (2) park brake lever switch wire harness clips from the ACM bracket and then remove the ACM and bracket assembly. 15. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 16. Loosely install the three (3) ACM attaching nuts. 17. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 6694 18. Install the park brake lever assembly. 19. Tighten the four (4) ACM nuts and the remaining park brake lever nut to 115 in-lbs (12.5 N.m). 20. Connect the park brake lever switch electrical connector and attach the wiring clips to the ACM bracket. 21. Install both rear park brake cables into the equalizer. 22. Pull the park brake lever handle all the way up. 23. Firmly grasp the park brake lever locking pin (drill bit) and quickly remove it from the mechanism. 24. Cycle the park brake lever once to position the park brake cables. 25. Make sure that the park brake lever is fully raised and then install the center console assembly. 26. Install the front two (2) center console attaching screws located near the cup holders (Figure 1). 27. Install the two (2) screws at the bottom of the storage bin (Figure 2). 28. Install the two (2) outer lower console bracket bolts on each side of the storage bin and then install the bolt covers. 29. For Manual Transmission Equipped Vehicles: Install the shifter knob and fastener. 30. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 31. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 32. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. Service Procedure For Dakota (AN) Vehicles: 1. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Pull back the floor carpet from the area around the center instrument panel support. 3. Remove the two (2) front center support bracket screws (Figure 6). 4. Remove the two (2) left side and one (1) right side support bracket screws (Figure 6). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 6695 5. Remove the support bracket. 6. Remove the ground eyelet screw from the left side of the ACM bracket. 7. Disconnect the ACM wiring connector (Figure 7): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 8. Remove the three (3) screws that secure the ACM mounting bracket to the floor pan transmission tunnel (Figure 8). 9. Remove the ACM and bracket assembly. 10. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 11. Tighten the three (3) ACM to floorpan transmission tunnel attaching screws to 105 in-lbs (11.8 N.m). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 6696 12. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. 13. Install the ground eyelet screw to the left side of the ACM bracket. 14. Install the center instrument panel support bracket. 15. Install the two (2) left side and one (1) right side support bracket screws (Figure 6). Tighten the bracket screws to 105 in-lbs (11.8 N.m). 16. Install the two (2) front center support bracket screws (Figure 6). Tighten the bracket screws to 105 in-lbs (11.8 N.m). 17. Reinstall the floor carpet around the center instrument panel support. 18. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 19. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 20. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. Service Procedure For Wrangler (TJ) Vehicles: 1. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Pull back the floor carpet from the area under the heater-A/C housing floor duct and forward of the center floor console. 3. For vehicles equipped with ABS: Remove the ABS acceleration sensor from its mounting bracket and set aside (Figure 9). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 6697 4. Remove the four (4) screws that secure the ACM mounting bracket to the floor pan transmission tunnel (Figure 10). 5. Disconnect the ACM wiring connector (Figure 11): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 6. Slide the ACM and bracket assembly out from under the heater-A/C housing floor duct and remove it from the vehicle. 7. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 8. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. 9. Tighten the four (4) ACM to floorpan transmission tunnel attaching screws to 95 in-lbs (10.7 N.m) (Figure 10). 10. For vehicles equipped with ABS: Reinstall the ABS acceleration sensor (Figure 9). Tighten the sensor mounting bolts to 40 in-lbs (4.5 N.m). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 6698 11. Reinstall the floor carpet under the heater-A/C floor duct. 12. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 13. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 14. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. Service Procedure For Grand Cherokee (ZJ) Vehicles: 1. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Remove the transmission shift lever handle by pulling straight up firmly and quickly. 3. Pry up the transmission shift indicator bezel with a trim stick (Figure 12). 4. Lift the bezel far enough to remove the lamp socket from the bezel and then remove the transmission shift indicator bezel from the console. 5. Pry up the transfer case shift indicator bezel with a trim stick (Figure 12). 6. Lift the bezel far enough to remove the lamp socket from the bezel and then remove the transfer case bezel from the console. 7. Remove the console attaching screws and then remove the console (Figure 12). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 6699 8. Disconnect the ACM wiring connector (Figure 13): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 9. Remove the four (4) screws that secure the ACM mounting bracket to the floor transmission tunnel (Figure 14). 10. Remove the ACM and bracket assembly. 11. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 12. Tighten the four (4) ACM attaching screws to 95 in-lbs (10.7 N.m). 13. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. 14. Install the console and secure it with the attaching screws (Figure 12). 15. Install the lamp socket into the transfer case shift bezel and then install the bezel into the console (Figure 12). 16. Install the lamp socket into the transmission shift indicator bezel and then install the bezel into the console (Figure 12). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 6700 17. Install the transmission shift lever handle. 18. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 19. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 20. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. Service Procedure For Viper GTS Coupe (SR) Vehicles: 1. Remove the left rear wheel and tire assembly. 2. Remove the left rear wheel well inner splash shield. 3. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 4. Remove the instrument panel center bezel and then disconnect the rear window defogger switch, the power window switches and the lighter (Figure 15). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 6701 5. Remove the right and left knee blockers (Figure 16). 6. Remove the headlamp switch knob by inserting a paper clip in the hole under the knob and pushing gently to release the lock clip (Figure 16). 7. Remove the tilt steering handle. 8. Remove the upper steering column shroud. 9. Remove the instrument panel bezel (Figure 16). NOTE: Be careful not to break the headlamp switch lock tab when removing the I/P bezel. 10. Remove the two (2) radio mounting screws. 11. Remove the radio and disconnect the wire connector, coaxial cable and antenna cable. 12. Remove the radio from the vehicle. 13. Remove the HVAC control module. Only disconnect the vacuum and electrical connectors. Do not disconnect the cable. Set the control module aside. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 6702 14. Reach through the radio opening and disconnect the ACM wiring connector (Figure 17): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 15. Remove the three (3) nuts that secure the ACM mounting bracket to the floor pan transmission tunnel (Figure 18). 16. Slide the ACM and bracket assembly out through the radio opening. 17. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 18. Tighten the three (3) ACM to floorpan transmission tunnel attaching screws to 95 in-lbs (10.7 N.m). 19. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. 20. Connect the HVAC control head electrical and vacuum connectors. Install the HVAC control module. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 6703 21. Connect the radio wire connector, coaxial cable and antenna cable. 22. Install the radio into the instrument panel and tighten the two (2) mounting screws. 23. Install the instrument panel bezel (Figure 16). NOTE: Be careful when installing the I/P bezel. Do not break the headlamp switch lock tab. 24. Install the headlamp switch knob (Figure 16). 25. Install the upper steering column cover. 26. Install the tilt steering handle. 27. Install the right and left knee blockers (Figure 16). 28. Connect the rear window defogger switch, the power window switches and the lighter and then install the instrument panel center bezel (Figure 15). 29. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 30. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 31. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. 32. Install the left rear wheel well inner splash shield. 33. Install the left rear wheel and tire assembly. Completion Reporting and Reimbursement / Parts Return Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. Parts Return Initially, a small number of ACM and bracket assemblies are required to be returned to the Warranty Material Return Center. When an adequate number of returned parts have been accumulated, Parts Return Documents will no longer be generated and parts are to be discarded. Note: See the Warranty Administration Manual, Recall Claim Processing Section for complete recall claim processing and material return instructions. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 6704 CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Dealer Service Instructions IMPORTANT Safety Recall # 731 -- Airbag Control Module ^ Effective immediately, this recall (# 731) cancels and supercedes Recall # 683 -- Airbag Control Module for 1997 Jeep Wrangler (TJ) vehicles. ^ This service requirement applies only to: ^ 1997 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Belvidere Assembly Plant ("D" in the 11th VIN Position) Through September 3, 1996 (MDH 090317) ^ 1997 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Toluca Assembly Plant ("T" in the 11th VIN Position) Through September 9, 1996 (MDH 090906) ^ 1997 Model Year Dodge Dakota (AN) Vehicles Built Through September 5, 1996 (MDH 090521) ^ 1997 Model Year Jeep Wrangler (TJ) Vehicles Built Through September 3, 1996 (MDH 090319) ^ 1997 Model Year Jeep Grand Cherokee (ZJ) Vehicles Built Through September 3, 1996 (MDH 090312) ^ 1996 Model Year Dodge Viper GTS Coupe (SR) Vehicles Built Through September 30, 1996 (MDH 093014) ^ The airbags on the above listed vehicles, may inadvertently deploy during a three (3) second period after the ignition key has been turned to the off position. To correct this condition, the airbag control module (ACM) must be replaced. Parts Packages: ^ Each involved dealer, to whom vehicles in the recall were invoiced, will receive enough ACM Packages to service about 25% of those vehicles. Owner Letter SAFETY RECALL TO REPLACE YOUR VEHICLE'S AIRBAG CONTROL MODULE Dear Chrysler Vehicle Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Chrysler Corporation has determined that a defect which relates to motor vehicle safety exists in some 1997 Plymouth and Dodge Neon; Dodge Dakota; Jeep Grand Cherokee and Wrangler; and 1996 Dodge Viper GTS Coupe vehicles. The problem is... The airbags on your vehicle (identified on the enclosed form), may inadvertently deploy during a three (3) second period after the ignition key has been turned to the off position, which could injure a vehicle occupant. What Chrysler and your dealer will do... Chrysler will repair your (vehicle) free of charge (parts and labor). To do this, your dealer will replace the airbag control module. The work will take about one hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do to ensure your safety... ^ Simply contact your dealer right away to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to the dealer. If you need help... Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > 731 > Jul > 97 > Recall Airbag Control Module > Page 6705 If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-853-1403. A representative will assist you in getting your vehicle repaired. If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590, or call the Toll Free Auto Safety Hotline at 1-800-424-9393. (Washington, D.C. area residents may call 366-0123.) We're sorry for any inconvenience, but we are sincerely concerned about your safety. Thanks for your attention to this important matter. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module Technical Service Bulletin # 731 Date: 970701 Recall - Airbag Control Module No. 731 July, 1997 To: All Dealers Subject: Safety Recall # 731 -- Airbag Control Module Models: ^ 1997 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Belvidere Assembly Plant ("D" in the 11th VIN Position) Through September 3, 1996 (MDH 090317) ^ 1997 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Toluca Assembly Plant ("T" in the 11th VIN Position) Through September 9, 1996 (MDH 090906) ^ 1997 Model Year Dodge Dakota (AN) Vehicles Built Through September 5, 1996 (MDH 090521) ^ 1997 Model Year Jeep Wrangler (TJ) Vehicles Built Through September 3, 1996 (MDH 090319) ^ 1997 Model Year Jeep Grand Cherokee (ZJ) Vehicles Built Through September 3, 1996 (MDH 090312) ^ 1996 Model Year Dodge Viper GTS Coupe (SR) Vehicles Built Through September 30, 1996 (MDH 093014) The airbags on the above listed vehicles, may inadvertently deploy during a three (3) second period after the ignition key has been turned to the off position, which could injure a vehicle occupant. To correct this condition, the airbag control module (ACM) must be replaced. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory, and should perform this recall on vehicles in for service as determined by using DIAL System Function 70. Details of this service action are explained in the following sections. Service Procedure Videotape No videotape of the service procedure for this recall will be provided. Dealer Notification & Vehicle List All dealers will receive a copy of this dealer recall notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53, 70 and VIP All involved vehicles will be entered to DIAL System Functions 53, 70 and VIP at the time of recall implementation for dealer inquiry as needed. Parts Important: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 6711 Each involved dealer, to whom vehicles in the recall were invoiced (or the current dealer at the same street address), will receive enough of each ACM Package to service about 25% of those vehicles. Each package contains one (1) ACM. Refer to the table above for the appropriate package application: Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for the service with their dealers. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Service Procedure For Neon (PL) Vehicles: 1. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. For Manual Transmission Equipped Vehicles: Remove the shifter knob fastener and remove the shifter knob. 3. Remove the front two (2) center console attaching screws located near the cup holders (Figure 1). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 6712 4. Remove the two (2) screws at the bottom of the storage bin (Figure 2). 5. Remove the bolt access covers and the two lower console bracket bolts on each side of the console bin. 6. Raise the park brake hand lever as high as possible. 7. Remove the center console assembly. WARNING: The auto adjusting feature of the park brake lever assembly contains a clock spring loaded to approximately 20 lbs. DO NOT release the auto adjuster lock out device before installing the cables into the equalizer. Keep hands out of auto adjuster sector and pawl area. Failure to observe caution in handling this mechanism could lead to serious injury. 8. Lower the park brake handle. 9. Grasp the park brake lever output cable by hand and pull upward until a 3/16" drill bit can be inserted into the handle and sector gear mechanism (Figure 3). This will remove the tension from the park brake cables. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 6713 10. Remove both rear park brake cables from the park brake cable equalizer (Figure 4). 11. Disconnect the brake warning light electrical connector from the park brake lever switch. 12. Remove the two park brake lever attaching nuts and remove the park brake lever assembly. 13. Disconnect the ACM wiring connector (Figure 5): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 14. Remove the remaining three (3) nuts that secure the ACM mounting bracket to the floor, disconnect the two (2) park brake lever switch wire harness clips from the ACM bracket and then remove the ACM and bracket assembly. 15. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 16. Loosely install the three (3) ACM attaching nuts. 17. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 6714 18. Install the park brake lever assembly. 19. Tighten the four (4) ACM nuts and the remaining park brake lever nut to 115 in-lbs (12.5 N.m). 20. Connect the park brake lever switch electrical connector and attach the wiring clips to the ACM bracket. 21. Install both rear park brake cables into the equalizer. 22. Pull the park brake lever handle all the way up. 23. Firmly grasp the park brake lever locking pin (drill bit) and quickly remove it from the mechanism. 24. Cycle the park brake lever once to position the park brake cables. 25. Make sure that the park brake lever is fully raised and then install the center console assembly. 26. Install the front two (2) center console attaching screws located near the cup holders (Figure 1). 27. Install the two (2) screws at the bottom of the storage bin (Figure 2). 28. Install the two (2) outer lower console bracket bolts on each side of the storage bin and then install the bolt covers. 29. For Manual Transmission Equipped Vehicles: Install the shifter knob and fastener. 30. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 31. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 32. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. Service Procedure For Dakota (AN) Vehicles: 1. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Pull back the floor carpet from the area around the center instrument panel support. 3. Remove the two (2) front center support bracket screws (Figure 6). 4. Remove the two (2) left side and one (1) right side support bracket screws (Figure 6). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 6715 5. Remove the support bracket. 6. Remove the ground eyelet screw from the left side of the ACM bracket. 7. Disconnect the ACM wiring connector (Figure 7): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 8. Remove the three (3) screws that secure the ACM mounting bracket to the floor pan transmission tunnel (Figure 8). 9. Remove the ACM and bracket assembly. 10. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 11. Tighten the three (3) ACM to floorpan transmission tunnel attaching screws to 105 in-lbs (11.8 N.m). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 6716 12. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. 13. Install the ground eyelet screw to the left side of the ACM bracket. 14. Install the center instrument panel support bracket. 15. Install the two (2) left side and one (1) right side support bracket screws (Figure 6). Tighten the bracket screws to 105 in-lbs (11.8 N.m). 16. Install the two (2) front center support bracket screws (Figure 6). Tighten the bracket screws to 105 in-lbs (11.8 N.m). 17. Reinstall the floor carpet around the center instrument panel support. 18. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 19. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 20. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. Service Procedure For Wrangler (TJ) Vehicles: 1. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Pull back the floor carpet from the area under the heater-A/C housing floor duct and forward of the center floor console. 3. For vehicles equipped with ABS: Remove the ABS acceleration sensor from its mounting bracket and set aside (Figure 9). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 6717 4. Remove the four (4) screws that secure the ACM mounting bracket to the floor pan transmission tunnel (Figure 10). 5. Disconnect the ACM wiring connector (Figure 11): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 6. Slide the ACM and bracket assembly out from under the heater-A/C housing floor duct and remove it from the vehicle. 7. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 8. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. 9. Tighten the four (4) ACM to floorpan transmission tunnel attaching screws to 95 in-lbs (10.7 N.m) (Figure 10). 10. For vehicles equipped with ABS: Reinstall the ABS acceleration sensor (Figure 9). Tighten the sensor mounting bolts to 40 in-lbs (4.5 N.m). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 6718 11. Reinstall the floor carpet under the heater-A/C floor duct. 12. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 13. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 14. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. Service Procedure For Grand Cherokee (ZJ) Vehicles: 1. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Remove the transmission shift lever handle by pulling straight up firmly and quickly. 3. Pry up the transmission shift indicator bezel with a trim stick (Figure 12). 4. Lift the bezel far enough to remove the lamp socket from the bezel and then remove the transmission shift indicator bezel from the console. 5. Pry up the transfer case shift indicator bezel with a trim stick (Figure 12). 6. Lift the bezel far enough to remove the lamp socket from the bezel and then remove the transfer case bezel from the console. 7. Remove the console attaching screws and then remove the console (Figure 12). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 6719 8. Disconnect the ACM wiring connector (Figure 13): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 9. Remove the four (4) screws that secure the ACM mounting bracket to the floor transmission tunnel (Figure 14). 10. Remove the ACM and bracket assembly. 11. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 12. Tighten the four (4) ACM attaching screws to 95 in-lbs (10.7 N.m). 13. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. 14. Install the console and secure it with the attaching screws (Figure 12). 15. Install the lamp socket into the transfer case shift bezel and then install the bezel into the console (Figure 12). 16. Install the lamp socket into the transmission shift indicator bezel and then install the bezel into the console (Figure 12). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 6720 17. Install the transmission shift lever handle. 18. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 19. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 20. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. Service Procedure For Viper GTS Coupe (SR) Vehicles: 1. Remove the left rear wheel and tire assembly. 2. Remove the left rear wheel well inner splash shield. 3. With the ignition key in the OFF position, disconnect and isolate the negative battery cable. WAIT TWO (2) MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE CONTINUING. Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 4. Remove the instrument panel center bezel and then disconnect the rear window defogger switch, the power window switches and the lighter (Figure 15). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 6721 5. Remove the right and left knee blockers (Figure 16). 6. Remove the headlamp switch knob by inserting a paper clip in the hole under the knob and pushing gently to release the lock clip (Figure 16). 7. Remove the tilt steering handle. 8. Remove the upper steering column shroud. 9. Remove the instrument panel bezel (Figure 16). NOTE: Be careful not to break the headlamp switch lock tab when removing the I/P bezel. 10. Remove the two (2) radio mounting screws. 11. Remove the radio and disconnect the wire connector, coaxial cable and antenna cable. 12. Remove the radio from the vehicle. 13. Remove the HVAC control module. Only disconnect the vacuum and electrical connectors. Do not disconnect the cable. Set the control module aside. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 6722 14. Reach through the radio opening and disconnect the ACM wiring connector (Figure 17): A. Pull the two white lock bars out about 1/8" (3 mm) on each side of the connector. B. Squeeze the two (2) connector latch tabs between your thumb and forefinger while pulling the connector out of the module. 15. Remove the three (3) nuts that secure the ACM mounting bracket to the floor pan transmission tunnel (Figure 18). 16. Slide the ACM and bracket assembly out through the radio opening. 17. Install the provided ACM and bracket assembly with the arrow on the module pointing forward. 18. Tighten the three (3) ACM to floorpan transmission tunnel attaching screws to 95 in-lbs (10.7 N.m). 19. Connect the wiring connector to the ACM. Make sure it is fully seated and the lock bars are engaged. 20. Connect the HVAC control head electrical and vacuum connectors. Install the HVAC control module. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 6723 21. Connect the radio wire connector, coaxial cable and antenna cable. 22. Install the radio into the instrument panel and tighten the two (2) mounting screws. 23. Install the instrument panel bezel (Figure 16). NOTE: Be careful when installing the I/P bezel. Do not break the headlamp switch lock tab. 24. Install the headlamp switch knob (Figure 16). 25. Install the upper steering column cover. 26. Install the tilt steering handle. 27. Install the right and left knee blockers (Figure 16). 28. Connect the rear window defogger switch, the power window switches and the lighter and then install the instrument panel center bezel (Figure 15). 29. Connect the DRB III, turn the ignition switch to the ON position and then exit the vehicle with the DRB III. 30. Reconnect the negative battery cable and then watch the airbag light in the instrument cluster, it should light for about 6-8 seconds and then go out. 31. With the DRB III, verify that no system diagnostic codes have been set. NOTE: If the airbag warning lamp fails to light or the light stays on, or the DRB displays a diagnostic code, a system malfunction exists. Diagnose and repair the condition following normal service procedures. 32. Install the left rear wheel well inner splash shield. 33. Install the left rear wheel and tire assembly. Completion Reporting and Reimbursement / Parts Return Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances as shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. Parts Return Initially, a small number of ACM and bracket assemblies are required to be returned to the Warranty Material Return Center. When an adequate number of returned parts have been accumulated, Parts Return Documents will no longer be generated and parts are to be discarded. Note: See the Warranty Administration Manual, Recall Claim Processing Section for complete recall claim processing and material return instructions. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 6724 CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Dealer Service Instructions IMPORTANT Safety Recall # 731 -- Airbag Control Module ^ Effective immediately, this recall (# 731) cancels and supercedes Recall # 683 -- Airbag Control Module for 1997 Jeep Wrangler (TJ) vehicles. ^ This service requirement applies only to: ^ 1997 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Belvidere Assembly Plant ("D" in the 11th VIN Position) Through September 3, 1996 (MDH 090317) ^ 1997 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Toluca Assembly Plant ("T" in the 11th VIN Position) Through September 9, 1996 (MDH 090906) ^ 1997 Model Year Dodge Dakota (AN) Vehicles Built Through September 5, 1996 (MDH 090521) ^ 1997 Model Year Jeep Wrangler (TJ) Vehicles Built Through September 3, 1996 (MDH 090319) ^ 1997 Model Year Jeep Grand Cherokee (ZJ) Vehicles Built Through September 3, 1996 (MDH 090312) ^ 1996 Model Year Dodge Viper GTS Coupe (SR) Vehicles Built Through September 30, 1996 (MDH 093014) ^ The airbags on the above listed vehicles, may inadvertently deploy during a three (3) second period after the ignition key has been turned to the off position. To correct this condition, the airbag control module (ACM) must be replaced. Parts Packages: ^ Each involved dealer, to whom vehicles in the recall were invoiced, will receive enough ACM Packages to service about 25% of those vehicles. Owner Letter SAFETY RECALL TO REPLACE YOUR VEHICLE'S AIRBAG CONTROL MODULE Dear Chrysler Vehicle Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Chrysler Corporation has determined that a defect which relates to motor vehicle safety exists in some 1997 Plymouth and Dodge Neon; Dodge Dakota; Jeep Grand Cherokee and Wrangler; and 1996 Dodge Viper GTS Coupe vehicles. The problem is... The airbags on your vehicle (identified on the enclosed form), may inadvertently deploy during a three (3) second period after the ignition key has been turned to the off position, which could injure a vehicle occupant. What Chrysler and your dealer will do... Chrysler will repair your (vehicle) free of charge (parts and labor). To do this, your dealer will replace the airbag control module. The work will take about one hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do to ensure your safety... ^ Simply contact your dealer right away to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to the dealer. If you need help... Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 731 > Jul > 97 > Recall - Airbag Control Module > Page 6725 If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-853-1403. A representative will assist you in getting your vehicle repaired. If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590, or call the Toll Free Auto Safety Hotline at 1-800-424-9393. (Washington, D.C. area residents may call 366-0123.) We're sorry for any inconvenience, but we are sincerely concerned about your safety. Thanks for your attention to this important matter. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 6726 Module Locations Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions Air Bag Control Module: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6729 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 Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6730 Electrostatic Discharge Symbol All Electrostatic Discharge (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, especially 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. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6731 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6732 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6733 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6734 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6735 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6736 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6737 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6738 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. 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. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6739 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6740 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6741 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6742 Air Bag Control Module: Diagnostic Aids 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 in 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 and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6743 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. 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 every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. 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 fuse circuit. 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 the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6744 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools 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 - This instrument is 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 vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. 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 non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6745 ABCM Connector Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6746 Airbag System Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Page 6747 Air Bag Control Module: Description and Operation DESCRIPTION The Airbag Control Module (ACM) contains the impact sensor, and a microprocessor that monitors the impact sensor and the airbag system electrical circuits to determine the system readiness. The ACM contains On-Board Diagnostics (OBD), and will send an airbag lamp-on message to the instrument cluster on the Chrysler Collision Detection (CCD) data bus to light the airbag indicator lamp in the instrument cluster when a monitored airbag system fault occurs. OPERATION The ACM also contains an energy-storage capacitor. This capacitor stores enough electrical energy to deploy the airbags for up to one second following a battery disconnect or failure during an impact. The purpose of the capacitor is to provide airbag system protection in a severe secondary impact, if the initial impact has damaged or disconnected the battery, but was not severe enough to deploy the airbags. The ACM cannot be repaired and, if damaged or faulty, it must be replaced. CIRCUIT OPERATION Two circuits provide battery voltage to the Airbag Control Module (ACM); F14 and F24. Circuits F14 and F24 are connected to separate bus bars in the junction block. Different circuits from the Power Distribution Center (PDC) and the ignition switch supply battery voltage to the junction block bus bars. Circuit F24 supplies battery voltage to the ACM only when the ignition switch is in the RUN position. Circuit F14 circuit powers the ACM when the ignition switch is in either the START or RUN position. The ACM is case grounded and has an external dedicated ground, circuit Z2. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Testing and Inspection > Helpful Information Air Bag Control Module: Testing and Inspection Helpful Information - Check the 10 Amp fuses in the junction block Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Testing and Inspection > Helpful Information > Page 6750 Air Bag Control Module: Testing and Inspection Module Testing Refer to Powertrain Management/Computers and Control Systems/Body Control Module/Testing and Inspection. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Testing and Inspection > Page 6751 Air Bag Control Module: Service and Repair WARNING: ^ The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components you must first disconnect and isolate the battery negative (ground) cable. Then wait two minutes for the system capacitor to discharge before further system service. This is the only sure way to disable the airbag system. Failure to do this could result in accidental air bag 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. 1. Disconnect and isolate the battery negative cable. if the airbag has not been deployed, wait two minutes for the system capacitor to discharge before further service. 2. Remove the instrument panel center support bracket. 3. Remove the screw that secures the instrument panel wire harness ground eyelet to the left side of the floor pan transmission tunnel. 4. Unplug the Airbag Control Module (ACM) wire harness connector. To unplug the connector, first pull the two white locks out about 3 mm (0.125 in.) from each side of the connector. Then squeeze the two connector latch tabs between the thumb and fore-finger, while pulling the connector out from the ACM. NOTE: Always remove and replace the airbag control module and its mounting bracket as a unit. Replacement modules include a replacement mounting bracket. Do not transfer the module to another mounting bracket. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Testing and Inspection > Page 6752 5. Remove the three screws that secure the ACM mounting bracket to the floor pan transmission tunnel. 6. Remove the ACM and mounting bracket as a unit. 7. When installing the ACM, position the unit with the arrow on the ACM housing pointing forward. 8. Attach the ACM to the floor pan transmission tunnel with the four mounting screws. Tighten the mounting screws to 11.8 N.m (105 in. lbs.). 9. Plug in the wire harness connector to the ACM. Be certain that the connector latches are fully engaged and that the connector locks are pushed in. 10. Reverse the remaining removal procedures to complete the installation. 11. Do not connect the battery negative cable at this time. See Testing and Inspection/Procedures for the proper procedures. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Arming and Disarming The airbag system is a sensitive, complex electromechanical unit. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components you must first disconnect and isolate the battery negative (ground) cable. Then wait two minutes for the system capacitor to discharge before further system service. This is the only sure way to disable the airbag system. Failure to do this could result in accidental air-bag deployment and possible personal injury. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation Child Seat Tether Attachment: Technical Service Bulletins Restraints - Child Seat Tether Installation NUMBER: 23-029-08 GROUP: Body DATE: October 24, 2008 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. B, DATED NOVEMBER 24, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. DEALERS PLEASE NOTE, THIS IS REIMBURSABLE REGARDLESS OF VEHICLE AGE OR MILEAGE. SUBJECT: Child Seat Tether Anchor Installation OVERVIEW: This bulletin describes procedures to install Child Seat Tether Anchors based on Customer Request. NOTE: Dealers are encouraged to honor any customers request for the installation of the Child Seat Tether Anchors and Dealer reimbursement will be made by Chrysler regardless of vehicle age or mileage. See the Warranty Policy and Procedure Manual and or Warranty Bulletin D-08-33 for reimbursement detail. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 2000 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1993 (AJ) Lebaron Coupe 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2000 (AN) Dakota 1989 - 1994 (AP) Shawdow/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1990 - 1994 (BD) Laser/Talon 1994 - 2001 (BR/BE) Ram Truck 1989 - 1992 (B2) Colt/Summit 1992 - 1995 (B3) Colt Vista 1989 (B5) Conquest 1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 6762 1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon 1993 - 1994 (B9) Colt/Summit 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GTS 2000 (TJ) Wrangler 1999 - 2000 (WJ) Grand Cherokee 1989 - 2000 (XJ) Cherokee/Wagoneer 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model Year, and in light trucks in the 2001 Model Year and later. Tether straps improve the performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit for a Kid" Program, owners of earlier products are expected to approach dealers for the free provision and installation of the anchor hardware. Chrysler is offering child seat tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary parts and a detailed instruction sheet. NOTE: This bulletin is provided to identify the parts and labor operation numbers necessary to install a Child Seat Tether Anchor. Each dealer is encouraged to install these kits based on customer request and Chrysler will reimburse any Chrysler / Dodge / or Jeep dealer installing these kits regardless of vehicle age or mileage. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 6763 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 6764 PARTS REQUIRED: POLICY: Customer Satisfaction, Reimbursable regardless of mileage or age. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 6765 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 6766 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 6767 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 6768 Child Seat Tether Attachment: Technical Service Bulletins Child Seat Tether Anchor - Labor/Parts Identification NUMBER: 23-35-99 Rev. A GROUP: Body DATE: Oct. 1, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-35-99 DATED SEPTEMBER 3, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE CHANGES IN SOME TIME ALLOWANCES. SUBJECT: Child Seat Tether Anchors NOTE: THIS BULLETIN DOES NOT APPLY TO DAIMLERCHRYSLER CANADA DEALERS. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 2000 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1993 (AJ) LeBaron Coupe 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2000 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1990 - 1994 (BD) Laser/Talon 1994 - 2000 (BR/BE) Ram Truck 1989 - 1992 (B2) Colt/Summit 1992 - 1995 (B3) Colt Vista 1989 (B5) Conquest 1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada) 1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon 1993 - 1994 (B9) Colt/Summit 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GTS 1999 - 2000 (WJ) Grand Cherokee 1989 - 2000 (XJ) Cherokee/Wagoneer 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND LABOR OPERATION NUMBERS NECESSARY TO INSTALL A CHILD SEAT TETHER ANCHOR. DAIMLERCHRYSLER WILL REIMBURSE YOU FOR THE ANCHORS AND LABOR TO INSTALL THEM. THIS IS BEING DONE IN THE INTEREST OF CUSTOMER SATISFACTION. REFER TO GLOBAL WARRANTY ADMINISTRATION BULLETIN # D-99-23 FOR COMPLETE REIMBURSEMENT INSTRUCTIONS. DISCUSSION User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model Year, and in light truck in the 2001 Model Year. Tether straps improve the performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit for a kid" Program, owners of earlier products are expected to approach dealers for the free provision and installation of the anchor hardware. DaimlerChrysler Corporation is offering child seat tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary parts and a Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 6769 detailed instruction sheet. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 6770 PARTS REQUIRED: Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 6771 POLICY: Customer Satisfaction Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 6772 TIME ALLOWANCE: Failure Code: CG - Customer Satisfaction Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 6773 Child Seat Tether Attachment: Technical Service Bulletins Child Seat - Tether Anchor Part Numbers & Labor Time NUMBER: 23-008-00 Rev. B GROUP: Body DATE: Nov. 24, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. A, DATED JULY 7, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND PARTS. SUBJECT: Child Seat Tether Anchors MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 2000 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1993 (AJ) Lebaron Coupe 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2000 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1990 - 1994 (BD) Laser/Talon 1994 - 2001 (BR/BE) Ram Truck 1989 - 1992 (B2) Colt/Summit 1992 - 1995 (B3) Colt Vista 1989 (B5) Conquest 1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada) 1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon 1993 - 1994 (B9) Colt/Summit 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 JA Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GTS **2000 (TJ) Wrangler** 1999 - 2000 (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1993 - 1998 (WJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND LABOR OPERATION NUMBERS NECESSARY TO INSTALL A CHILD SEAT TETHER ANCHOR. DAIMLERCHRYSLER WILL REIMBURSE YOU FOR THE ANCHORS AND LABOR TO INSTALL THEM. THIS IS BEING DONE IN THE INTEREST OF CUSTOMER SATISFACTION. REFER TO GLOBAL WARRANTY ADMINISTRATION BULLETIN # D-99-23 FOR COMPLETE REIMBURSEMENT INSTRUCTIONS. DISCUSSION: User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model Year, and in light trucks in the 2001 Model Year. Tether straps improve the performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit for a Kid" Program, owners of earlier products are expected to approach dealers for the free provision and installation of the anchor hardware. DaimlerChrysler Corporation is offering child seat tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary parts and a detailed instruction sheet. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 6774 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 6775 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 6776 PARTS REQUIRED: POLICY: Customer Satisfaction Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 6777 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 6778 TIME ALLOWANCE: FAILURE CODE: Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Description and Operation Seat Belt Reminder Lamp: Description and Operation SYSTEM OPERATION The seat belt reminder lamp gives a visual reminder to the vehicle occupants to fasten their seat belts. The lamp is turned on by the instrument cluster circuitry for about seven seconds when the ignition switch is turned to the On position. The instrument cluster also receives a hard-wired input from the driver seat belt switch. If the driver seat belt switch is closed (seat belt is not buckled), the instrument cluster will send a chime request to the Central Timer Module (CTM) lasting the duration of the seat belt reminder lamp illumination. The chime warning will stop when the driver seat belt switch is open (seat belt is buckled). The driver seat belt switch is integral to the driver seat belt tip-half retractor assembly The normally open switch monitors the amount of seat belt webbing wound onto the seat belt retractor spool. When the seat belt tip-half webbing is pulled out of the retractor far enough to engage the seat belt bucklehalf, the switch closes. The seat belt reminder lamp also serves as a backup for the airbag indicator lamp. About twenty seconds after the ignition switch is turned to the On position, if an inoperative airbag indicator lamp circuit was detected during the bulb test sequence, the instrument cluster circuitry will flash the seat belt reminder lamp on and off for about thirty seconds. If the seat belt reminder lamp stays on after flashing for thirty seconds, or comes on at any time other than about twenty seconds after the initial ignition-on sequence, it indicates an airbag system fault has been detected and that the airbag indicator lamp is inoperative. CIRCUIT OPERATION Circuit G13 connects between the instrument cluster and the seat belt switch. The seat belt switch is normally OPEN with the seat belt buckled. When the seat belt is not buckled a ground path is completed on circuit F12 through the CLOSED contacts in the switch to circuit G13. The instrument cluster senses this ground path and illuminates the lamp in the instrument cluster. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Description and Operation > Page 6782 Seat Belt Reminder Lamp: Testing and Inspection The diagnosis found here addresses an inoperative seat belt reminder lamp condition. If the lamp comes on and flashes following its display function (for about seven seconds after the ignition switch is turned to the On position), refer to the diagnosis for the airbag indicator lamp in Air Bags and Seat Belts /Air Bags. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check the fuse in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Turn the ignition switch to the On position. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the ignition switch as required. 3. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Unplug the wire harness connector from the seat belt switch in the driver side seat belt retractor. Check for continuity between the fused ignition switch output circuit cavity of the body half of the seat belt switch wire harness connector and the fuse in the junction block. There should be continuity If OK, go to Step 4. If not OK, repair the open circuit as required. 4. Check for continuity between the two cavities of the seat belt retractor half of the seat belt switch wire harness connector. There should be no continuity with the seat belt webbing wound on the retractor spool, and continuity with the seat belt webbing pulled out of the retractor. If OK, go to Step 5. If not OK, replace the faulty seat belt and retractor assembly 5. Remove the instrument cluster bezel and the instrument cluster. Check for continuity between the seat belt switch sense circuit cavities of the cluster wire harness connector and the body half of the seat belt switch wire harness connector. There should be continuity. If OK, see Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Instrument Cluster for diagnosis of the seat belt reminder lamp and the instrument cluster circuitry. If not OK, repair the open circuit as required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches Air Bag Deactivation Switch: Technical Service Bulletins Air Bag - On/Off Switches NUMBER: 08-025-01 GROUP: Electrical DATE: Nov. 23, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-037-99, DATED NOVEMBER 12, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1999 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-00004). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS, PARTS, AND 2001 MODEL YEAR PROCEDURES. NOTE: THIS BULLETIN DOES NOT APPLY TO DIAMLERCHRYSLER CANADA DEALERS. SUBJECT: Airbag On-Off Switches MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - **2001** (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) Lebaron Coupe/Convertible 1994 - **2001** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - **2001** (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - **2001** (DN) Durango 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus **2001** (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 1993 - **2001** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - **2001** (PL) Neon 1997 (PR) Prowler **2001 (PT) PT Cruiser** **2001** (RS) Town & Country/Caravan/Voyager Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6788 1996 - 1997 (SR) Viper **2001 - 2002 (ST) Sebring Coupe/Stratus Coupe** 1997 - 2001** (TJ) Wrangler 1999 - **2001** (WJ) Grand Cherokee 1997 - **2001** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. NOTE: **SOME 2001 MODEL YEAR PACKAGES (AN/AN84/DN/JR/LH/PL/PT/RS/TJ) REQUIRE OCCUPANT RESTRAINT CONTROLLER (ORC) CONFIGURATION USING THE DRB III(R) AS DETAILED IN EACH VEHICLE SPECIFIC PACKAGE.** DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. NOTE: FOR SOME 2000 MODEL YEAR APPLICATIONS (AB/AN/AN84/DN/JA/NS) **AND SOME 2001 CARRYOVER APPLICATIONS (AB/BR/WJ/XJ)**, A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05013528AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT IS ORANGE, AND MUST BE PRESENTED TO THE CUSTOMER IN PLACE OF THE YELLOW ONE, P/N 05013517AA, THAT WILL COME IN THE AIRBAG KIT. **FOR SOME 2001 MODEL YEAR APPLICATIONS (WITH J1850 BUS, AN/AN84/DN/JR/LH/PL(PT/RS/TJ) A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05016025AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT MUST BE PRESENTED TO THE CUSTOMER AFTER INSTALLATION.** Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6789 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6790 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6791 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6792 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6793 PARTS REQUIRED: NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have~ 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available in the "Forms Folder" under "TSB/Recall" tab of MDS2 and printed on your dealership letterhead. keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6794 Air Bag Deactivation Switch: Technical Service Bulletins Air Bag System - ON-OFF Switch Availibility NO: 08-17-98 Rev. C GROUP: Electrical DATE: Dec. 30, 1998 SUBJECT: Airbag On-Off Switches THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-17-98 Rev. B DATED SEPTEMBER 18, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL MODELS HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: **1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan** 1995 - **1999** (AB) Ram Van/Wagon **1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon** 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/Convertible 1994 -**1999** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan/Voyager **1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue** 1994 - **1999** (BR) Ram Pickup **1995 - 1996 (B7) Stealth** 1998 - **1999** (DN) Durango **1995 - 1999 (FJ) Avenger/Sebring/Talon** 1995 - **1999** (JA) Breeze/Cirrus/Stratus 1996 - **1999** (JX) Sebring Convertible 1993 -**1999** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - **1999** (NS) Town & Country/Caravan/ Voyager 1995 - **1999** (PL) Neon 1996 - 1997 (SR) Viper 1997 - **1999** (TJ) Wrangler 1997 - **1999** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. Other applicable passenger vehicles will be announced as soon as the switches are available. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6795 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6796 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6797 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6798 PARTS REQUIRED: Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6799 NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have. 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available on T.I.L. and printed on your dealership letterhead. Keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 6800 POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation Impact Sensor: Description and Operation DESCRIPTION Airbag Control Module Remove/Install The impact sensor provides verification of the direction and severity of an impact. One impact sensor is used. It is located inside the Airbag Control Module (ACM), which is secured to a bracket on the floor pan transmission tunnel inside the vehicle. OPERATION The impact sensor is an accelerometer that senses the rate of deceleration. The microprocessor in the ACM monitors the impact sensor signal. A pre-programmed decision algorithm in the microprocessor determines when the deceleration rate indicates an impact is severe enough to require airbag system protection. When the programmed conditions are met, the ACM sends an electrical signal to deploy the airbag system components. The impact sensor is calibrated for the specific vehicle. The sensor is only serviced as a unit with the ACM. The sensor cannot be repaired or adjusted and, if faulty or damaged, the ACM unit must be replaced. CIRCUIT OPERATION The Airbag system uses a sensor internal to the Airbag Control Module (ACM) to detect impact. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Description and Operation Antenna: Description and Operation SYSTEM OPERATION All models use a fixed-length stainless steel rod-type antenna mast, installed at the right front fender of the vehicle. The mast has a spiral groove cut down its length to reduce wind noise. The antenna mast is connected to the center wire of the coaxial antenna cable, and is not grounded to any part of the vehicle. To eliminate static, the antenna base must have a good ground. The coaxial antenna cable shield (the outer wire mesh of the cable) is grounded to the antenna base and the radio chassis. The antenna coaxial cable has an additional disconnect, located near the inboard side of the glove box opening on the back of the instrument panel, to allow instrument panel installation and removal without removing the radio. The factory-installed ETRs automatically compensate for radio antenna trim. Therefore, no antenna trimmer adjustment is required or possible when replacing the receiver or the antenna. CIRCUIT OPERATION RKE Antenna The Central Timer Module (CTM) used in this vehicle contains the antenna for the Remote Keyless Entry (RKE) system. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Description and Operation > Page 6808 Antenna: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. The following four tests are used to diagnose the antenna with an ohmmeter: - Test 1 - Mast to ground test - Test 2 - Tip-of-mast to tip-of-conductor test - Test 3 - Body ground to battery ground test - Test 4 - Body ground to coaxial shield test. Antenna Tests The ohmmeter test lead connections for each test are shown in Antenna Tests. NOTE: - This model has a special coating on the antenna mast which is not electrically conductive. Remove the antenna mast from the antenna base before attempting to perform Tests 1 and 2. - This model has a two-piece antenna cable. Tests 2 and 4 must be conducted in two steps to isolate a coaxial cable problem; from the coaxial cable connection under the right end of the instrument panel near the right cowl side panel to the antenna base, and then from the coaxial cable connection to the radio chassis connection. Test I Test 1 determines if the antenna mast is insulated from the base. Proceed as follows: 1. Unplug the antenna coaxial cable connector from the radio chassis and isolate. Remove the antenna mast from the antenna base. 2. Insert one ohmmeter test lead into the socket for the antenna mast in the center of the antenna base, and touch the other test lead to the perimeter of the antenna base. Check for continuity. 3. There should be no continuity If continuity is found, replace the faulty or damaged antenna base and cable assembly. Test 2 Test 2 checks the antenna for an open circuit as follows: 1. Unplug the antenna coaxial cable connector from the radio chassis. Remove the antenna mast from the antenna base. 2. Insert one ohmmeter test lead into the socket for the antenna mast in the center of the antenna base, and touch the other test lead to the center pin of the antenna coaxial cable connector. 3. Continuity should exist (the ohmmeter should only register a fraction of an ohm). High or infinite resistance indicates damage to the base and cable assembly. Replace the faulty base and cable, if required. Test 3 Test 3 checks the condition of the vehicle body ground connection. This test should be performed with the battery positive cable removed from the battery. Disconnect both battery cables, the negative cable first. Reconnect the battery negative cable and perform the test as follows: 1. Connect one ohmmeter test lead to the vehicle fender, and connect the other test lead to the battery negative post. 2. The resistance should be less than one ohm. 3. If the resistance is more than one ohm, check the braided ground Strap connected to the engine and the vehicle body for being loose, corroded, or damaged. Repair the ground strap connection, if required. Test 4 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Description and Operation > Page 6809 Test 4 checks the condition of the ground between the antenna base and the vehicle body as follows: 1. Connect one ohmmeter test lead to the vehicle fender, and connect the other test lead to the outer crimp on the antenna coaxial cable connector. 2. The resistance should be less then one ohm. 3. If the resistance is more then one ohm, clean and/or tighten the antenna base to fender mounting hardware. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Description and Operation > Page 6810 Antenna: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Cowl Side Trim Remove/Install 2. Using a trim stick or another suitable widebladed flat tool, gently pry along the edges of the passenger side door sill trim to release the snap-clip retainers that secure it to the sill. Carefully disengage the ends of the sill trim from the cowl side trim at the front, and the cab side trim at the rear, then remove the sill trim from the vehicle. 3. Using a trim stick or another suitable widebladed flat tool, gently pry the passenger side cowl side trim to release the snap-clip retainer that secures it to the door hinge pillar and remove it from the vehicle. Antenna Cable Routing 4. Reach under the instrument panel below the glove box to unplug the coaxial cable connector. 5. Disengage the coaxial cable from the retainer clips on the lower instrument panel reinforcement and the heater-A/C housing. 6. Disengage the coaxial cable retainers at the right cowl side inner panel and inside the right front fender. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Description and Operation > Page 6811 Antenna Mast Remove/Install - Typical 7. Remove the antenna mast from the antenna body. Antenna Cap Nut Remove/Install - Typical 8. Remove the antenna cap nut with an antenna nut wrench (Special Tool C-4816). Antenna Mounting 9. Lower the antenna body and cable assembly through the fender far enough to access the antenna body by reaching between the right cowl side Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Description and Operation > Page 6812 outer panel and the fender through the front door opening. 10. Disengage the coaxial cable grommet from the hole in the right cowl side outer panel. 11. Pull the coaxial cable out through the right cowl side outer panel and remove the antenna body and cable from the vehicle. 12. Reverse the removal procedures to install. Tighten the antenna cap nut to 8 N.m (70 in. lbs.). Tighten the antenna mast to 3.3 N.m (30 in. lbs.). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Door Sensor/Switch (For Alarm) > Component Information > Description and Operation Door Sensor/Switch (For Alarm): Description and Operation SYSTEM OPERATION Door Jamb Switch The door jamb switches are mounted to the door hinge pillars. The switches close a path to ground for the Central Timer Module (CTM) when a door is opened, and open when a door is closed. The door jamb switches cannot be repaired and, if faulty or damaged, they must be replaced. CIRCUIT OPERATION Door Ajar Switches The Vehicle Theft Security System (VTSS) uses the door ajar switches to provide an input to the Central Timer Module (CTM). These switches are normally OPEN with the doors closed. When a door is opened the switch CLOSES completing a path to ground. Circuit G16 is used to monitor the doors. Disarm Switches Circuit G69 connects from the Central Timer Module (CTM) to the disarm switches located in the vehicle doors. These switches are normally OPEN. When the switch CLOSES a ground path is completed through the switch to circuit Z1. When the CTM senses a ground path on this circuit is turns the system OFF. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Door Sensor/Switch (For Alarm) > Component Information > Description and Operation > Page 6817 Door Sensor/Switch (For Alarm): Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Grasp the body of the door jamb switch with a pair of pliers and move the switch gently back-and-forth while pulling it out of the door hinge pillar mounting hole. Door Jamb Switch Remove/Install 3. Pull the switch out from the pillar far enough to access the wire harness connector. 4. Unplug the wire harness connector from the switch. 5. Reverse the removal procedures to install. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch (For Alarm) > Component Information > Description and Operation Hood Sensor/Switch (For Alarm): Description and Operation CIRCUIT OPERATION Circuit G71 connects from the Central Timer Module to the hood switch. The hood switch is normally OPEN when the hood is CLOSED. When the hood is OPENED the switch CLOSES completing a path to ground on circuit Z1. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Receiver > Component Information > Description and Operation Keyless Entry Receiver: Description and Operation SYSTEM OPERATION The Remote Keyless Entry (RKE) receiver is a radio frequency unit contained in the high-line version of the Central Timer Module (CTM). The CTM also contains the program circuitry for the RKE system. The CTM is located under the passenger side end of the instrument panel, outboard of the glove box. The RKE receiver is energized by one of two messages from the RKE transmitter; Unlock, or Lock. The CTM circuitry responds to these messages to lock or unlock the doors by energizing the power lock motors. For diagnosis of the RKE receiver, the high-line CTM, or the CCD data bus, a DRE scan tool and the proper Diagnostic Procedures are recommended. The RKE receiver is only serviced as a unit with the high-line CTM and, if faulty or damaged, the CTM unit must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Transmitter Battery: > 08-39-97 > Nov > 97 > RKE Transmitter - Premature Battery Failure Keyless Entry Transmitter Battery: Customer Interest RKE Transmitter - Premature Battery Failure NO: 08-39-97 GROUP: Electrical DATE: Nov. 28, 1997 SUBJECT: Remote Keyless Entry Transmitter Batteries Discharge Prematurely MODELS: 1997 - 1998 (AB) Ram Van/Wagon 1997 - 1998 (AN) Dakota/Dakota Cab & Chassis 1998 (BRIBE)Ram Truck 1998 (DN) Durango 1997 (LH) Concorde/Intrepid/LHS/Vision 1997 - 1998 (NS) Town & Country/Caravan/Voyager 1997 - 1998 (PL) Neon 1997 (PR) Prowler 1997 - 1998 (ZJ) Grand Cherokee NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO AUGUST 15, 1997 (MDH 0815XX). SYMPTOM/CONDITION: Remote Keyless Entry (RKE) transmitter batteries discharge in approximately 6 weeks. DIAGNOSIS: If the vehicle operator describes the Symptom/Condition and the vehicle was built prior to MDH 0815XX, perform the Repair Procedure. PARTS REQUIRED: AR 04686366 Transmitter, RKE- NS, PL & PR AR 04759136AB Transmitter, RKE- LH AR 56007049 Transmitter, RKE- AB & 1997 AN AR 56008761 Transmitter 1, RKE- ZJ & DN AR 56008762 Transmitter 2, RKE- ZJ AR 56021903AA Transmitter, RKE- BR/BE & 1998 AN REPAIR PROCEDURE: This bulletin involves replacing the RKE transmitter(s). 1. Replace RKE transmitter(s) that have discharged batteries. 2. Program the RKE transmitter(s) to the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-28-93 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter Battery: > 08-39-97 > Nov > 97 > RKE Transmitter - Premature Battery Failure Keyless Entry Transmitter Battery: All Technical Service Bulletins RKE Transmitter - Premature Battery Failure NO: 08-39-97 GROUP: Electrical DATE: Nov. 28, 1997 SUBJECT: Remote Keyless Entry Transmitter Batteries Discharge Prematurely MODELS: 1997 - 1998 (AB) Ram Van/Wagon 1997 - 1998 (AN) Dakota/Dakota Cab & Chassis 1998 (BRIBE)Ram Truck 1998 (DN) Durango 1997 (LH) Concorde/Intrepid/LHS/Vision 1997 - 1998 (NS) Town & Country/Caravan/Voyager 1997 - 1998 (PL) Neon 1997 (PR) Prowler 1997 - 1998 (ZJ) Grand Cherokee NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO AUGUST 15, 1997 (MDH 0815XX). SYMPTOM/CONDITION: Remote Keyless Entry (RKE) transmitter batteries discharge in approximately 6 weeks. DIAGNOSIS: If the vehicle operator describes the Symptom/Condition and the vehicle was built prior to MDH 0815XX, perform the Repair Procedure. PARTS REQUIRED: AR 04686366 Transmitter, RKE- NS, PL & PR AR 04759136AB Transmitter, RKE- LH AR 56007049 Transmitter, RKE- AB & 1997 AN AR 56008761 Transmitter 1, RKE- ZJ & DN AR 56008762 Transmitter 2, RKE- ZJ AR 56021903AA Transmitter, RKE- BR/BE & 1998 AN REPAIR PROCEDURE: This bulletin involves replacing the RKE transmitter(s). 1. Replace RKE transmitter(s) that have discharged batteries. 2. Program the RKE transmitter(s) to the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-28-93 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Description and Operation Lock Cylinder Switch: Description and Operation SYSTEM OPERATION The door lock cylinder switches are mounted to the back of the key lock cylinder inside each door. They are normally-open momentary switches that close to ground only when the lock cylinder is rotated to the unlock position. The door lock cylinder switches cannot be repaired and, if faulty or damaged, they must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Description and Operation > Page 6842 Lock Cylinder Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel and the door outside latch handle. Door Lock Cylinder Switch Remove/Install - Typical 3. Pull the door outside latch handle out from the outside of the door far enough to access the door lock cylinder switch. 4. Unplug the door lock cylinder switch from the back of the lock cylinder. 5. Unplug the door lock cylinder switch wire harness connector. 6. Disengage the two retainers that secure the door lock cylinder switch wire harness to the door inner panel. 7. Remove the door lock cylinder switch from the door. 8. Reverse the removal procedures to install. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Security Lamp/Indicator > Component Information > Description and Operation Security Lamp/Indicator: Description and Operation SYSTEM OPERATION The security lamp gives an indication of the status of the Vehicle Theft Security System (VTSS). The lamp is controlled by a hard-wired input to the instrument cluster from the Central Timer Module (CTM). The lamp is turned on by the instrument cluster circuitry for about two seconds when the ignition switch is turned to the On position as a bulb test. After the bulb test, the CTM turns the lamp on or off based upon the arming status of the VTSS. If the security lamp stays on for about thirty seconds after the ignition switch is turned to the On position, it indicates that Chrysler Collision Detection (CCD) data bus communication with the Powertrain Control Module (PCM) is inoperative, and that the next attempt to arm the VTSS may not be successful. The Security lamp is an amber lamp located within the instrument cluster on the instrument panel. The Security lamp receives fused battery feed at all times and is grounded by the high-line Central Timer Module (CTM) to give a visible indication of the Vehicle Theft Security System arming status. The Security lamp incandescent bulb and bulb holder can be serviced. CIRCUIT OPERATION Vehicle Theft Security System Set Lamp Power for the Vehicle Theft Security System (VTSS) set lamp is supplied on circuit M1. This is the Ignition-Off Draw (IOD) circuit and protected by a 10 Amp fuse located in the junction block. Ground for the lamp is controlled by the Central Timer Module (CTM) on circuit G52. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Security Lamp/Indicator > Component Information > Description and Operation > Page 6846 Security Lamp/Indicator: Testing and Inspection The diagnosis found here addresses an inoperative security lamp condition. If the problem being diagnosed is an inaccurate security lamp, refer to Vehicle Theft/Security Systems for diagnosis of the Vehicle Theft Security System (VTSS). WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check the fuse in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the Power Distribution Center (PDC) as required. 3. Disconnect and isolate the battery negative cable. Remove the Central Timer Module (CTM) as described. Unplug the CTM wire harness connectors. Connect the battery negative cable. Install a jumper wire between the security indicator control circuit cavity of the CTM wire harness connector and a good ground. The security lamp should light. If OK, use a DRB scan tool and the proper Diagnostic Procedures to diagnose the Vehicle Theft Security System (VTSS) and the CTM. If not OK, go to Step 4. 4. Disconnect and isolate the battery negative cable. Remove the instrument cluster bezel and the cluster as described. Check for continuity between the fused B(+) circuit cavity of the cluster wire harness connector and the fuse in the junction block. There should be continuity. If OK, go to Step 5. If not OK, repair the open circuit to the junction block as required. 5. Check for continuity between the security indicator control circuit cavities of the cluster wire harness connector and the CTM wire harness connector. There should be continuity If OK, replace the faulty bulb. If not OK, repair the open circuit as required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations Technical Service Bulletin # 08-23-99 Date: 990709 Radio Communication Equipment - Recommendations NUMBER: 08-23-99 GROUP: Electrical DATE: Jul. 9, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-16-98, DATED APRIL 17, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-99003). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF THE 2000 MODEL YEAR VEHICLES. SUBJECT: Installation of Radio Transmitting Equipment MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - **2000** (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Pickup/Ramcharger 1989 - 1993 (AG) Daytona 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - **2000** (AN) Dakota 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1994 - **2000** (BR/BE) Ram Pickup 1998 - **2000** (DN) Durango 1992 - 1995 (ES) Chrysler Voyager (European Market) 1995 - **2000** (FJ) Sebring/Avenger/Talon 1996 - **2000** (GS) Chrysler Voyager (International Market) 1995 **2000** (JA) Cirrus/Stratus/Breeze 1993 - **2000** (LH) Concorde/Intrepid/Vision/LHS/New Yorker 1989 - 1992 (MJ) Comanche 1996 - **2000** (NS) Town & Country/Caravan/Voyager 1995 **2000** (PL) Neon 1992 - **2000** (SR) Viper/Viper GTS 1997 - **2000** (TJ) Wrangler 1999 **2000** (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1989 - 1995 (YJ) Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Market) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Included is a copy of DaimlerChrysler's Radio Communication Equipment Installation Recommendations. It is being provided with this Technical Service Bulletin to assist in properly installing communication equipment in DaimlerChrysler vehicles. This information should be given to any owner inquiring about installing radio-transmitting equipment. Installation Recommendations DaimlerChrysler Radio Communication Equipment Installation Recommendations Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 6851 The following is excerpted from the owners manual of new DaimlerChrysler products: "INSTALLATION OF RADIO TRANSMITTING EQUIPMENT Special design considerations are incorporated into this vehicle's electronic system to provide immunity to radio frequency signals. Mobile two-way radio and telephone equipment must be installed properly by trained personnel. The following must be observed during installation. The positive power connection should be made directly to the battery and fused as close to the battery as possible. The negative power connection should be made to body sheet metal adjacent to the negative battery connection. This connection should not be fused. Antennas for two-way radios should be mounted on the roof or the rear area of the vehicle. Care should be used in mounting antennas with magnet bases. Magnets may affect the accuracy or operation of the compass on vehicles so equipped. The antenna cable should be as short as practical and routed away from the vehicle wiring when possible. Use only fully shielded coaxial cable. Carefully match the antenna and cable to the radio to ensure a low Standing Wave Ratio (SWR). Mobile radio equipment with output power greater than normal may require special precautions. All installations should be checked for possible interference between the communications equipment and the vehicle's electronic systems. A Technical Service Bulletin (TSB) is available for detailed assistance." The owner's first line of contact regarding vehicle problems is the dealer. The literature supplied with each vehicle lists the steps to be taken in the event the dealer is unable to resolve the problem. To assist in properly installing communications equipment in DaimlerChrysler vehicles, the following information is provided. Always use good construction practices (see The ARRL Handbook or other standard reference works). The information contained in this guide has been prepared for use by persons installing two-way radio equipment (transmitters and receivers) in vehicles. It has been prepared in accordance with current engineering principles and generally accepted practices, using the best information available at the time of publication. It is not possible to cover all of the possible installations of two-way radio equipment in this guide. Accordingly, DaimlerChrysler Corporation cannot be held responsible for incidental or consequent damages arising out of the use of the information contained herein. The responsibility for installations and modifications is the sole responsibility of the customer. The installation recommendations presented here are intended to supplement the radio manufacturer's instructions. Test the entire installation for anomalies, especially drivetrain and brake control before extensive driving. 1. CONTROLS Mount the transceiver to a solid surface. If you use screws through the floor pan, put body sealer over the underbody projections. (Stamped acorn nuts, filled with sealer are available at most body shops for this purpose.) This will keep moisture out of the carpet and insulation, and will forestall rust in this area. Watch out for wire harnesses routed under carpet and behind instrument panel. If you mount the radio under the instrument panel, be sure that there is no interference with proper operation of the foot controls. Mount the control head or front panel (especially the microphone cable) so that it is clear of the steering wheel and column controls and passenger airbag. If the unit is heavy, extra bracing may be needed for stability. Newer vehicles have more structure and energy absorbing materials in the knee blocker (the lower part of the Instrument Panel). For one-piece transceivers, if ignition switch control is desired, it is good practice to use a power relay to avoid overloading the ignition switch, and to maintain the advantages of direct battery feed. Try the installation out before you start drilling holes. 2. POWER WIRING To reduce the hazard of working on the vehicle, disconnect the battery NEGATIVE before beginning work. Note that some components may lose short-term memory (e.g.: radio presets) after a protracted time without battery power. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 6852 For low or medium power transmitters (up to 55W FM or 110W SSB or CW), the power outlet or cigar lighter feed may be used. Use a 1/4" jumper terminal at the socket or splice (solder and heat shrink or tape). For higher power transmitters, including amplifiers, connect the power (battery +) lead at the battery or at the power distribution center or at the positive jump-start post, if the vehicle has one. An appropriate terminal should be used. If the terminal is exposed to the weather, solder and apply a commercial protectant (wheel bearing grease is an acceptable alternative.) to retard corrosion. This lead should be fused as close to the battery as practical to protect the wiring (and the vehicle)! If the power connection is underhood, use a weatherproof fuse holder. Motorola Communications Division supplies a weatherproof holder, part number 09-84277B01 for 5AG cartridge fuses that is part of their standard installation kit. Packard Electric Division of Delphi Automotive Systems makes an insulator, part number 12033769, terminal number 12020156 with cover 12033731 for standard SAE plastic fuses. Vinyl-insulated wire, typically supplied with transceivers is not entirely suitable for the higher underhood temperatures in modern vehicles. Route underhood wiring away from all hot areas. Body sheet metal, away from the exhaust, radiator, A/C liquid line and engine is usually the coolest location. DO NOT FUSE THE GROUND LEAD. If the ground-side fuse were to open, the entire supply current would be conducted by an alternate current return path, which could cause the feedline to overheat, with possible resulting damage. For low or medium power installations, connect the ground (battery -) to body sheet near the power feed point. If you use a screw through the floor, put body sealer over the underbody projection. (Stamped acorn nuts, filled with sealer are available at most body shops for this purpose.) For high power installations, connect the ground (battery -) lead at the battery connection to the body. This is usually a 6 or 8 AWG black wire from the battery negative terminal to a screw at the wheelhouse or radiator support. If a separate sheet metal ground is used, clean the paint off a one inch or so diameter area of body panel where the ground lead is to be connected (usually the case with commercial trunk mount radios). An awl is the best tool to use to pierce a starting hole for a #12 or 5mm, minimum plated ground screw. A ring terminal with lockwasher serrations of the proper size for the screw or a separate serrated (not a split or SAE) lockwasher should be used between the terminal and the screw head. As above, some grease or protectant should be used if the connection is in an unprotected area. If the power cable must pass through the dash panel, try to find an existing hole with a grommet that is unused. If none is available, pull the carpet back from under the dash panel in the passenger footwell in the cabin. Locate a place where there are no other components on either side, as high up as possible. An awl is the best tool to use to punch a small hole through to the engine compartment. If the position is good, enlarge the hole by driving the awl in up to the shank. If this is not large enough to easily pass the cable, enlarge it by using a larger tapered punch. This will leave an extruded hole with no sharp edges. Install the cable and seal the hole with silicone RTV or commercial body sealer on both sides. Seal any extra holes that you may have made. Dress the underhood wiring so that it is sate from all hazards, which include the following: exhaust manifold, steering shaft, throttle linkage, fans, etc. Tie wrap as required. 3. CABLING Route control cables under the floor mats, inside the corner where the floor pan meets the rocker panel for best protection. Remove the sill plates and tuck the cable under the floor mats or carpet and padding. For most left hand drive vehicles, use the right side for best separation to the main body harness (usually on the left side). Route the cable along the extreme outboard edge of the floor pan, under the side trim, if possible. 4. REMOTE TRANSCEIVER For trunk mount installations in passenger cars, you may need to remove the rear seat cushion and seat back to get the cable into the trunk. The seat cushion is usually clipped at the front, lower edge by its own frame: push down and back, then lift. Note the front and rear clipping points for ease of reinstallation. The seat back is usually clipped to the rear compartment inner panel: pull out at the bottom and slide up to remove. Again, note the clipping points for ease of reinstallation. There is usually a vapor/sound barrier behind the seat back, which must be pierced to pass the cable. Open the trunk and pick a spot where the cable is safe from chafing on any sharp sheet metal. Tie wrap or tape in place at this location. Repair the barrier sheet if necessary. Replace the seat back and cushion, taking care that the cable is not pinched by the seat cushion when there is someone sitting in the seat. On some vehicles, there may be a channel for wiring at this location. For remote control radios, a sheet of 1/2 in. plywood one or two inches larger than the radio, is a good method to mount the transceiver to the shelf. It provides a good mounting surface, some shock and vibration isolation, and it keeps moisture away from the radio. Mounting on the floor of the trunk is not recommended. To conserve trunk space, in some vehicles, the radio may be mounted to the rear compartment panel. Locate as far as possible from any vehicle electronic modules located in the rear of the vehicle. In any case, provide good air circulation; a 50 watt RF output FM transmitter will dissipate about 22 watts (@70% efficiency). Do not pile things on top of the unit. 5. TRANSMISSION LINE The transmission line (coaxial cable) should be treated in the same way as the control and power cables. Route flat along body sheet metal wherever possible to avoid sharp edges and pinches. If it is necessary to cross over wiring, cross at right angles. In some cases, additional shielding between the transmission line and the vehicle wiring may be helpful. It is important to maintain the maximum spacing from the vehicle harnesses, especially if the antenna is not a good match. Use the best cable available (98-99% braid coverage or braid/foil) especially at UHF and above. Mechanical pressure on the cable can cause degradation or even short circuits. Do not rely on the obsolete military "RG" designations as an indicator of quality. Cut off, do not coil excess transmission line (This forms a choke balun.) and terminate in the correct connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 6853 The use of N, BNC or C connectors is recommended over "UHF" (PL-259/S0-239) connectors. A small amount of silicone dielectric grease (not the white heat sink compound) in the connector (after soldering) will minimize condensation problems. Cut the line as short as practical, to minimize losses. 6. ANTENNA LOCATION Antenna location is the most important consideration in any mobile installation. For VHF and UHF antennas the recommended place on almost all vehicles is in the center of the roof. The center of the deck lid is an acceptable alternate. Glass-mounted antennas should be mounted at the very top edge of the clear portion of the glass away from the heater grid. Vehicles with printed-on-glass antennas may be damaged by through-glass installations. For HF antennas, refer to the manufacturer's instructions and follow them closely, unless you are an accomplished antenna experimenter. HF antennas should be mounted to body or frame steel for a good counterpoise as well as structural strength. Aluminum bumpers are heavily anodized for corrosion protection, and the coating (aluminum oxide) is very hard as well as nonconductive. A small grinder with a coarse stone will break through the anodized coating for electrical connection. 7. ANTENNA INSTALLATION Permanently installed antennas are preferable over magnetic, glass or body-lip mounts for anything other than for low power or temporary installations. Most of these alternate antennas will reflect some power back at the feedpoint. Much of this will be radiated from the feedline inside the passenger compartment, and may be picked up by the vehicle wiring. For deck lid installations, the deck lid must be bonded to the body, across the hinges, with short, wide tinned braid straps. They must connect to clean sheet metal at both ends. For AM/SSB and even some FM installations, the hood must be bonded to the body. In some cases the doors may need to be bonded, as well. Glass-mount antennas will not work or will only work very poorly in vehicles with metallized glass (Electrically-heated windshields or some solar reflective glass). Non-metallic bodies (e.g., Viper) require a half-wavelength antenna or a ground plane with radius approximately equal to the length of a quarter-wave antenna. Copper is the best choice, but aluminum or even steel may be used. Install on the inside of the body panel with a good adhesive or tape and provide a good RF connection to the coax shield at the feedpoint. Screen, mesh or thin sheet stock may be used. Shape is not critical, but some directional characteristics may be noted if it is not round. Try to stay one-quarter wavelength away from edges, including sunroof openings. Consider the sunroof mechanism for interference to the base and to the feedline. For VHF and UHF, a good quality "NMO" (New Motorola) base or other mount with feedline (center conductor and shield) soldered to base is recommended. This will allow the maximum flexibility in antenna selection and is the best choice for electrical and mechanical considerations. Use the proper hole saw (3/4 in. for NMO) or have it done professionally if you are not comfortable with power tools. Hole plugs are available, for use at sale or trade-in, if you expect to remove the antenna base. To install the antenna base in the hole, remove the one or two-door trim pieces at the pillar where the cable is to be routed and ease the headliner away from the roof. Insert a piece of flat steel or plastic banding (1/2 in. to 3/4 in. wide) and guide to the desired corner. Pull the banding through, leaving 6 in., which can be taped, to the transmission line (easier without the connector, but possible even with a PL-259). Continue pulling until the antenna base is one inch or less from the hole, then seat the base and screw on the outside ring, 0-ring down. A little silicone grease helps maintain a good seal for the life of the vehicle. Tighten with an open-end wrench, and apply a small amount of silicone grease to the contact and insulator surface of the base. This will help exclude water, but must be renewed periodically. Tip: if you remove your antenna to go through the car wash, there are caps available to exclude water during the process. In most vehicles, RG-58-sized cable will fit between the pillar trim and body sheet metal. If necessary, the technique used on the roof can also be used to snake the cable down the inside the pillar. Install the connector very carefully. There are good instructions in The ARRL Handbook. Use a clean, hot, high-wattage iron and work quickly, to prevent damage to the cable dielectric. If you are a beginner or are not comfortable with this kind of detail work, ask for help. It is extremely important. Electrical/Electronic Systems Compatibility Department CIMS 481-47-20 DaimlerChrysler Corporation 800 Chrysler Drive East Auburn Hills, MI 48326-2757 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations Technical Service Bulletin # 08-23-99 Date: 990709 Radio Communication Equipment - Recommendations NUMBER: 08-23-99 GROUP: Electrical DATE: Jul. 9, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-16-98, DATED APRIL 17, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-99003). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF THE 2000 MODEL YEAR VEHICLES. SUBJECT: Installation of Radio Transmitting Equipment MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - **2000** (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Pickup/Ramcharger 1989 - 1993 (AG) Daytona 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - **2000** (AN) Dakota 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1994 - **2000** (BR/BE) Ram Pickup 1998 - **2000** (DN) Durango 1992 - 1995 (ES) Chrysler Voyager (European Market) 1995 - **2000** (FJ) Sebring/Avenger/Talon 1996 - **2000** (GS) Chrysler Voyager (International Market) 1995 **2000** (JA) Cirrus/Stratus/Breeze 1993 - **2000** (LH) Concorde/Intrepid/Vision/LHS/New Yorker 1989 - 1992 (MJ) Comanche 1996 - **2000** (NS) Town & Country/Caravan/Voyager 1995 **2000** (PL) Neon 1992 - **2000** (SR) Viper/Viper GTS 1997 - **2000** (TJ) Wrangler 1999 **2000** (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1989 - 1995 (YJ) Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Market) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Included is a copy of DaimlerChrysler's Radio Communication Equipment Installation Recommendations. It is being provided with this Technical Service Bulletin to assist in properly installing communication equipment in DaimlerChrysler vehicles. This information should be given to any owner inquiring about installing radio-transmitting equipment. Installation Recommendations DaimlerChrysler Radio Communication Equipment Installation Recommendations Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 6858 The following is excerpted from the owners manual of new DaimlerChrysler products: "INSTALLATION OF RADIO TRANSMITTING EQUIPMENT Special design considerations are incorporated into this vehicle's electronic system to provide immunity to radio frequency signals. Mobile two-way radio and telephone equipment must be installed properly by trained personnel. The following must be observed during installation. The positive power connection should be made directly to the battery and fused as close to the battery as possible. The negative power connection should be made to body sheet metal adjacent to the negative battery connection. This connection should not be fused. Antennas for two-way radios should be mounted on the roof or the rear area of the vehicle. Care should be used in mounting antennas with magnet bases. Magnets may affect the accuracy or operation of the compass on vehicles so equipped. The antenna cable should be as short as practical and routed away from the vehicle wiring when possible. Use only fully shielded coaxial cable. Carefully match the antenna and cable to the radio to ensure a low Standing Wave Ratio (SWR). Mobile radio equipment with output power greater than normal may require special precautions. All installations should be checked for possible interference between the communications equipment and the vehicle's electronic systems. A Technical Service Bulletin (TSB) is available for detailed assistance." The owner's first line of contact regarding vehicle problems is the dealer. The literature supplied with each vehicle lists the steps to be taken in the event the dealer is unable to resolve the problem. To assist in properly installing communications equipment in DaimlerChrysler vehicles, the following information is provided. Always use good construction practices (see The ARRL Handbook or other standard reference works). The information contained in this guide has been prepared for use by persons installing two-way radio equipment (transmitters and receivers) in vehicles. It has been prepared in accordance with current engineering principles and generally accepted practices, using the best information available at the time of publication. It is not possible to cover all of the possible installations of two-way radio equipment in this guide. Accordingly, DaimlerChrysler Corporation cannot be held responsible for incidental or consequent damages arising out of the use of the information contained herein. The responsibility for installations and modifications is the sole responsibility of the customer. The installation recommendations presented here are intended to supplement the radio manufacturer's instructions. Test the entire installation for anomalies, especially drivetrain and brake control before extensive driving. 1. CONTROLS Mount the transceiver to a solid surface. If you use screws through the floor pan, put body sealer over the underbody projections. (Stamped acorn nuts, filled with sealer are available at most body shops for this purpose.) This will keep moisture out of the carpet and insulation, and will forestall rust in this area. Watch out for wire harnesses routed under carpet and behind instrument panel. If you mount the radio under the instrument panel, be sure that there is no interference with proper operation of the foot controls. Mount the control head or front panel (especially the microphone cable) so that it is clear of the steering wheel and column controls and passenger airbag. If the unit is heavy, extra bracing may be needed for stability. Newer vehicles have more structure and energy absorbing materials in the knee blocker (the lower part of the Instrument Panel). For one-piece transceivers, if ignition switch control is desired, it is good practice to use a power relay to avoid overloading the ignition switch, and to maintain the advantages of direct battery feed. Try the installation out before you start drilling holes. 2. POWER WIRING To reduce the hazard of working on the vehicle, disconnect the battery NEGATIVE before beginning work. Note that some components may lose short-term memory (e.g.: radio presets) after a protracted time without battery power. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 6859 For low or medium power transmitters (up to 55W FM or 110W SSB or CW), the power outlet or cigar lighter feed may be used. Use a 1/4" jumper terminal at the socket or splice (solder and heat shrink or tape). For higher power transmitters, including amplifiers, connect the power (battery +) lead at the battery or at the power distribution center or at the positive jump-start post, if the vehicle has one. An appropriate terminal should be used. If the terminal is exposed to the weather, solder and apply a commercial protectant (wheel bearing grease is an acceptable alternative.) to retard corrosion. This lead should be fused as close to the battery as practical to protect the wiring (and the vehicle)! If the power connection is underhood, use a weatherproof fuse holder. Motorola Communications Division supplies a weatherproof holder, part number 09-84277B01 for 5AG cartridge fuses that is part of their standard installation kit. Packard Electric Division of Delphi Automotive Systems makes an insulator, part number 12033769, terminal number 12020156 with cover 12033731 for standard SAE plastic fuses. Vinyl-insulated wire, typically supplied with transceivers is not entirely suitable for the higher underhood temperatures in modern vehicles. Route underhood wiring away from all hot areas. Body sheet metal, away from the exhaust, radiator, A/C liquid line and engine is usually the coolest location. DO NOT FUSE THE GROUND LEAD. If the ground-side fuse were to open, the entire supply current would be conducted by an alternate current return path, which could cause the feedline to overheat, with possible resulting damage. For low or medium power installations, connect the ground (battery -) to body sheet near the power feed point. If you use a screw through the floor, put body sealer over the underbody projection. (Stamped acorn nuts, filled with sealer are available at most body shops for this purpose.) For high power installations, connect the ground (battery -) lead at the battery connection to the body. This is usually a 6 or 8 AWG black wire from the battery negative terminal to a screw at the wheelhouse or radiator support. If a separate sheet metal ground is used, clean the paint off a one inch or so diameter area of body panel where the ground lead is to be connected (usually the case with commercial trunk mount radios). An awl is the best tool to use to pierce a starting hole for a #12 or 5mm, minimum plated ground screw. A ring terminal with lockwasher serrations of the proper size for the screw or a separate serrated (not a split or SAE) lockwasher should be used between the terminal and the screw head. As above, some grease or protectant should be used if the connection is in an unprotected area. If the power cable must pass through the dash panel, try to find an existing hole with a grommet that is unused. If none is available, pull the carpet back from under the dash panel in the passenger footwell in the cabin. Locate a place where there are no other components on either side, as high up as possible. An awl is the best tool to use to punch a small hole through to the engine compartment. If the position is good, enlarge the hole by driving the awl in up to the shank. If this is not large enough to easily pass the cable, enlarge it by using a larger tapered punch. This will leave an extruded hole with no sharp edges. Install the cable and seal the hole with silicone RTV or commercial body sealer on both sides. Seal any extra holes that you may have made. Dress the underhood wiring so that it is sate from all hazards, which include the following: exhaust manifold, steering shaft, throttle linkage, fans, etc. Tie wrap as required. 3. CABLING Route control cables under the floor mats, inside the corner where the floor pan meets the rocker panel for best protection. Remove the sill plates and tuck the cable under the floor mats or carpet and padding. For most left hand drive vehicles, use the right side for best separation to the main body harness (usually on the left side). Route the cable along the extreme outboard edge of the floor pan, under the side trim, if possible. 4. REMOTE TRANSCEIVER For trunk mount installations in passenger cars, you may need to remove the rear seat cushion and seat back to get the cable into the trunk. The seat cushion is usually clipped at the front, lower edge by its own frame: push down and back, then lift. Note the front and rear clipping points for ease of reinstallation. The seat back is usually clipped to the rear compartment inner panel: pull out at the bottom and slide up to remove. Again, note the clipping points for ease of reinstallation. There is usually a vapor/sound barrier behind the seat back, which must be pierced to pass the cable. Open the trunk and pick a spot where the cable is safe from chafing on any sharp sheet metal. Tie wrap or tape in place at this location. Repair the barrier sheet if necessary. Replace the seat back and cushion, taking care that the cable is not pinched by the seat cushion when there is someone sitting in the seat. On some vehicles, there may be a channel for wiring at this location. For remote control radios, a sheet of 1/2 in. plywood one or two inches larger than the radio, is a good method to mount the transceiver to the shelf. It provides a good mounting surface, some shock and vibration isolation, and it keeps moisture away from the radio. Mounting on the floor of the trunk is not recommended. To conserve trunk space, in some vehicles, the radio may be mounted to the rear compartment panel. Locate as far as possible from any vehicle electronic modules located in the rear of the vehicle. In any case, provide good air circulation; a 50 watt RF output FM transmitter will dissipate about 22 watts (@70% efficiency). Do not pile things on top of the unit. 5. TRANSMISSION LINE The transmission line (coaxial cable) should be treated in the same way as the control and power cables. Route flat along body sheet metal wherever possible to avoid sharp edges and pinches. If it is necessary to cross over wiring, cross at right angles. In some cases, additional shielding between the transmission line and the vehicle wiring may be helpful. It is important to maintain the maximum spacing from the vehicle harnesses, especially if the antenna is not a good match. Use the best cable available (98-99% braid coverage or braid/foil) especially at UHF and above. Mechanical pressure on the cable can cause degradation or even short circuits. Do not rely on the obsolete military "RG" designations as an indicator of quality. Cut off, do not coil excess transmission line (This forms a choke balun.) and terminate in the correct connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 6860 The use of N, BNC or C connectors is recommended over "UHF" (PL-259/S0-239) connectors. A small amount of silicone dielectric grease (not the white heat sink compound) in the connector (after soldering) will minimize condensation problems. Cut the line as short as practical, to minimize losses. 6. ANTENNA LOCATION Antenna location is the most important consideration in any mobile installation. For VHF and UHF antennas the recommended place on almost all vehicles is in the center of the roof. The center of the deck lid is an acceptable alternate. Glass-mounted antennas should be mounted at the very top edge of the clear portion of the glass away from the heater grid. Vehicles with printed-on-glass antennas may be damaged by through-glass installations. For HF antennas, refer to the manufacturer's instructions and follow them closely, unless you are an accomplished antenna experimenter. HF antennas should be mounted to body or frame steel for a good counterpoise as well as structural strength. Aluminum bumpers are heavily anodized for corrosion protection, and the coating (aluminum oxide) is very hard as well as nonconductive. A small grinder with a coarse stone will break through the anodized coating for electrical connection. 7. ANTENNA INSTALLATION Permanently installed antennas are preferable over magnetic, glass or body-lip mounts for anything other than for low power or temporary installations. Most of these alternate antennas will reflect some power back at the feedpoint. Much of this will be radiated from the feedline inside the passenger compartment, and may be picked up by the vehicle wiring. For deck lid installations, the deck lid must be bonded to the body, across the hinges, with short, wide tinned braid straps. They must connect to clean sheet metal at both ends. For AM/SSB and even some FM installations, the hood must be bonded to the body. In some cases the doors may need to be bonded, as well. Glass-mount antennas will not work or will only work very poorly in vehicles with metallized glass (Electrically-heated windshields or some solar reflective glass). Non-metallic bodies (e.g., Viper) require a half-wavelength antenna or a ground plane with radius approximately equal to the length of a quarter-wave antenna. Copper is the best choice, but aluminum or even steel may be used. Install on the inside of the body panel with a good adhesive or tape and provide a good RF connection to the coax shield at the feedpoint. Screen, mesh or thin sheet stock may be used. Shape is not critical, but some directional characteristics may be noted if it is not round. Try to stay one-quarter wavelength away from edges, including sunroof openings. Consider the sunroof mechanism for interference to the base and to the feedline. For VHF and UHF, a good quality "NMO" (New Motorola) base or other mount with feedline (center conductor and shield) soldered to base is recommended. This will allow the maximum flexibility in antenna selection and is the best choice for electrical and mechanical considerations. Use the proper hole saw (3/4 in. for NMO) or have it done professionally if you are not comfortable with power tools. Hole plugs are available, for use at sale or trade-in, if you expect to remove the antenna base. To install the antenna base in the hole, remove the one or two-door trim pieces at the pillar where the cable is to be routed and ease the headliner away from the roof. Insert a piece of flat steel or plastic banding (1/2 in. to 3/4 in. wide) and guide to the desired corner. Pull the banding through, leaving 6 in., which can be taped, to the transmission line (easier without the connector, but possible even with a PL-259). Continue pulling until the antenna base is one inch or less from the hole, then seat the base and screw on the outside ring, 0-ring down. A little silicone grease helps maintain a good seal for the life of the vehicle. Tighten with an open-end wrench, and apply a small amount of silicone grease to the contact and insulator surface of the base. This will help exclude water, but must be renewed periodically. Tip: if you remove your antenna to go through the car wash, there are caps available to exclude water during the process. In most vehicles, RG-58-sized cable will fit between the pillar trim and body sheet metal. If necessary, the technique used on the roof can also be used to snake the cable down the inside the pillar. Install the connector very carefully. There are good instructions in The ARRL Handbook. Use a clean, hot, high-wattage iron and work quickly, to prevent damage to the cable dielectric. If you are a beginner or are not comfortable with this kind of detail work, ask for help. It is extremely important. Electrical/Electronic Systems Compatibility Department CIMS 481-47-20 DaimlerChrysler Corporation 800 Chrysler Drive East Auburn Hills, MI 48326-2757 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Description and Operation Amplifier: Description and Operation CIRCUIT OPERATION Battery voltage for the power amplifier is provided on circuit X2O. This circuit is protected by a 15 Amp fuse located in the junction block. The X2O circuit provides two battery feeds to the amplifier. Ground for the amplifier is supplied on circuit Z2. Circuit X6O connects between the radio and power amplifier. This circuit provides the amplifier with the ON/OFF control. Operation of the speakers is covered in "Speaker- Premium Radio". Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Description and Operation > Page 6865 Amplifier: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Cowl Side Trim Remove/Install 2. Using a trim stick or another suitable widebladed flat tool, gently pry along the edges of the passenger side door sill trim to release the snap-clip retainers that secure it to the sill. Carefully disengage the ends of the sill trim from the cowl side trim at the front, and the cab side trim at the rear, then remove the sill trim from the vehicle. 3. Using a trim stick or another suitable widebladed flat tool, gently pry the passenger side cowl side trim to release the snap-clip retainer that secures it to the door hinge pillar and remove it from the vehicle. Amplifier Connections Remove/Install 4. Unplug the two wire harness connectors from the amplifier. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Description and Operation > Page 6866 Amplifier Remove/Install 5. Remove the two screws that secure the amplifier to the right cowl side inner panel. 6. To disengage the upper hook bracket of the amplifier from the upper hinge access hole in the cowl side inner panel: a. Raise the amplifier upwards about 5 cm (2 in.). b. Tilt the top of the amplifier inwards, towards the instrument panel. c. Keep the top of the amplifier tilted towards the instrument panel while lowering the unit from between the cowl side inner panel and the heater A/C housing. 7. Reverse the removal procedures to install. Tighten the amplifier mounting screws to 2 N.m (17 in. lbs.). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Technical Service Bulletins > Customer Interest: > 08-27-97A > Sep > 97 > Radio/CD Player - Inoperative Compact Disc Player (CD): Customer Interest Radio/CD Player - Inoperative NO: 08-27-97 Rev. A GROUP: Electrical DATE: Sep. 26, 1997 SUBJECT: Inoperative CD Player Sales Code RAZ Radio THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN NUMBER 08-27-97, DATED JULY 18, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION ADDS NS MODELS TO THE LABOR OPERATION MODEL APPLICATIONS. THE CHANGES ARE HIGHLIGHTED WITH ASTERISKS. NOTE: THIS BULLETIN APPLIES TO 1997 VEHICLES EQUIPPED WITH AN AM/FM/CASSETTE/CD PLAYER, SALES CODE "RAZ" RADIO. MODELS: 1997 (AB) Ram Van/ Ram Wagon 1997 (AN) Dakota 1997 (BR) Ram Truck 1997 (FJ) Avenger/Sebring/Talon 1997 (JX) Sebring Convertible 1997 (LH) Concorde/Intrepid/Vision/LHS 1997 (NS) Caravan/Voyager/Town & Country 1997 (XJ) Cherokee 1997 (ZJ) Grand Cherokee SYMPTOM/CONDITION: The CD pLayer may become inoperative, and will not accept the CD when attempting to insert the disk into the radio. This may be caused by a sticking micro switch internal to the CD player mechanism. The condition can be intermittent and may occur more often in hotter ambient temperatures. The AM/FM radio and cassette portion of the radio will continue to operate normally. DIAGNOSIS: If any customer complaints are received indicating inoperative CD players as described above, contact your authorized Mitsubishi Radio Repair Center via DIAL function ii and arrange for an exchange unit before removing the suspect radio. Schedule the service appointment after the exchange unit arrangements have been made to avoid any unnecessary customer inconvenience. The following is a list of the part numbers for the new radios containing the revised CD player mechanism: Radio Part Number Models 47O4382AC NS, XJ 47O4S83AD ZJ 4704384AC JX 4704385AC FJ 47O4383AE LH, AN, AB, BR REPAIR PROCEDURE: This bulletin involves exchanging the radio for a revised unit, available from an authorized Mitsubishi Radio Repair Center. 1. Record the preset radio stations. 2. Disconnect and isolate the battery negative cable. 3 Remove the radio from the instrument panel. 4. Install the exchange radio supplied by the Mitsubishi Radio Repair Center. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Technical Service Bulletins > Customer Interest: > 08-27-97A > Sep > 97 > Radio/CD Player - Inoperative > Page 6875 5. Connect the battery negative cable and set the clock and radio stations recorded earlier. POLICY: Reimbursable within the provisions of the warranty. **TIME ALLOWANCE:** Labor Operation No: 08-60-02-92 AN, JX,FJ (Avenger/Sebring) 0.2 Hrs. AB, BR, LH, **NS**, XJ, ZJ, FJ (Talon) 0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compact Disc Player (CD): > 08-11-00 > Mar > 00 > CD Player - CD Compatibility Compact Disc Player (CD): All Technical Service Bulletins CD Player - CD Compatibility BULLETIN NUMBER: 08-11-00 GROUP: Electrical DATE: March 24, 2000 SUBJECT: Recordable Compact Discs Used in Automotive CD players MODELS: 1989 - 2000 (AB) Ram Van/Wagon 1989 - 2000 (AN) Dakota 1994 - 2000 (BR/BE) Ram Truck 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GT 1997 - 2000 (TJ) Wrangler 1999 - 2000 (WJ) Grand Cherokee 1997 - 2000 (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee DISCUSSION: Some recordable compact disc media, such as CD-R and CD-RW, may not comply with the standard CD format used in automotive CD players. When these CD's are used, customers may encounter error messages, skipping, or delaminating of the labels, which can cause an eject failure. It is important to question whether these kinds of CD media are being used. When customers encounter these symptoms, check the system with a known playable CD. Explain that the media may not be compatible with some automotive CD players. Replacing or exchanging the CD player will not address these issues. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compact Disc Player (CD): > 08-27-97A > Sep > 97 > Radio/CD Player - Inoperative Compact Disc Player (CD): All Technical Service Bulletins Radio/CD Player - Inoperative NO: 08-27-97 Rev. A GROUP: Electrical DATE: Sep. 26, 1997 SUBJECT: Inoperative CD Player Sales Code RAZ Radio THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN NUMBER 08-27-97, DATED JULY 18, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION ADDS NS MODELS TO THE LABOR OPERATION MODEL APPLICATIONS. THE CHANGES ARE HIGHLIGHTED WITH ASTERISKS. NOTE: THIS BULLETIN APPLIES TO 1997 VEHICLES EQUIPPED WITH AN AM/FM/CASSETTE/CD PLAYER, SALES CODE "RAZ" RADIO. MODELS: 1997 (AB) Ram Van/ Ram Wagon 1997 (AN) Dakota 1997 (BR) Ram Truck 1997 (FJ) Avenger/Sebring/Talon 1997 (JX) Sebring Convertible 1997 (LH) Concorde/Intrepid/Vision/LHS 1997 (NS) Caravan/Voyager/Town & Country 1997 (XJ) Cherokee 1997 (ZJ) Grand Cherokee SYMPTOM/CONDITION: The CD pLayer may become inoperative, and will not accept the CD when attempting to insert the disk into the radio. This may be caused by a sticking micro switch internal to the CD player mechanism. The condition can be intermittent and may occur more often in hotter ambient temperatures. The AM/FM radio and cassette portion of the radio will continue to operate normally. DIAGNOSIS: If any customer complaints are received indicating inoperative CD players as described above, contact your authorized Mitsubishi Radio Repair Center via DIAL function ii and arrange for an exchange unit before removing the suspect radio. Schedule the service appointment after the exchange unit arrangements have been made to avoid any unnecessary customer inconvenience. The following is a list of the part numbers for the new radios containing the revised CD player mechanism: Radio Part Number Models 47O4382AC NS, XJ 47O4S83AD ZJ 4704384AC JX 4704385AC FJ 47O4383AE LH, AN, AB, BR REPAIR PROCEDURE: This bulletin involves exchanging the radio for a revised unit, available from an authorized Mitsubishi Radio Repair Center. 1. Record the preset radio stations. 2. Disconnect and isolate the battery negative cable. 3 Remove the radio from the instrument panel. 4. Install the exchange radio supplied by the Mitsubishi Radio Repair Center. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compact Disc Player (CD): > 08-27-97A > Sep > 97 > Radio/CD Player - Inoperative > Page 6885 5. Connect the battery negative cable and set the clock and radio stations recorded earlier. POLICY: Reimbursable within the provisions of the warranty. **TIME ALLOWANCE:** Labor Operation No: 08-60-02-92 AN, JX,FJ (Avenger/Sebring) 0.2 Hrs. AB, BR, LH, **NS**, XJ, ZJ, FJ (Talon) 0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Compact Disc Player (CD): > 08-11-00 > Mar > 00 > CD Player - CD Compatibility Compact Disc Player (CD): All Technical Service Bulletins CD Player - CD Compatibility BULLETIN NUMBER: 08-11-00 GROUP: Electrical DATE: March 24, 2000 SUBJECT: Recordable Compact Discs Used in Automotive CD players MODELS: 1989 - 2000 (AB) Ram Van/Wagon 1989 - 2000 (AN) Dakota 1994 - 2000 (BR/BE) Ram Truck 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GT 1997 - 2000 (TJ) Wrangler 1999 - 2000 (WJ) Grand Cherokee 1997 - 2000 (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee DISCUSSION: Some recordable compact disc media, such as CD-R and CD-RW, may not comply with the standard CD format used in automotive CD players. When these CD's are used, customers may encounter error messages, skipping, or delaminating of the labels, which can cause an eject failure. It is important to question whether these kinds of CD media are being used. When customers encounter these symptoms, check the system with a known playable CD. Explain that the media may not be compatible with some automotive CD players. Replacing or exchanging the CD player will not address these issues. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 08-18-00 > May > 00 > Radio - Interference To/From Two Way Radio Receiver Radio/Stereo Noise Filter: Customer Interest Radio - Interference To/From Two Way Radio Receiver NUMBER: 08-18-00 GROUP: Electrical DATE: May 12, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-06-99 REV. A, DATED DECEMBER 17, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1999 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-00004). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITIONAL MODEL YEARS. SUBJECT: Radio Interference To/From Two-Way Radio Receivers OVERVIEW: This bulletin involves installing a RFI filter in series with the electric fuel pump motor. MODELS: 1997 - 2000 (AN) Dakota 1998 **2001** (BR/BE) Ram Truck SYMPTOM/CONDITION: Customers may complain of intermittent poor reception on their two-way radios. NOTE: THIS CONDITION DOES NOT AFFECT THE OPERATION OF ANY AM OR FM BAND RADIO. DISCUSSION: Radio receivers from approximately 20 MHZ to 174 MHZ may be susceptible to Radio Frequency Interference (RFI) from the fuel pump module's motor. The following services are within this band range of 20 MHZ to 174 MHZ: - 27 MHZ Citizen Band - Ten Meter Amateur Radio Band (28 - 29.7 MHZ) - Public Service Low Band VHF (30 - 50 MHZ) - Six Meter Amateur Radio Band (50 - 54 MHZ) - VHF Aircraft Communications Band (118 - 136 MHZ) - Two Meter Amateur Radio Band (114 - 148MHZ) - Public Service High Band (148 - 174 MHZ) DIAGNOSIS: Turn the ignition key to the RUN position. Operate the two-way radio and monitor for RFI/static/poor reception. If RFI is present with the ignition key in the RUN position, RFI is being emitted from something other than the fuel pump module's motor. Start the engine and monitor for RFI. If RFI is identified only while the engine is running, perform the following Repair Procedure. NOTE : IT IS IMPORTANT TO IDENTIFY WHICH COMPONENTS ARE EMITTING RFI. AFTER A REPAIR HAS BEEN MADE, PERFORM THE DIAGNOSIS AGAIN TO IDENTIFY IF ANY OTHER COMPONENT IS PRODUCING RFI. SOME VEHICLES MAY REQUIRE ADDITIONAL DIAGNOSIS. PARTS REQUIRED: Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 08-18-00 > May > 00 > Radio - Interference To/From Two Way Radio Receiver > Page 6900 REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Disconnect and isolate the battery negative cable. 2. Disconnect the fuel pump module connector at the fuel pump module. The connector has a locking tab that must be released prior to disconnecting. Slide the red lock tab back. Depress the lock tab and slide the connector apart. 3. Connect the RFI module (p/n 04883825AD) to the harness and to the fuel pump module connector. Secure the connectors by sliding the red lock tab back into its original position. 4. Apply foam tape (p/n 04318028) to the back of the RFI module. 5. Secure the RFI module by tie strapping (p/n 04856503) it to the truss bracket. The truss bracket is adjacent to the fuel tank rail and chassis rail. 6. Connect the negative cable and reprogram the clock. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE AND FAILURE CODE Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 08-18-00 > May > 00 > Radio - Interference To/From Two Way Radio Receiver Radio/Stereo Noise Filter: All Technical Service Bulletins Radio - Interference To/From Two Way Radio Receiver NUMBER: 08-18-00 GROUP: Electrical DATE: May 12, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-06-99 REV. A, DATED DECEMBER 17, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1999 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-00004). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITIONAL MODEL YEARS. SUBJECT: Radio Interference To/From Two-Way Radio Receivers OVERVIEW: This bulletin involves installing a RFI filter in series with the electric fuel pump motor. MODELS: 1997 - 2000 (AN) Dakota 1998 **2001** (BR/BE) Ram Truck SYMPTOM/CONDITION: Customers may complain of intermittent poor reception on their two-way radios. NOTE: THIS CONDITION DOES NOT AFFECT THE OPERATION OF ANY AM OR FM BAND RADIO. DISCUSSION: Radio receivers from approximately 20 MHZ to 174 MHZ may be susceptible to Radio Frequency Interference (RFI) from the fuel pump module's motor. The following services are within this band range of 20 MHZ to 174 MHZ: - 27 MHZ Citizen Band - Ten Meter Amateur Radio Band (28 - 29.7 MHZ) - Public Service Low Band VHF (30 - 50 MHZ) - Six Meter Amateur Radio Band (50 - 54 MHZ) - VHF Aircraft Communications Band (118 - 136 MHZ) - Two Meter Amateur Radio Band (114 - 148MHZ) - Public Service High Band (148 - 174 MHZ) DIAGNOSIS: Turn the ignition key to the RUN position. Operate the two-way radio and monitor for RFI/static/poor reception. If RFI is present with the ignition key in the RUN position, RFI is being emitted from something other than the fuel pump module's motor. Start the engine and monitor for RFI. If RFI is identified only while the engine is running, perform the following Repair Procedure. NOTE : IT IS IMPORTANT TO IDENTIFY WHICH COMPONENTS ARE EMITTING RFI. AFTER A REPAIR HAS BEEN MADE, PERFORM THE DIAGNOSIS AGAIN TO IDENTIFY IF ANY OTHER COMPONENT IS PRODUCING RFI. SOME VEHICLES MAY REQUIRE ADDITIONAL DIAGNOSIS. PARTS REQUIRED: Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 08-18-00 > May > 00 > Radio - Interference To/From Two Way Radio Receiver > Page 6906 REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Disconnect and isolate the battery negative cable. 2. Disconnect the fuel pump module connector at the fuel pump module. The connector has a locking tab that must be released prior to disconnecting. Slide the red lock tab back. Depress the lock tab and slide the connector apart. 3. Connect the RFI module (p/n 04883825AD) to the harness and to the fuel pump module connector. Secure the connectors by sliding the red lock tab back into its original position. 4. Apply foam tape (p/n 04318028) to the back of the RFI module. 5. Secure the RFI module by tie strapping (p/n 04856503) it to the truss bracket. The truss bracket is adjacent to the fuel tank rail and chassis rail. 6. Connect the negative cable and reprogram the clock. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE AND FAILURE CODE Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Description and Operation Speaker: Description and Operation SYSTEM OPERATION The standard equipment speaker system includes four speaker locations. The optional premium speaker system includes six speaker locations. On four-speaker systems, one full-range speaker is located in each front door. There is also one full-range speaker located in each rear cab side panel, 13.3 cm (5.25 in.) diameter units for the standard cab and 16.5 cm (6.50 in.) diameter units for the club cab. The premium speaker option upgrades all the speakers to Infinity models, and includes a 100 watt amplifier. Each front door has two separate Infinity speakers, a woofer mounted low in the door, and a tweeter mounted high in the door. Infinity coaxial speakers are mounted in the rear cab side panels, 13.3 cm (5.25 in.) diameter units for the standard cab and 16.5 cm (6.50 in.) diameter units for the club cab. The Infinity amplifier is mounted to the right inner cowl side panel, near the right end of the instrument panel. The amplifier is serviced by removing the right cowl side trim panel. CIRCUIT OPERATION Standard Radio Circuit X53 feeds the speaker in the left front door. Circuit X55 is the return from the speaker to the radio. Circuit X54 feeds the right front door speaker. Circuit X56 is the return from the speaker to the radio. Circuit X51 feeds the speaker in the left rear of the vehicle. Circuit X57 is the return from the speaker to the radio. Circuit X52 feeds the right rear speaker. Circuit X58 is the return from the speaker to the radio. Premium Radio Circuits X53 and X55 are the feeds and returns from the radio to the amplifier. Circuits X54 and X56 are the feeds and returns from the radio to the amplifier. Circuit X87 feeds the speakers in the left front door. Circuit X85 is the return from the speakers to the radio. Circuit X82 feeds the right front door speakers. Circuit X8O is the return from the speakers to the radio. Circuit X51 feeds the speaker in the left rear of the vehicle. Circuit X57 is the return from the speaker to the radio. Circuit X52 feeds the right rear speaker. Circuit X58 is the return from the speaker to the radio. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Description and Operation > Page 6910 Speaker: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. CAUTION: The speaker output of the radio is a "floating ground" system. Do not allow any speaker lead to short to ground, as damage to the radio may result. 1. Turn the ignition switch to the On position. Turn the radio on. Adjust the balance and fader controls to check the performance of each individual speaker. Note the speaker locations that are not performing correctly. Go to Step 2. 2. Turn the radio off. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Remove the instrument cluster bezel and remove the radio as described. If the vehicle is equipped with the Infinity speaker package, also unplug the wire harness connectors at the amplifier. Check both the speaker feed (+) circuit and return (-) circuit cavities for the inoperative speaker location(s) at the radio wire harness connectors for continuity to ground. In each case, there should be no continuity. If OK, go to Step 3. If not OK, repair the shorted speaker circuit(s) as required. 3. If the vehicle is equipped with the Infinity speaker package, go to Step 6. If the vehicle is equipped with the standard speaker system, check the resistance between the speaker feed (+) circuit and return (-) circuit cavities of the radio wire harness connectors for the inoperative speaker location(s). The meter should read between 2 and 12 ohms (speaker resistance). If OK, go to Step 4. If not OK, go to Step 5. 4. Install a known good radio. Connect the battery negative cable. Turn the ignition switch to the On position. Turn on the radio and test the speaker operation. If OK, replace the faulty radio. If not OK, turn the radio off, turn the ignition switch to the Off position, disconnect and isolate the battery negative cable, remove the test radio, and go to Step 5. 5. Unplug the speaker wire harness connector at the inoperative speaker. Check for continuity between the speaker feed (+) circuit cavities of the radio wire harness connector and the speaker wire harness connector. Repeat the check between the speaker return (-) circuit cavities of the radio wire harness connector and the speaker wire harness connector. In each case, there should be continuity If OK, replace the faulty speaker. If not OK, repair the open circuit(s) as required. 6. For each inoperative speaker location, check for continuity between the speaker feed (+) circuit cavities of the radio wire harness connectors and the amplifier wire harness connectors. Repeat the check for each inoperative speaker location between the speaker return (-) circuit cavities of the radio wire harness connectors and the amplifier wire harness connectors. In each case, there should be continuity. If OK, go to Step 7. If not OK, repair the open circuit as required. 7. Check for continuity between the two ground circuit cavities of the amplifier wire harness connector and a good ground. There should be continuity If OK, go to Step 8. If not OK, repair the open circuit(s) as required. 8. Check the amplifier fuse in the junction block. If OK, go to Step 9. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 9. Check for battery voltage at the amplifier fuse in the junction block. If OK, go to Step 10. If not OK, repair the open circuit to the PDC as required. 10. Install the radio. Connect the battery negative cable. Check for battery voltage at the two fused B(+) circuit cavities of the amplifier wire harness connector. If OK, go to Step 11. If not OK, repair the open circuit to the fuse in the junction block as required. 11. Turn the ignition switch to the On position. Turn the radio on. Check for battery voltage at the radio 12 Volt output circuit cavity of the amplifier wire harness connector. If OK, go to Step 12. If not OK, repair the open circuit to the radio as required. 12. Turn the radio off. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. For each inoperative speaker location, check both the amplified feed (+) circuit and the amplified return (-) circuit cavities of the amplifier wire harness connectors for continuity to ground. In each case there should be no continuity If OK, go to Step 13. If not OK, repair the short circuit as required. 13. For each inoperative speaker location, check the resistance between the amplified feed (+) circuit and the amplified return (-) circuit cavities of the amplifier wire harness connectors. The meter should read between 2 and 12 ohms (speaker resistance). If OK, replace the faulty amplifier. If not OK, go to Step 14. 14. Unplug the speaker wire harness connector at the inoperative speaker. Check for continuity between the amplified feed (+) circuit cavities of the speaker wire harness connector and the amplifier wire harness connector. Repeat the check between the amplified return (-) circuit cavities of the speaker wire harness connector and the amplifier wire harness connector. In each case there should be continuity If OK, replace the faulty speaker. If not OK, repair the open circuit as required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door Speaker: Service and Repair Front Door REMOVAL Lower 1. Disconnect and isolate the battery negative cable. Inside Door Latch Release Handle Pocket Screw Remove/Install 2. Pull the inside door latch release handle to the open position and remove the screw in the release handle pocket that secures the door trim panel to the inside door handle bracket. Window Regulator Crank Handle Remove - Typical 3. If the vehicle is so equipped, remove the window regulator crank handle with a removal tool. 4. If the vehicle is so equipped, remove the power window and lock switches as follows: Power Window And Lock Switches Remove/Install a. Using a wide flat-bladed tool such as a trim stick, gently pry the upper edge of the switch bezel to release the snap-clip retainer that secures the Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door > Page 6913 bezel to the door trim panel. b. Pull the switch bezel away from the door trim panel far enough to access the wire harness connectors. c. Gently pry the locking tabs of the wire harness connectors away from the switches and carefully unplug the switches. Door Trim Panel Remove/Install 5. Remove the four screws that secure the door trim panel to the inner door. 6. To disengage the stepped retainers that secure the door trim panel to the inner door, gently pull the lower edge of the trim panel away from the door while lifting the panel upwards. 7. Pull the door trim panel away from the inner door far enough to access the inside door latch release linkage rod at the back of the inside door handle. 8. Unsnap the plastic retainer clip from the inside door handle end of the latch release linkage rod, and remove the rod end from the inside door handle. Door Trim Panel Wire Harness Connectors 9. On the driver side only, if the vehicle is so equipped, unplug the power mirror switch wire harness connector. 10. If the vehicle is so equipped, unplug the Infinity upper door speaker wire harness connector. Lower Door Speaker Remove/Install Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door > Page 6914 11. Remove the screws that secure the speaker to the inner door panel. 12. Pull the speaker out from the door far enough to unplug the speaker wire harness connector and remove the speaker from the door. 13. Reverse the removal procedures to complete the installation. Tighten the speaker mounting screws to 2 N.m (17 in. lbs.). Upper 1. Remove the front door trim panel as described in the Removal and Installation procedure for Speaker, Front Door, Lower. 2. The speaker is snap-fit to the back of the trim panel. Gently pry the molded retainers that secure the speaker to the trim panel away from the speaker mounting flange tabs and remove the speaker. NOTE: Both the front door trim panel and the upper door speaker mounting flange have provisions for mounting the speaker using screws. Screws should be used to mount these speakers if any of the molded trim panel speaker snap retainers should become damaged. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door > Page 6915 Speaker: Service and Repair Rear Cab Side Panel REMOVAL Standard Cab 1. Disconnect and isolate the battery negative cable. 2. Remove the B-pillar trim panel. Rear Speaker Remove/Install - Standard Cab 3. Move the B-pillar trim panel away from the cab side far enough to access the speaker wire harness connector. 4. Unplug the wire harness connector from the speaker. 5. Remove the screws that secure the speaker to the B-pillar trim panel. 6. Remove the speaker from the B-pillar trim panel. 7. Reverse the removal procedures to install. Tighten the speaker mounting screws to 2 N.m (17 in. lbs.). Club Cab 1. Disconnect and isolate the battery negative cable. 2. Remove the quarter trim panel. Rear Speaker Remove/Install - Club Cab 3. Remove the screws that secure the speaker to the rear cab side inner panel. 4. Pull the speaker away from the cab side inner panel far enough to access the wire harness connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door > Page 6916 5. Unplug the wire harness connector from the speaker. 6. Remove the speaker from the vehicle. 7. Reverse the removal procedures to install. Tighten the speaker mounting screws to 2 N.m (17 in. lbs.). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Description and Operation Door Sensor/Switch (For Alarm): Description and Operation SYSTEM OPERATION Door Jamb Switch The door jamb switches are mounted to the door hinge pillars. The switches close a path to ground for the Central Timer Module (CTM) when a door is opened, and open when a door is closed. The door jamb switches cannot be repaired and, if faulty or damaged, they must be replaced. CIRCUIT OPERATION Door Ajar Switches The Vehicle Theft Security System (VTSS) uses the door ajar switches to provide an input to the Central Timer Module (CTM). These switches are normally OPEN with the doors closed. When a door is opened the switch CLOSES completing a path to ground. Circuit G16 is used to monitor the doors. Disarm Switches Circuit G69 connects from the Central Timer Module (CTM) to the disarm switches located in the vehicle doors. These switches are normally OPEN. When the switch CLOSES a ground path is completed through the switch to circuit Z1. When the CTM senses a ground path on this circuit is turns the system OFF. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Description and Operation > Page 6921 Door Sensor/Switch (For Alarm): Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Grasp the body of the door jamb switch with a pair of pliers and move the switch gently back-and-forth while pulling it out of the door hinge pillar mounting hole. Door Jamb Switch Remove/Install 3. Pull the switch out from the pillar far enough to access the wire harness connector. 4. Unplug the wire harness connector from the switch. 5. Reverse the removal procedures to install. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Description and Operation Hood Sensor/Switch (For Alarm): Description and Operation CIRCUIT OPERATION Circuit G71 connects from the Central Timer Module to the hood switch. The hood switch is normally OPEN when the hood is CLOSED. When the hood is OPENED the switch CLOSES completing a path to ground on circuit Z1. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Description and Operation Lock Cylinder Switch: Description and Operation SYSTEM OPERATION The door lock cylinder switches are mounted to the back of the key lock cylinder inside each door. They are normally-open momentary switches that close to ground only when the lock cylinder is rotated to the unlock position. The door lock cylinder switches cannot be repaired and, if faulty or damaged, they must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Description and Operation > Page 6928 Lock Cylinder Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel and the door outside latch handle. Door Lock Cylinder Switch Remove/Install - Typical 3. Pull the door outside latch handle out from the outside of the door far enough to access the door lock cylinder switch. 4. Unplug the door lock cylinder switch from the back of the lock cylinder. 5. Unplug the door lock cylinder switch wire harness connector. 6. Disengage the two retainers that secure the door lock cylinder switch wire harness to the door inner panel. 7. Remove the door lock cylinder switch from the door. 8. Reverse the removal procedures to install. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6934 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 Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6935 Electrostatic Discharge Symbol All Electrostatic Discharge (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, especially 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. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6936 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6937 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6938 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6939 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6940 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6941 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6942 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6943 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. 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. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6944 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6945 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6946 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6947 Trailer Connector: Diagnostic Aids 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 in 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 and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6948 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. 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 every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. 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 fuse circuit. 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 the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6949 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools 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 - This instrument is 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 vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. 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 non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6950 Trailer Connector: Electrical Diagrams Trailer Tow (Part 1 Of 2) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6951 Trailer Tow (Part 2 Of 2) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Page 6952 Trailer Connector: Description and Operation CIRCUIT OPERATION The vehicle is equipped with jumper harness for the aftermarket trailer brake controllers. At the time of delivery, the harness is stored under the passengers front seat. The jumper harness connects to an instrument panel harness connector near the steering column. The jumper harness contains circuits L5O from the stop lamp switch, ground circuit Z1, circuit B4O for trailer brakes, and circuit A6 for power supply. The trailer tow harness contains a relay that operates the trailer tail lights. When the headlamps or parking lamps ON, circuit L7 from the headlamp switch powers the coil side of the relay Circuit Z1 provides ground for the relay When the relay energizes, it powers circuit L76. Circuit L76 supplies power to the trailer tow connector for the trailer tail lamps and side marker lamps. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations Trailer Lighting Relay: Locations Power Distribution Center Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Page 6956 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6961 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 Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6962 Electrostatic Discharge Symbol All Electrostatic Discharge (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, especially 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. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6963 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6964 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6965 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6966 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6967 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6968 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6969 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6970 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. 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. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6971 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6972 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6973 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6974 Trailer Connector: Diagnostic Aids 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 in 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 and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6975 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. 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 every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. 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 fuse circuit. 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 the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6976 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools 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 - This instrument is 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 vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. 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 non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6977 Trailer Connector: Electrical Diagrams Trailer Tow (Part 1 Of 2) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6978 Trailer Tow (Part 2 Of 2) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Page 6979 Trailer Connector: Description and Operation CIRCUIT OPERATION The vehicle is equipped with jumper harness for the aftermarket trailer brake controllers. At the time of delivery, the harness is stored under the passengers front seat. The jumper harness connects to an instrument panel harness connector near the steering column. The jumper harness contains circuits L5O from the stop lamp switch, ground circuit Z1, circuit B4O for trailer brakes, and circuit A6 for power supply. The trailer tow harness contains a relay that operates the trailer tail lights. When the headlamps or parking lamps ON, circuit L7 from the headlamp switch powers the coil side of the relay Circuit Z1 provides ground for the relay When the relay energizes, it powers circuit L76. Circuit L76 supplies power to the trailer tow connector for the trailer tail lamps and side marker lamps. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Description and Operation Trip Computer: Description and Operation SYSTEM OPERATION A mini trip computer is available on this model to provide several electronic functions and features. The trip computer contains a central processing unit and interfaces with other modules in the vehicle on the Chrysler Collision Detection (CCD) data bus network. The CCD data bus network allows the sharing of sensor information. This helps to reduce wire harness complexity, reduce internal controller hardware, and reduce component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. Some of the functions and features that the trip computer supports and/or controls, include the following display options: Compass and temperature - Trip odometer (ODO) - Average fuel economy (AVG ECO) - Instant fuel economy (ECO) - Distance to empty (DTE) - Elapsed time (ET) - Blank display Momentarily depressing and releasing the Step button when the ignition switch is in the On position will cause the overhead console display to step sequentially through the listed display options. Momentarily depressing and releasing the U.S./Metric button toggles the display between U.S. and Metric measurements. For more information on the trip computer features and functions, refer to the owner 5 manual in the vehicle glove box. The push button (Step and U.S./Metric) switches and the compass flux-gate unit are integral to the trip computer, compass, and thermometer display module unit. The ambient temperature sensor is hard-wired to the module. Data input for all other trip computer functions is received through CCD data bus messages. The trip computer uses its internal programming and all of these inputs to calculate and display the requested data. If the data displayed is incorrect, perform the self-diagnostic tests as described. If these tests prove inconclusive, the use of a DRB scan tool and the proper Diagnostic Procedures are recommended for further testing of the trip computer and the CCD data bus. The trip computer, compass, and thermometer display module cannot be repaired, and are only available for service as a unit. If faulty or damaged, the complete module must be replaced. COMPASS MINI-TRIP COMPUTER (CMTC) This system, located in the overhead console, displays information on outside temperature, compass direction and trip information. Compass And Temperature Display This display provides the outside temperature and one of eight compass readings to indicate the direction the vehicle is facing. Trip Odometer (ODO) Shows the distance travelled since the last reset. Average Fuel Economy (AVE ECO) Shows the average fuel economy in MPG (miles per gallon) or L/100Km since the last reset. Instantaneous Fuel Economy Shows the fuel economy for the last few seconds in MPG or L/100Km. Distance to Empty (DTE) Shows the estimated distance that can be travelled with the fuel remaining in the tank. This is calibrated using the MPG for the last few minutes. Elapsed Time (ET) Shows the accumulated ignition on time since the last reset. Step Button Press this button to cycle through all the mini-trip computer displays. US/M Button Press this button to convert all vehicle displays from US to metric to US. To Reset the Display Press the Step and US/M buttons simultaneously for at least two seconds and all resettable conditions will be rest. This will occur only if a resettable function (AVG ECO, ECO, ET) is currently being displayed. Automatic Compass Calibration This compass is self-calibrating which eliminates the need to manually set the compass. When the vehicle is new, the compass may appear erratic Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Description and Operation > Page 6983 and the CAL symbol will be displayed. After completing three 360° turns in an area free from large metal or metallic objects, the CAL symbol will turn off and the compass will function normally. Compass Variance Compass Variance is the difference between Magnetic North and Geographic North. In some areas of the country, the difference between Magnetic and Geographic North is great enough to cause the compass to give false readings. If this occurs, the compass variance must be set. Enhanced Accident Response (Highline CTM only) If the Airbag Control Module (ACM) deploys the airbags, a message is transmitted over the CCD bus to the CTM module to unlock the doors. The interior lights will be turned on when the vehicle speed message on the CCD bus indicates 0 mph or the message is not present. In addition to unlocking the doors, the door lock feature will be disabled for a predetermined amount of time following the deployment. Once the ignition key has been cycled to the "off" position, normal operation will resume. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Description and Operation > Page 6984 Trip Computer: Testing and Inspection If the problem with the trip computer, compass, and thermometer display module is an inaccurate or scrambled display, use the Self-Diagnostic Test procedures. If the problem is incorrect display lighting levels, use a DRB scan tool and the proper Diagnostic Procedures to test for the correct dimming message inputs being received from the instrument cluster over the Chrysler Collision Detection (CCD) data bus. If the problem is a no-display condition, use the following procedures. 1. Check the fuses in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse(s). 2. Check for battery voltage at the fused B(+) fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the Power Distribution Center (PDC) as required. 3. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output fuse in the junction block. If OK, go to Step 4. If not OK, repair the open circuit to the ignition switch as required. 4. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Remove the overhead console as described. Check for continuity between the ground circuit cavities of the overhead console wire harness connector and a good ground. There should be continuity. If OK, go to Step 5. If not OK, repair the open circuit to ground as required. 5. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the overhead console wire harness connector. If OK, go to Step 6. If not OK, repair the open circuit to the junction block as required. 6. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output circuit cavity of the overhead console wire harness connector. If OK, proceed to the Self-Diagnostic Test for further diagnosis of the module and the CCD data bus. If not OK, repair the open circuit to the junction block as required. Self-Diagnostic Test A self-diagnostic test is used to determine that the trip computer, compass, thermometer, and all of the display module segments are operating properly electrically. Initiate the self-diagnostic test as follows: 1. With the ignition switch in the Off position, simultaneously press and hold the Step button and the U.S./Metric button. 2. Turn the ignition switch to the On position. 3. Continue to hold both buttons until the display module performs a display segment test. In this test, all of the vacuum fluorescent display segments are lighted. This test will: a. Verify that all display segments are functional b. Check the internal circuitry of the module c. Check that all of the CCD data bus messages needed are being received. 4. Respond to the respective test results as follows. If all tests are passed, the module will automatically return to normal operation. d. In the display segment test, if any segment should fail to light the unit is faulty and must be replaced. e. If the internal circuitry test is failed, the module will display "FAIL". If "FAIL" is displayed, the unit is faulty and must be replaced. f. If the CCD data bus message test is failed, the module will display "CCD". If "CCD" is displayed, the use of a DRB scan tool and the proper Diagnostic Procedures are required for further diagnosis. 5. Momentarily depress and release either button one time to exit the self-diagnostic test mode and return the trip computer, compass, and thermometer display module to normal operation. NOTE: If the compass functions, but accuracy Is suspect, it may be necessary to perform a variation adjustment. This procedure allows the compass unit to accommodate variations in the earth's magnetic field strength, based on geographic location. See the Instrument Panel, Gauges and Warning Indicators/Compass/Testing and Inspection/ProceduresCompass Variation Adjustment procedures. - If the compass reading has blanked out, and only "CAL" appears in the display module, demagnetizing may be necessary to remove excessive residual magnetic fields from the vehicle. See the Instrument Panel, Gauges and Warning Indicators/Compass/Testing and Inspection/Procedures/Compass Demagnetizing procedure. Thermometer The thermometer function is supported by a ambient temperature sensor, a wiring circuit, and a portion of the overhead console trip computer, compass, and thermometer display module display The sensor is mounted outside the passenger compartment near the front and center of the vehicle. If any portion of the ambient temperature sensor circuit fails, the thermometer display will self-diagnose the circuit. An "SC" (short circuit) will appear in the display in place of the temperature, when the sensor is exposed to temperatures above 110 °C (230 °F), or if the sensor circuit is shorted. An "OC" (open circuit) will appear in the display in place of the temperature, when the sensor is exposed to temperatures below -50 °C (-58 °F), or if the sensor circuit is open. The ambient temperature sensor circuit can also be diagnosed using the following Sensor Test, and Sensor Circuit Test. If the temperature sensor and circuit are confirmed to be OK, but the temperature display is inoperative or incorrect, see the Trip Computer, Compass, and Thermometer Display Module diagnosis in Instrument Panel, Gauges and Warning Indicators. Sensor Test 1. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Unplug the temperature sensor wire harness connector. 2. Measure the resistance of the 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, go to the Sensor Circuit Test. If not OK, Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Description and Operation > Page 6985 replace the faulty sensor. Sensor Circuit Test 1. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Unplug the ambient temperature sensor wire harness connector and the overhead console wire harness connector. 2. Connect a jumper wire between the two terminals in the body half of the sensor wire harness connector. 3. Check for continuity between the sensor return circuit and the ambient temperature sensor signal circuit cavities of the overhead console wire harness connector. There should be continuity If OK, go to Step 4. If not OK, repair the open circuit as required. 4. Remove the jumper wire from the ambient temperature sensor wire harness connector. Check for continuity between the sensor return circuit cavity of the overhead console wire harness connector and a good ground. There should be no continuity If OK, go to Step 5. If not OK, repair the short circuit as required. 5. Check for continuity between the ambient temperature sensor signal circuit cavity of the overhead console wire harness connector and a good ground. There should be no continuity If OK, see the Trip Computer, Compass, and Thermometer Display Module diagnosis in Instrument Panel, Gauges and Warning Indicators. If not OK, repair the short circuit as required. NOTE: For complete testing, refer to Powertrain Management/Computers and Control Systems/Body Control Module/Testing and Inspection. See: Body and Frame/Body Control Systems/Central Timer Module ( CTM ) High Option/Testing and Inspection Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Adjustments > Setting the Compass Trip Computer: Adjustments Setting the Compass SETTING THE COMPASS The compass/mini-trip module is self-calibrated and requires no adjustment. The word CAL will be displayed to indicate that the compass is in the fast calibrating mode. CAL will turn off after the vehicle has gone in three complete circles without stopping, in an area free of magnetic disturbance. If the module displays the temperature while the compass is blank or shows a false reading, the vehicle must be demagnetized. If the compass still goes blank after the vehicle is demagnetized, the compass/mini-trip module must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Adjustments > Setting the Compass > Page 6988 Trip Computer: Adjustments Setting the Variance SETTING THE VARIANCE Setting The Variance Variance is the difference between magnetic north and geographic north. To determine the variance for the area you are in, refer to the zone map provided. The number shown for your area is the variance number for your area. 1. Set the Compass/Mini-Trip Console (CMTC) to compass/temperature mode. 2. Press and hold down the reset button for 5 seconds. NOTE: If the buttons are held for 10 seconds instead of 5, the CMTC will set the variance to 8 and enter the fast calibration mode. 3. The VAR light will come on and the last variance setting will be displayed. 4. Press the STEP button to set the zone number. 5. Press the US/M button and resume normal operation. NOTE: Do not attach any magnetic device such as a magnetic CB antenna to the vehicle. This can cause the compass to give false readings. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Adjustments > Page 6989 Trip Computer: Service and Repair REMOVAL 1. Remove the overhead console as described. Trip Computer, Compass, And Thermometer Display Module Remove/Install 2. Remove the four screws that secure the trip computer, compass, and thermometer display module to the overhead console housing. 3. Release the clip that secures the overhead console wire harness connector to the top of the display module housing and remove the connector. 4. Unplug the display module wire harness connector from the right side of the display module. 5. Remove the display module from the overhead console housing. 6. Remove the display module lens and bezel from the overhead console housing. 7. Reverse the removal procedures to install. Tighten the display module mounting screws to 2.2 N.m (20 in. lbs.). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Locations > Data Link Connector DLC Location Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Locations > Data Link Connector > Page 6996 Module Locations Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Locations > Data Link Connector > Page 6997 Module Locations Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Locations > Data Link Connector > Page 6998 Module Locations Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions Central Timer Module ( CTM ) High Option: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7001 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 Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7002 Electrostatic Discharge Symbol All Electrostatic Discharge (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, especially 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. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7003 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7004 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7005 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7006 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7007 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7008 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7009 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7010 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. 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. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7011 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7012 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7013 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7014 Central Timer Module ( CTM ) High Option: Diagnostic Aids 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 in 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 and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7015 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. 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 every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. 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 fuse circuit. 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 the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7016 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools 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 - This instrument is 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 vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. 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 non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7017 Central Timer Module ( CTM ) High Option: Connector Views Data Link Connector Pinout ABCM Connector Pinout Passenger Airbag Connector Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7018 Drivers Airbag Squib Connector Pinout Clockspring 2-Way Connector Pinout Central Timer Module (CTM) Connector "A" Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7019 Central Timer Module (CTM) Connector "B" Pinout Left Instrument Cluster Connector "A" (Black) Pinout Right Instrument Cluster Connector "B" (Gray) Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7020 Overhead Console Compass/Mini-Trip Computer Pinout Ambient Temperature Sensor Connector Pinout Door Jamb Switch Connector Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7021 Door Disarm Switch Connector Pinout Power Door Lock Switch Connections Door Lock Actuator Connector Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7022 Key-In Ignition Connector Pinout Multifunction Switch Connector Pinout Windshield Wiper Motor Connector Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7023 Central Timer Module ( CTM ) High Option: Electrical Diagrams Airbag System Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7024 Chrysler Collision Detection (CCD) Bus System Compass/Mini-Trip Computer System Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7025 Central Timer Module Block Diagram Power Lock System Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7026 Windshield Wiper System Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Service Precautions > Technician Safety Information Central Timer Module ( CTM ) High Option: Technician Safety Information Technician Safety Information DANGER!!! Engines produce carbon monoxide that is odorless, causes slower reaction time, and can lead to serious injury. When the engine is operating, keep service areas WELL VENTILATED or attach the vehicle exhaust system to the shop exhaust removal system. Set the parking brake and block the wheels before testing or repairing the vehicle. It is especially important to block the wheels on front-wheel drive vehicles; the parking brake does not hold the drive wheels. When servicing a vehicle, always wear eye protection, and remove any metal jewelry such as watchbands or bracelets that might make an inadvertent electrical contact. When diagnosing a body system problem, it is important to follow approved procedures where applicable. Following these procedures is very important to the safety of individuals performing diagnostic tests. 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. Servicing Sub-Assemblies SERVICING SUB-ASSEMBLIES Some components of the body system are intended to be serviced in 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 Service and Repair procedures should be serviced. DRB III Safety Information DRBIII SAFETY INFORMATION WARNING: Exceeding the limits of the DRB 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 DRB 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 function for the measurement. Do not try voltage or current measurements that may exceed the rated capacity. DRB III Safety Limits - Do not exceed the limits shown in the table below: - Voltage between any terminal and ground must not exceed 500v DC or 500v peak AC. - Use caution when measuring voltage above 25v DC or 25v AC. - The circuit being tested must be protected by a 10A fuse or circuit breaker. - Use the low current shunt to measure circuits up to 10A. Use the high current clamp to measure circuits exceeding 10A. - 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Service Precautions > Technician Safety Information > Page 7029 - 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 DRB away from spark plug or coil wires to avoid measuring error from outside interference. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Service Precautions > Technician Safety Information > Page 7030 Central Timer Module ( CTM ) High Option: Vehicle Damage Warnings Vehicle Damage Warnings 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. Road Testing A Complaint Vehicle ROAD TESTING A COMPLAINT VEHICLE 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 screen while in motion. Do not hang the DRB from the rear view mirror or operate it yourself. Have an assistant available to operate the DRB. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Service Precautions > Page 7031 Central Timer Module ( CTM ) High Option: Application and ID GLOSSARY OF ACRONYMS ACM ..................................................................................................................................................... ....................................... Airbag Control Module CAB ........................................................................ ................................................................................................................ Controller Anti-lock Brake CCD ................................................................................................................................... Chrysler Collision Detection (Vehicle Communications Bus) CMTC ................................................................. ................................................................................................................ Compass/mini-trip Computer CTM .................................................................................................................................... .......................................................... Central Timer Module DAB ....................................................... ...................................................................................................................................................... Driver Airbag DLC ............................................................................................................................... ................................................................... Data Link Connector DTC ............................................... ............................................................................................................................................ Diagnostic Trouble Code MIC ............................................................................................................................... ................................................... Mechanical Instrument Cluster PAB ................................................ ........................................................................................................................................................ Passenger Airbag PCM ....................................................................................................................... ................................................................ Powertrain Control Module PDC ........................................ .................................................................................................................................................. Power Distribution Center RKE ...................................................................................................................... ......................................................................... Remote Keyless Entry SQUIB ................................................................................................................................... Also Called Initiator (Located In Rear Of Airbag Module) VTSS ............................................................................ ..................................................................................................... Vehicle Theft Security System Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System Central Timer Module ( CTM ) High Option: Description and Operation Airbag System Airbag System Description AIRBAG SYSTEM The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front end collision. The system is most effective when used in conjunction with the seat belt system. The airbag control module (ACM) is an electronic module that monitors the airbag system for proper operation, stores Diagnostic Trouble Code (DTCs), controls the airbag warning lamp, monitors the pressure in the passenger airbag module 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 the diagnostic information DTCs to the technician through the DRB III via the CCD bus. Some circuits are tested continuously; others are checked only under certain circumstances. The warning lamp is driven with messages relayed to the Mechanical Instrument Cluster (MIC) from the ACM via the CCD bus. The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be observed by the customer. Whenever the ignition key is turned to the run or start" position, the airbag control module performs a lamp check by turning the AIRBAG warning lamp on for 6-8 seconds. If the lamp remains off, it means that the ACM has checked the system and found it to be free of discernible malfunctions. If the lamp remains on, there could be an active fault in the system or the circuit that operates the lamp may be shorted to ground. If the lamp comes on and stays on for a period longer than 6-8 seconds, then goes off, there is usually an intermittent problem in the system. Perform the WARNING LAMP CIRCUIT OPEN procedure in this book to find the cause of any customer complaint regarding the AIRBAG warning lamp, such as: Warning Lamp Does Not Illuminate - Warning Lamp Stays Illuminated WARNING! The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must first disconnect and isolate the battery negative (ground) cable. Then wait two minutes for the system capacitor to discharge before further system service. This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Never strike or kick the airbag control module, as it can damage the impact sensor or affect its calibration. If an airbag control module is accidentally dropped during service, the module must be scrapped and replaced with a new unit. Airbag Diagnostic Trouble Codes AIRBAG DIAGNOSTIC TROUBLE CODES Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Always begin by reading the diagnostic trouble codes using the DRB. This procedure begins with AIRBAG TEST 1A - Identifying Airbag System Problems. This will direct you to the specific test(s) that must be performed. Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures within this manual, diagnostic trouble codes are used as a diagnostic tool. ACTIVE CODES The codes become 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 are automatically erased 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 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 7034 "Loss of Ignition Run Only" code which is an active code only. A "stored" code indicates that there was an active code present at some time. However, the code currently may not be present as an active code, although another code could be. When a trouble code occurs, the airbag warning lamp illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. If a malfunction is detected a diagnostic trouble code is stored and will remain stored as long as the malfunction exists. When and if the malfunction ceases to exist, and ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of that same malfunction, the diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. If no obvious problems are found, erase stored codes, and with the ignition "on" wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 7035 Central Timer Module ( CTM ) High Option: Description and Operation Interior Lighting INTERIOR LIGHTING The courtesy lights are controlled by the CTM. The door switches are inputs to the CTM and the courtesy lights are outputs. The glove box lamp and the ash receiver lamp (if equipped) are not controlled by the CTM. They are hardwired to individual switches and fuses. The ignition key halo lamp is controlled by the CTM and will remain on for thirty seconds after the door is closed. The Highline CTM also provides for an illuminated entry option. If the CTM detects an unlock signal from the RKE transmitter, a door disarm switch input or the door jamb switch input, the interior courtesy lights will be turned on. The illuminated entry function is cancelled if the CTM senses an ignition "on" condition or the "lock" command from a valid key fob. If a door is left open or the dome lamp switch is left in the "on" position for more than fifteen minutes, the CTM will extinguish the lamps to avoid discharging the battery. If the lamps are turned on by rotation of the headlamp panel dimmer switch, the CTM will not be able to turn them off. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 7036 Central Timer Module ( CTM ) High Option: Description and Operation Central Timer Module INTRODUCTION Central Timer Module The Central Timer Module (CTM) is used to supply the vehicles occupants with visual and audible information, control various vehicle functions, and provide a centralized power distribution for the passenger compartment. To both provide and receive vehicle information the BCM is interfaced to the CCD Bus. Power for the CTM is supplied from three sources. Circuit F12 supplies power to the CTM in the START and RUN position. This circuit is protected by a 10 Amp fuse located in the junction block. Power is also supplied to the CTM on circuit F35. This circuit is HOT at all times and protected by a 20 Amp fuse located in the junction block. In the RUN position circuit V6 provides battery power to the CTM. This circuit is protected by a 20 Amp fuse located in the junction block. Ground for the ECM is provided by circuits Z1 and Z2. CCD Bus interface is accomplished on circuits D1 and D2. The D1 circuit is used for Bus (+), and D2 is for Bus (-). SYSTEM OPERATION Central Timer Module Two versions of the Central Timer Module (CTM) are available on this vehicle, a base version and a high-line version. The base version of the CTM is used on base models of the vehicle. The base version of the CTM combines the functions of a chime/buzzer module, an intermittent wipe module, and an ignition lamp time delay relay in a single unit. The high-line version of the CTM is used on highline vehicles. The high-line CTM provides all of the functions of the base version CTM, but also is used to control and integrate many of the additional electronic functions and features included on the high- line models. The high-line version of the CTM contains a central processing unit and interfaces with other modules in the vehicle on the Chrysler Collision Detection (CCD) data bus network. The CCD data bus network allows the sharing of sensor information. This helps to reduce wire harness complexity, reduce internal controller hardware, and reduce component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. The power lock and Remote Keyless Entry (RKE) systems are two of the systems that the high-line CTM controls. The high-line CTM receives hard-wired inputs from the power lock switches, CCD message inputs from the Powertrain Control Module (PCM) and Airbag Control Module (ACM), and coded radio signal inputs from the RKE transmitters. In response to those inputs, the internal programming of the CTM sends the proper outputs to control the power lock motors, the horn relay, and the courtesy lamps. Some of the features and functions of the power lock and Remote Keyless Entry (RKE) systems made possible because of the communication of the CTM on the CCD data bus network include: - A door-lock inhibit feature which prevents the power lock system from being energized with a power door lock switch if the key is in the ignition and/or the headlamps are on. However, the locks can still be operated manually with a key or energized with the RKE transmitter. - An enhanced accident response feature will prevent the doors from locking, then unlock both doors after receiving a CCD message from the ACM indicating a frontal impact requiring airbag deployment. This feature will also turn on the courtesy lamps ten seconds after receiving the ACM deployment message, if the CCD vehicle speed message from the PCM indicates the vehicle is not moving. Of course, these responses are dependent upon functional battery power and wiring circuitry following the impact. - Rolling door locks is a programmable feature of the power lock system. This feature will automatically lock all of the doors after the vehicle reaches a speed of about 24 kilometers-per-hour (15 miles-per-hour) or greater. This feature will also lock the doors if a door is opened, then closed again at any speed above 24 kilometers-per-hour (15 miles-per-hour). This feature can be enabled or disabled using the DRB scan tool and the proper Diagnostic Procedures. - A programmable feature of the RKE system is the enabling or disabling of the horn chirp following the RKE Lock function. This feature can be enabled or disabled using the DRB scan tool and the proper Diagnostic Procedures. The horn relay is one of the outputs that the high-line CTM can control. The high-line CTM is programmed to energize or de-energize the horn relay in response to certain inputs from the Vehicle Theft Security System (VTSS) and the Remote Keyless Entry (RKE) system. One of the features that the high-line CTM supports and controls is the Vehicle Theft Security System (VTSS). In the VTSS, the CTM receives hard-wired inputs from the door jamb, door lock cylinder, and ignition switches. The programming in the CTM allows it to process the information from these inputs and send control outputs to energize or de-energize the headlamp relay, horn relay, and the Security lamp. The CTM also sends CCD data bus messages to the Powertrain Control Module (PCM) to control the engine no-run feature of the VTSS The CTM also contains the receiver and control logic for the power lock and Remote Keyless Entry (RKE) systems, which are integrated into the arming, disarming, and triggering functions of the VTSS. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 7037 Both versions of the CTM are mounted under the passenger side end of the instrument panel, behind the instrument panel top cover and outboard of the glove box opening. For diagnosis of the base version of the CTM, refer to Wiper and Washer Systems or Chime/Buzzer Warning Systems. For diagnosis of the high-line version of the CTM or the CCD data bus, a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 7038 Central Timer Module ( CTM ) High Option: Description and Operation Chime System CHIME SYSTEM The chime system is built into the CTM. The system also supports an external chime request from the instrument cluster. This feature allows the instrument cluster to request a chime from the CTM for gauge problems and tell-tale warnings. There are two chime rates, Low; 50 chimes per minute for reminders and High; 180 chimes per minute for serious conditions that require immediate attention. The high rate chime sounds when the key is left in the ignition and the doors are open or the headlights are left on. The low rate chime sounds for any of the other conditions. There is a variable rate feature that allows the chime to sound continuously for key-in and headlamp warning as long as the door is open. The seat belt warning chime is activated for six seconds, and all other chime conditions will activate the chime once at the time the warning light on the cluster is illuminated. The chime will sound for the following conditions: - Ignition oft, key in ignition, driver's door open - Ignition oft, headlamps on, driver's door open - Seat belt warning - Check engine lamp illuminated (after prove-out) - Airbag lamp illuminated (after prove-out) - Anti-lock lamp illuminated (after prove-out if equipped) - Check gauges lamp illuminated - Low fuel - Low washer fluid - Engine temp critical - Engine oil press too low CIRCUIT OPERATION Seat Belt Warning Chime The seat belt chime is used to indicate to the operator that the seat belt is not fastened when the ignition switch is in the RUN position. The seat belt switch is normally OPEN with the seat belt buckled. Circuit G10 is connected between the Central Timer Module (CTM) and the switch. Ground for the switch is provided on circuit Z1. Exterior Lamp-On Warning Chime The exterior lamp ON chime is used to indicate to the operator that the lamps are ON with the drivers door OPEN and the key removed from the ignition. The Central Timer Module (CTM) uses information from circuit G26 to determine if the lamps are ON, and circuit G16 for drivers door ajar. Key-In Ignition Warning Chime The Key-In chime is used to indicate to the operator that the key is in the ignition with the driver's door OPEN. If the key is in the ignition, a ground path is completed from the G26 circuit at the Central Timer Module (CTM), through the CLOSED switch, to the Z1 circuit. The Z1 circuit is the ground circuit. When the driver's door is open the normally OPEN door ajar switch CLOSES completing a path to ground on circuit G16. The CTM processes this information and turns on the chime. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 7039 Central Timer Module ( CTM ) High Option: Description and Operation Airbag System Description AIRBAG SYSTEM The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front end collision. The system is most effective when used in conjunction with the seat belt system. The airbag control module (ACM) is an electronic module that monitors the airbag system for proper operation, stores Diagnostic Trouble Code (DTCs), controls the airbag warning lamp, monitors the pressure in the passenger airbag module 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 the diagnostic information DTCs to the technician through the DRB III via the CCD bus. Some circuits are tested continuously; others are checked only under certain circumstances. The warning lamp is driven with messages relayed to the Mechanical Instrument Cluster (MIC) from the ACM via the CCD bus. The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be observed by the customer. Whenever the ignition key is turned to the run or start" position, the airbag control module performs a lamp check by turning the AIRBAG warning lamp on for 6-8 seconds. If the lamp remains off, it means that the ACM has checked the system and found it to be free of discernible malfunctions. If the lamp remains on, there could be an active fault in the system or the circuit that operates the lamp may be shorted to ground. If the lamp comes on and stays on for a period longer than 6-8 seconds, then goes off, there is usually an intermittent problem in the system. Perform the WARNING LAMP CIRCUIT OPEN procedure in this book to find the cause of any customer complaint regarding the AIRBAG warning lamp, such as: Warning Lamp Does Not Illuminate - Warning Lamp Stays Illuminated WARNING! The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must first disconnect and isolate the battery negative (ground) cable. Then wait two minutes for the system capacitor to discharge before further system service. This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Never strike or kick the airbag control module, as it can damage the impact sensor or affect its calibration. If an airbag control module is accidentally dropped during service, the module must be scrapped and replaced with a new unit. Airbag Diagnostic Trouble Codes AIRBAG DIAGNOSTIC TROUBLE CODES Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Always begin by reading the diagnostic trouble codes using the DRB. This procedure begins with AIRBAG TEST 1A - Identifying Airbag System Problems. This will direct you to the specific test(s) that must be performed. Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures within this manual, diagnostic trouble codes are used as a diagnostic tool. ACTIVE CODES The codes become 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 are automatically erased 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 7040 A "stored" code indicates that there was an active code present at some time. However, the code currently may not be present as an active code, although another code could be. When a trouble code occurs, the airbag warning lamp illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. If a malfunction is detected a diagnostic trouble code is stored and will remain stored as long as the malfunction exists. When and if the malfunction ceases to exist, and ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of that same malfunction, the diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. If no obvious problems are found, erase stored codes, and with the ignition "on" wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Interior Lighting INTERIOR LIGHTING The courtesy lights are controlled by the CTM. The door switches are inputs to the CTM and the courtesy lights are outputs. The glove box lamp and the ash receiver lamp (if equipped) are not controlled by the CTM. They are hardwired to individual switches and fuses. The ignition key halo lamp is controlled by the CTM and will remain on for thirty seconds after the door is closed. The Highline CTM also provides for an illuminated entry option. If the CTM detects an unlock signal from the RKE transmitter, a door disarm switch input or the door jamb switch input, the interior courtesy lights will be turned on. The illuminated entry function is cancelled if the CTM senses an ignition "on" condition or the "lock" command from a valid key fob. If a door is left open or the dome lamp switch is left in the "on" position for more than fifteen minutes, the CTM will extinguish the lamps to avoid discharging the battery. If the lamps are turned on by rotation of the headlamp panel dimmer switch, the CTM will not be able to turn them off. Central Timer Module INTRODUCTION Central Timer Module The Central Timer Module (CTM) is used to supply the vehicles occupants with visual and audible information, control various vehicle functions, and provide a centralized power distribution for the passenger compartment. To both provide and receive vehicle information the BCM is interfaced to the CCD Bus. Power for the CTM is supplied from three sources. Circuit F12 supplies power to the CTM in the START and RUN position. This circuit is protected by a 10 Amp fuse located in the junction block. Power is also supplied to the CTM on circuit F35. This circuit is HOT at all times and protected by a 20 Amp fuse located in the junction block. In the RUN position circuit V6 provides battery power to the CTM. This circuit is protected by a 20 Amp fuse located in the junction block. Ground for the ECM is provided by circuits Z1 and Z2. CCD Bus interface is accomplished on circuits D1 and D2. The D1 circuit is used for Bus (+), and D2 is for Bus (-). SYSTEM OPERATION Central Timer Module Two versions of the Central Timer Module (CTM) are available on this vehicle, a base version and a high-line version. The base version of the CTM is used on base models of the vehicle. The base version of the CTM combines the functions of a chime/buzzer module, an intermittent wipe module, and an ignition lamp time delay relay in a single unit. The high-line version of the CTM is used on highline vehicles. The high-line CTM provides all of the functions of the base version CTM, but also is used to control and integrate many of the additional electronic functions and features included on the high- line models. The high-line version of the CTM contains a central processing unit and interfaces with other modules in the vehicle on the Chrysler Collision Detection (CCD) data bus network. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 7041 The CCD data bus network allows the sharing of sensor information. This helps to reduce wire harness complexity, reduce internal controller hardware, and reduce component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. The power lock and Remote Keyless Entry (RKE) systems are two of the systems that the high-line CTM controls. The high-line CTM receives hard-wired inputs from the power lock switches, CCD message inputs from the Powertrain Control Module (PCM) and Airbag Control Module (ACM), and coded radio signal inputs from the RKE transmitters. In response to those inputs, the internal programming of the CTM sends the proper outputs to control the power lock motors, the horn relay, and the courtesy lamps. Some of the features and functions of the power lock and Remote Keyless Entry (RKE) systems made possible because of the communication of the CTM on the CCD data bus network include: - A door-lock inhibit feature which prevents the power lock system from being energized with a power door lock switch if the key is in the ignition and/or the headlamps are on. However, the locks can still be operated manually with a key or energized with the RKE transmitter. - An enhanced accident response feature will prevent the doors from locking, then unlock both doors after receiving a CCD message from the ACM indicating a frontal impact requiring airbag deployment. This feature will also turn on the courtesy lamps ten seconds after receiving the ACM deployment message, if the CCD vehicle speed message from the PCM indicates the vehicle is not moving. Of course, these responses are dependent upon functional battery power and wiring circuitry following the impact. - Rolling door locks is a programmable feature of the power lock system. This feature will automatically lock all of the doors after the vehicle reaches a speed of about 24 kilometers-per-hour (15 miles-per-hour) or greater. This feature will also lock the doors if a door is opened, then closed again at any speed above 24 kilometers-per-hour (15 miles-per-hour). This feature can be enabled or disabled using the DRB scan tool and the proper Diagnostic Procedures. - A programmable feature of the RKE system is the enabling or disabling of the horn chirp following the RKE Lock function. This feature can be enabled or disabled using the DRB scan tool and the proper Diagnostic Procedures. The horn relay is one of the outputs that the high-line CTM can control. The high-line CTM is programmed to energize or de-energize the horn relay in response to certain inputs from the Vehicle Theft Security System (VTSS) and the Remote Keyless Entry (RKE) system. One of the features that the high-line CTM supports and controls is the Vehicle Theft Security System (VTSS). In the VTSS, the CTM receives hard-wired inputs from the door jamb, door lock cylinder, and ignition switches. The programming in the CTM allows it to process the information from these inputs and send control outputs to energize or de-energize the headlamp relay, horn relay, and the Security lamp. The CTM also sends CCD data bus messages to the Powertrain Control Module (PCM) to control the engine no-run feature of the VTSS The CTM also contains the receiver and control logic for the power lock and Remote Keyless Entry (RKE) systems, which are integrated into the arming, disarming, and triggering functions of the VTSS. Both versions of the CTM are mounted under the passenger side end of the instrument panel, behind the instrument panel top cover and outboard of the glove box opening. For diagnosis of the base version of the CTM, refer to Wiper and Washer Systems or Chime/Buzzer Warning Systems. For diagnosis of the high-line version of the CTM or the CCD data bus, a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. Chime System CHIME SYSTEM The chime system is built into the CTM. The system also supports an external chime request from the instrument cluster. This feature allows the instrument cluster to request a chime from the CTM for gauge problems and tell-tale warnings. There are two chime rates, Low; 50 chimes per minute for reminders and High; 180 chimes per minute for serious conditions that require immediate attention. The high rate chime sounds when the key is left in the ignition and the doors are open or the headlights are left on. The low rate chime sounds for any of the other conditions. There is a variable rate feature that allows the chime to sound continuously for key-in and headlamp warning as long as the door is open. The seat belt warning chime is activated for six seconds, and all other chime conditions will activate the chime once at the time the warning light on the cluster is illuminated. The chime will sound for the following conditions: - Ignition oft, key in ignition, driver's door open - Ignition oft, headlamps on, driver's door open - Seat belt warning - Check engine lamp illuminated (after prove-out) - Airbag lamp illuminated (after prove-out) - Anti-lock lamp illuminated (after prove-out if equipped) - Check gauges lamp illuminated - Low fuel - Low washer fluid - Engine temp critical - Engine oil press too low Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 7042 CIRCUIT OPERATION Seat Belt Warning Chime The seat belt chime is used to indicate to the operator that the seat belt is not fastened when the ignition switch is in the RUN position. The seat belt switch is normally OPEN with the seat belt buckled. Circuit G10 is connected between the Central Timer Module (CTM) and the switch. Ground for the switch is provided on circuit Z1. Exterior Lamp-On Warning Chime The exterior lamp ON chime is used to indicate to the operator that the lamps are ON with the drivers door OPEN and the key removed from the ignition. The Central Timer Module (CTM) uses information from circuit G26 to determine if the lamps are ON, and circuit G16 for drivers door ajar. Key-In Ignition Warning Chime The Key-In chime is used to indicate to the operator that the key is in the ignition with the driver's door OPEN. If the key is in the ignition, a ground path is completed from the G26 circuit at the Central Timer Module (CTM), through the CLOSED switch, to the Z1 circuit. The Z1 circuit is the ground circuit. When the driver's door is open the normally OPEN door ajar switch CLOSES completing a path to ground on circuit G16. The CTM processes this information and turns on the chime. Compass Mini-Trip Computer (CMTC) SYSTEM OPERATION A mini trip computer is available on this model to provide several electronic functions and features. The trip computer contains a central processing unit and interfaces with other modules in the vehicle on the Chrysler Collision Detection (CCD) data bus network. The CCD data bus network allows the sharing of sensor information. This helps to reduce wire harness complexity, reduce internal controller hardware, and reduce component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. Some of the functions and features that the trip computer supports and/or controls, include the following display options: Compass and temperature - Trip odometer (ODO) - Average fuel economy (AVG ECO) - Instant fuel economy (ECO) - Distance to empty (DTE) - Elapsed time (ET) - Blank display Momentarily depressing and releasing the Step button when the ignition switch is in the On position will cause the overhead console display to step sequentially through the listed display options. Momentarily depressing and releasing the U.S./Metric button toggles the display between U.S. and Metric measurements. For more information on the trip computer features and functions, refer to the owner 5 manual in the vehicle glove box. The push button (Step and U.S./Metric) switches and the compass flux-gate unit are integral to the trip computer, compass, and thermometer display module unit. The ambient temperature sensor is hard-wired to the module. Data input for all other trip computer functions is received through CCD data bus messages. The trip computer uses its internal programming and all of these inputs to calculate and display the requested data. If the data displayed is incorrect, perform the self-diagnostic tests as described. If these tests prove inconclusive, the use of a DRB scan tool and the proper Diagnostic Procedures are recommended for further testing of the trip computer and the CCD data bus. The trip computer, compass, and thermometer display module cannot be repaired, and are only available for service as a unit. If faulty or damaged, the complete module must be replaced. COMPASS MINI-TRIP COMPUTER (CMTC) This system, located in the overhead console, displays information on outside temperature, compass direction and trip information. Compass And Temperature Display This display provides the outside temperature and one of eight compass readings to indicate the direction the vehicle is facing. Trip Odometer (ODO) Shows the distance travelled since the last reset. Average Fuel Economy (AVE ECO) Shows the average fuel economy in MPG (miles per gallon) or L/100Km since the last reset. Instantaneous Fuel Economy Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 7043 Shows the fuel economy for the last few seconds in MPG or L/100Km. Distance to Empty (DTE) Shows the estimated distance that can be travelled with the fuel remaining in the tank. This is calibrated using the MPG for the last few minutes. Elapsed Time (ET) Shows the accumulated ignition on time since the last reset. Step Button Press this button to cycle through all the mini-trip computer displays. US/M Button Press this button to convert all vehicle displays from US to metric to US. To Reset the Display Press the Step and US/M buttons simultaneously for at least two seconds and all resettable conditions will be rest. This will occur only if a resettable function (AVG ECO, ECO, ET) is currently being displayed. Automatic Compass Calibration This compass is self-calibrating which eliminates the need to manually set the compass. When the vehicle is new, the compass may appear erratic and the CAL symbol will be displayed. After completing three 360° turns in an area free from large metal or metallic objects, the CAL symbol will turn off and the compass will function normally. Compass Variance Compass Variance is the difference between Magnetic North and Geographic North. In some areas of the country, the difference between Magnetic and Geographic North is great enough to cause the compass to give false readings. If this occurs, the compass variance must be set. Enhanced Accident Response (Highline CTM only) If the Airbag Control Module (ACM) deploys the airbags, a message is transmitted over the CCD bus to the CTM module to unlock the doors. The interior lights will be turned on when the vehicle speed message on the CCD bus indicates 0 mph or the message is not present. In addition to unlocking the doors, the door lock feature will be disabled for a predetermined amount of time following the deployment. Once the ignition key has been cycled to the "off" position, normal operation will resume. Disclaimers DISCLAIMERS All information, illustrations, and specifications contained in this database are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice. Glossary of Terms/Acronyms GLOSSARY OF ACRONYMS ACM ..................................................................................................................................................... ....................................... Airbag Control Module CAB ........................................................................ ................................................................................................................ Controller Anti-lock Brake CCD ................................................................................................................................... Chrysler Collision Detection (Vehicle Communications Bus) CMTC ................................................................. ................................................................................................................ Compass/mini-trip Computer CTM .................................................................................................................................... .......................................................... Central Timer Module DAB ....................................................... ...................................................................................................................................................... Driver Airbag DLC ............................................................................................................................... ................................................................... Data Link Connector DTC ............................................... ............................................................................................................................................ Diagnostic Trouble Code MIC ............................................................................................................................... ................................................... Mechanical Instrument Cluster PAB ................................................ ........................................................................................................................................................ Passenger Airbag PCM ....................................................................................................................... ................................................................ Powertrain Control Module PDC ........................................ .................................................................................................................................................. Power Distribution Center RKE ...................................................................................................................... ......................................................................... Remote Keyless Entry SQUIB ................................................................................................................................... Also Called Initiator (Located In Rear Of Airbag Module) VTSS ............................................................................ ..................................................................................................... Vehicle Theft Security System Introduction SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION The body system consists of four modules that communicate over the (CCD) bus (Chrysler Collision Detection multiplex system). There are two additional modules, the Powertrain Control Module (PCM) and the Controller Anti-lock Brake (CAB) that are not part of the body system, but do utilize the CCD bus for communication. The CAB also utilizes the bus for diagnostics. The PCM sends and receives messages on the CCD bus, Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 7044 however diagnostics are performed through the Serial Communication Interface or (SCI), the same as last year. All of the information about the functioning of all the systems is organized, controlled, and communicated by the CCD bus. Through the CCD bus, information about the operation of vehicle components and circuits is relayed quickly to the appropriate module(s). All modules receive all the information transmitted on the bus even though a module may not require all information to perform it's function. It will only respond to messages "addressed" to it through a binary coding process. This method of data transmission significantly reduces the complexity of the wiring in the vehicle and the size of the wiring harnesses. Mechanical Instrument Cluster (MIC) MECHANICAL INSTRUMENT CLUSTER (MIC) The MIC is available in 4 different versions. Two of the versions are Canadian clusters. There is a Highline and a low line cluster available. The difference between Highline and low line is the addition of a tachometer in the Highline. In order to accomplish this, the fuel level gauge is reduced in size and the oil pressure gauge is relocated. The cluster positions it's gauges with bus messages received from the Powertrain Control Module (PCM). The odometer is a Liquid Crystal Display (LCD). The cluster will provide bus bias and the PCM provides termination. The MIC has an internal self-test routine that can be accessed by pushing and holding the trip odometer and rotating the key to the on position. The cluster will then place all the gauges at their calibration points and will light all the CCD driven tell-tales. It will also light all the segments of the LCD display for a visual verification check. All of the red warning symbols are non-replaceable LED's, amber tell-tales are serviceable incandescent bulbs. The MIC is not addressable with the DRB. All diagnostics are performed with the on-board sequence described above. If there are faults found during the diagnostic routine, the cluster will report them on the LCD odometer display. For further information about the diagnostic routine and the explanation of faults, please refer to Powertrain Management/Computers and Control Systems/Testing and Inspection/. Power Door Lock System POWER DOOR LOCKS The CTM controls the door lock actuator assemblies to handle locking and unlocking with the key fob or interior switch. There is also a door lock inhibit feature that prevents power locking of the doors if the ignition is off and the key is in the ignition. Automatic or "rolling locks" are included as a DRB programmable feature. If the vehicle is moving approximately 15 mph and approximately 10 degrees of throttle opening is seen by the PCM, (the PCM will send this info to the CTM via the CCD bus) indicating acceleration, the CTM will cycle the lock actuators. Remote Keyless Entry (RKE) /Vehicle Theft Security System (VTSS) INTRODUCTION Remote Keyless Entry System The Remote Keyless Entry (RKE) system is a radio frequency system that allows the use of a remote transmitter to control the power lock and illuminated entry systems. If the vehicle is so equipped, the RKE transmitter can also control the vehicle theft alarm system. The RKE system consists of the remote key fob transmitter and a receiver with program logic, which is integral to the high-line version of the Central Timer Module (CTM). The RKE system can retain the vehicle access codes of up to four transmitters. The transmitter codes are retained in memory, even if the battery is disconnected. If a transmitter is faulty or lost, new transmitter vehicle access codes can be programmed into the system using a DRE scan tool and the proper Diagnostic Procedures. The high line Central Timer Module (CTM) provides for Remote Keyless Entry (RKE) and the Vehicle Theft Security System (VTSS). The base CTM is not able to provide these functions. The presence of either of these options dictates that the vehicle be equipped with a Highline CTM. The VTSS system monitors the door jamb switches and ignition switch to detect unauthorized entry into the vehicle. Once the vehicle is "armed", any one of these inputs can cause the VTSS system to be tripped. Once tripped, the horn and lights will pulse for 3 minutes and if an attempt is made to start the engine, it will start and stall. If the trigger condition is still present, the lights will continue to flash for an additional 15 minutes. After 15 minutes the system will stop pulsing the lights and return to the "armed" state. The cause of the last 4 alarm triggers is stored by the CTM and may be retrieved by the DRB. The system may be disarmed by either an unlock command from a valid RKE key fob or by using a key in either door. Both front door key cylinders are equipped with disarm switches. There is also a VTSS lamp on the dash that provides information to the driver about the state of the vehicle theft system. The RKE system is placed in the programming mode by the DRB. The system will stores up to four key fob codes. Through the DRB, programming of one key fob without deleting the others is possible. If the key fob is stolen, all the fob codes stored previously may be erased to provide the owner of the vehicle with an extra sense of security. Wiper System SPEED SENSITIVE INTERMITTENT WIPERS The Dakota trucks equipped with a Highline Central Timer Module (CTM) will utilize speed sensitive intermittent wipers. Only a Highline CTM will be able to support this feature. A base CTM will provide for intermittent wipers without the speed sensitive feature. The low and high speeds Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 7045 are controlled through the wiper stalk switch. The intermittent portion of the wiper control is handled by the CTM through the intermittent wiper relay. When the module detects a decrease in delay time as selected by the driver, an immediate wipe of the windshield takes place and the new delay interval is implemented. This feature is present only on the Highline CTM. hen the vehicle is moving at speeds at or below 10 mph, the delay time ranges from 1 to 36 seconds. When the speed rises above 10 mph, the delay times are cut in half for a range of 1/2 to 18 seconds. The speed signal is provided to the CTM from the PCM over the CCD bus. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Central Timer Module ( CTM ) High Option: Initial Inspection and Diagnostic Overview VEHICLE COMMUNICATION The Chrysler Collision Detection multiplex system (CCD bus) consists of a twisted pair of wires. These wires run from one module to another. They receive and deliver coded information between the modules. The information is coded to identify the message as well as the importance of the message. When there are multiple messages trying to access the CCD bus at one time, the code determines the message that has higher priority, and is then allowed to access the bus first. The two wires of the twisted pair that make up the CCD multiplex system are called "bus+" (bus plus) and "bus-" (bus minus) respectively. Each wire has a measurable voltage level of roughly 2.5 volts. In order to maintain the 2.5 volts on each line and provide a means of transportation for the coded messages, there is a "voltage divider network" located in the module that supplies bus bias or voltage. Along with the module that supplies bias, some modules provide termination. Bias is the voltage necessary to make the bus operational. At least one point of termination is necessary, some systems use more than one. Some modules are capable of biasing and terminating the bus by themselves. Termination in the circuitry (a 120 ohm resistor placed across the bus) is required to complete the voltage divider network and also provides some electromagnetic protection for the bus. In this vehicle, the bias is supplied by the instrument cluster and termination is provided by the Powertrain Control Module (PCM). Without termination, voltage on the bus goes to approximately 5 volts on one wire and 0 volts on the other wire. In this application, the instrument cluster supplies bus bias and termination and the PCM supplies an additional point of termination. NOTE: Communication over the bus is essential to the proper operation of the vehicle's on-board diagnostic systems and the DRB. Problems with the operation of the bus or DRB must be corrected before proceeding with diagnostic testing. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7048 Central Timer Module ( CTM ) High Option: Component Tests and General Diagnostics DIAGNOSTICS The Central Timer Module (CTM) is fully addressable with DRB III and it is the recommended method for diagnosis. The CTM reports 6 Diagnostic Trouble Codes. All of the inputs to the CTM can be read with DRB and the outputs can be actuated. If the inputs are OK and the outputs can be cycled with the DRB, the problem is "USUALLY" the Central Timer Module. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7049 Central Timer Module ( CTM ) High Option: Scan Tool Testing and Procedures DRB III Does Not Power Up (Blank Screen) DRB III ERROR MESSAGES AND BLANK SCREEN Under normal operation, the DRB will display one of only two error messages: - User-Requested WARM Boot - User-Requested COLD Boot If the DRB should display any other error message, record the entire display and call the MDS Hotline, or call for information and assistance at 1-800-825-8737. This is a sample of such an error message display: VER: 2.14 date: 26 Jul93 file: key_itf.cc date: Jul 26 1993 line: 548 err. Ox1 User-Requested COLD boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. DRB III DOES NOT POWER UP (BLANK SCREEN) 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. If all connection are proper between the DRB and the Vehicle or other devices, and the vehicle battery is fully charged, an inoperative DRB may be the result of faulty cable of vehicle wiring. Perform Vehicle Communication TEST 1A. DRB III Safety Limits WARNING: Never exceed DRBIII safety limits! Display Is Not Visible DISPLAY IS NOT VISIBLE Low temperatures will effect the visibility of the display. Adjust the contrast to compensate for this condition. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Adjustments > Setting the Compass Central Timer Module ( CTM ) High Option: Adjustments Setting the Compass SETTING THE COMPASS The compass/mini-trip module is self-calibrated and requires no adjustment. The word CAL will be displayed to indicate that the compass is in the fast calibrating mode. CAL will turn off after the vehicle has gone in three complete circles without stopping, in an area free of magnetic disturbance. If the module displays the temperature while the compass is blank or shows a false reading, the vehicle must be demagnetized. If the compass still goes blank after the vehicle is demagnetized, the compass/mini-trip module must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Adjustments > Setting the Compass > Page 7052 Central Timer Module ( CTM ) High Option: Adjustments Setting the Variance SETTING THE VARIANCE Setting The Variance Variance is the difference between magnetic north and geographic north. To determine the variance for the area you are in, refer to the zone map provided. The number shown for your area is the variance number for your area. 1. Set the Compass/Mini-Trip Console (CMTC) to compass/temperature mode. 2. Press and hold down the reset button for 5 seconds. NOTE: If the buttons are held for 10 seconds instead of 5, the CMTC will set the variance to 8 and enter the fast calibration mode. 3. The VAR light will come on and the last variance setting will be displayed. 4. Press the STEP button to set the zone number. 5. Press the US/M button and resume normal operation. NOTE: Do not attach any magnetic device such as a magnetic CB antenna to the vehicle. This can cause the compass to give false readings. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Service and Repair > Maintenance and Service Information Central Timer Module ( CTM ) High Option: Service and Repair Maintenance and Service Information MAINTENANCE AND SERVICE INFORMATION When replacing a blown fuse, it is important to use only a fuse having the correct amperage rating. The use of a fuse with a rating other than indicated may result in a dangerous electrical system overload. If a properly rated fuse continues to blow, it indicates a problem in the circuit that must be corrected. When replacing any bulbs, do not touch the new bulb with your fingers. Oil contamination will severely shorten bulb life. If the bulb comes in contact with an oily surface, clean the bulb with rubbing alcohol. WARNING: Failure to have the airbag system properly serviced by an authorized dealer may lead to possible injury in the event of an accident. Aside from the maintenance required in response to the airbag lamp conditions, an inspection of the mechanical and electrical components of the system is included in the regular maintenance service recommended for every 3 years or 30,000 miles. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Service and Repair > Maintenance and Service Information > Page 7055 Central Timer Module ( CTM ) High Option: Service and Repair Setting the Compass SETTING THE COMPASS The compass/mini-trip module is self-calibrated and requires no adjustment. The word CAL will be displayed to indicate that the compass is in the fast calibrating mode. CAL will turn off after the vehicle has gone in three complete circles without stopping, in an area free of magnetic disturbance. If the module displays the temperature while the compass is blank or shows a false reading, the vehicle must be demagnetized. If the compass still goes blank after the vehicle is demagnetized, the compass/mini-trip module must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Service and Repair > Maintenance and Service Information > Page 7056 Central Timer Module ( CTM ) High Option: Service and Repair Setting the Variance SETTING THE VARIANCE Setting The Variance Variance is the difference between magnetic north and geographic north. To determine the variance for the area you are in, refer to the zone map provided. The number shown for your area is the variance number for your area. 1. Set the Compass/Mini-Trip Console (CMTC) to compass/temperature mode. 2. Press and hold down the reset button for 5 seconds. NOTE: If the buttons are held for 10 seconds instead of 5, the CMTC will set the variance to 8 and enter the fast calibration mode. 3. The VAR light will come on and the last variance setting will be displayed. 4. Press the STEP button to set the zone number. 5. Press the US/M button and resume normal operation. NOTE: Do not attach any magnetic device such as a magnetic CB antenna to the vehicle. This can cause the compass to give false readings. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Central Timer Module ( CTM ) High Option <--> [Body Control Module] > Component Information > Service and Repair > Page 7057 Central Timer Module ( CTM ) High Option: Tools and Equipment REQUIRED TOOLS AND EQUIPMENT DRB III (diagnostic read-out box) Jumper Wires Ohmmeter Voltmeter Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair Front Door Exterior Handle: Service and Repair FRONT DOOR OUTSIDE HANDLE REMOVAL 1. Remove door trim panel. 2. Remove water dam as necessary to gain access to door handle. 3. Roll glass up. 4. Remove fastener access plug from door end panel. 5. Disengage lock cylinder to latch rod from the latch. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair > Page 7065 6. Disengage outside hadnle to latch rod from the latch. 7. Remove nuts attaching outside door handle to door. 8. Separate outside handle from the door. INSTALLATION 1. Position outside handle in the door. 2. Install nuts attaching outside door handle to door. 3. Engage outside handle to latch rod to the latch. 4. Engage lock cylinder to latch rod to the latch. 5. Install fastener access plug in the door end panel. 6. Install water dam. 7. Install door trim panel. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Service and Repair Front Door Window Motor: Service and Repair REMOVAL 1. Raise the door window to its full up position. 2. Disconnect and isolate the battery negative cable. 3. Remove the power window switch as described. Inside Door Latch Release Handle Pocket Screw Remove/Install 4. Pull the inside door latch release handle to the open position and remove the screw in the release handle pocket that secures the door trim panel to the inside door handle bracket. Door Trim Panel Remove/Install 5. Remove the four screws that secure the door trim panel to the inner door. 6. To disengage the stepped retainers that secure the door trim panel to the inner door, gently pull the lower edge of the trim panel away from the door while lifting the panel upwards. 7. Pull the door trim panel away from the inner door far enough to access the inside door latch release linkage rod at the back of the inside door handle. 8. Unsnap the plastic retainer clip from the inside door handle end of the latch release linkage rod, and remove the rod end from the inside door handle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Service and Repair > Page 7069 Door Trim Panel Wire Harness Connectors 9. On the driver side only, if the vehicle is so equipped, unplug the power mirror switch wire harness connector. 10. If the vehicle is so equipped, unplug the Infinity upper door speaker wire harness connector. 11. Remove the door trim panel and set it aside. 12. Pull the door watershield away from the inner door panel. 13. Lower the door glass far enough to access the glass lift channel nuts. Door Glass 14. Remove the nuts that secure the glass lift channel to the regulator arms. 15. Separate the glass and lift channel from the regulator arms. 16. Lift the glass to its fully-raised position and apply tape to secure the glass to the upper door frame. Power Window Regulator Remove/Install 17. Unplug the power window motor wire harness connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Service and Repair > Page 7070 Fig. 39 Power Regulator Bolts 18. Loosen the three bolts that secure the regulator to the keyed holes of the inner door panel. 19. Remove the three remaining bolts that secure the regulator to the inner door panel. 20. Remove the power window regulator and motor as a unit from the door through the lower access hole in the inner door panel. 21. Reverse the removal procedures to install. Tighten the regulator mounting bolts and the glass lift channel nuts to 9 N.m (80 in. lbs.). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Exterior Handle > System Information > Service and Repair Rear Door Exterior Handle: Service and Repair REAR DOOR OUTSIDE HANDLE REMOVE 1. Remove trim panel. 2. Peel back waterdam to access outside handle. 3. Remove glass channel. 4. Disconnect latch rod. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Exterior Handle > System Information > Service and Repair > Page 7075 5. Remove nuts attaching handle to outer door panel. 6. Separate outside handle from rear door. INSTALLATION 1. Position outside handle in rear door Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Exterior Handle > System Information > Service and Repair > Page 7076 2. Install nuts attaching handle to outer door panel. 3. Connect latch rod. 4. Install glass run channel. 5. Install waterdam. 6. Install trim panel. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Description and Operation Hood Sensor/Switch (For Alarm): Description and Operation CIRCUIT OPERATION Circuit G71 connects from the Central Timer Module to the hood switch. The hood switch is normally OPEN when the hood is CLOSED. When the hood is OPENED the switch CLOSES completing a path to ground on circuit Z1. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > License Plate Bracket > Component Information > Technical Service Bulletins > Front License Plate Bracket - Installation License Plate Bracket: Technical Service Bulletins Front License Plate Bracket - Installation NO: 13-01-96 GROUP: Frame & Bumpers DATE: Oct. 18, 1996 SUBJECT: Front License Plate Bracket Difficult To Install Or Align Properly MODELS: 1997 (AN) Dakota SYMPTOM/CONDITION: Front license plate bracket may be difficult to install or is not aligned properly after installation. DISCUSSION: This condition is caused by the contour of the front bumper fascia which when installing the bracket, requires more attention to detail to install the bracket properly. REPAIR PROCEDURE: This bulletin provides complete installation instructions for the front license plate bracket. 1. Use an 1/8 in. diameter drill bit and drill two (2) pilot holes through the drill dimples located on the lower front bumper fascia. These holes are to be drilled horizontally to the front bumper fascia surface (Figure 1). 2. Attach the front license plate bracket (from package P/N 55076597) to the front bumper fascia at the top two (2) attaching holes with the screws provided in the license plate bracket package. These two (2) screws are to be installed horizontally or perpendicular to the license plate bracket surface. 3. Use an 1/8 in. diameter drill bit and drill two (2) pilot holes through the lower front bumper fascia using the lower license plate bracket attaching holes as a template for proper location. These holes are to be drilled on an approximately 27 degree angle from horizontal (Figure 1). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > License Plate Bracket > Component Information > Technical Service Bulletins > Front License Plate Bracket - Installation > Page 7087 4. Install the two (2) lower license plate bracket screws. These screws MUST be installed on an approximately 27 degree angle from horizontal with the washer head of the screw fully seated against the angled surface of the license plate bracket for proper installation (Figure 1). NOTE: THE LENGTH OF THE TWO LOWER ATTACHING SCREWS WILL BE TOO SHORT IF THEY ARE INSTALLED HORIZONTALLY. INSTALLING LONGER SCREWS WILL ONLY RESULT IN AN IMPROPER AND DISTORTED FIT OF THE FRONT LICENSE PLATE BRACKET TO THE FRONT BUMPER FASCIA. 5. Attach the license plate to the front license plate bracket. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > Customer Interest for Cross-Member: > 03-01-99A > Aug > 99 > Propeller Shaft Boot - Torn/Cut Cross-Member: Customer Interest Propeller Shaft Boot - Torn/Cut NUMBER: 03-01-99 Rev. A GROUP: Axle And Propshafts DATE: Aug. 13, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 03-01-99, DATED FEB. 02, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE REPLACEMENT OF THE VEHICLE CROSSMEMBER ON AUTOMATIC TRANSMISSION EQUIPPED VEHICLES. SUBJECT: Two-Piece Propeller Shaft Boot Torn OVERVIEW: ** This bulletin involves replacing of the propeller shaft assembly and, on certain applications, the replacement of the vehicle crossmember.** MODELS: 1997 - 1998 (AN) Dakota NOTE: THIS BULLETIN APPLIES TO TWO WHEEL DRIVE VEHICLES WITH THE FOLLOWING CONFIGURATIONS: ^ ALL CLUB CAB VEHICLES EQUIPPED WITH A MANUAL TRANSMISSION ^ ALL STANDARD CAB/EIGHT FOOT BOX VEHICLES EQUIPPED WITH A MANUAL TRANSMISSION ^ CLUB CAB VEHICLES EQUIPPED WITH AN AUTOMATIC TRANSMISSION BUILT BEFORE SEPTEMBER 8, 1997 (MDH 0908XX). SYMPTOM/CONDITION: Two-piece propeller shaft boot is torn. DIAGNOSIS: Raise the vehicle on a hoist and inspect the two-piece propeller shaft boot for a cut or tear in the vicinity of the crossmember. If the boot shows signs that it had been cut or torn because it may have contacted the crossmember, perform the Repair Procedure. PARTS REQUIRED: (1) 52105850AA Propshaft, Two-Piece, 2.5L/3.9L Engine, Manual Transmission, Two Wheel Drive, Standard Cab, Eight Foot Box (1) 52105851AA Propshaft, Two-Piece, 2.5L/3.9L Engine, Manual Transmission, Two Wheel Drive, Club Cab (1) 52105873AA Propshaft, Two-Piece, 5.2L Engine, Manual Transmission, Two Wheel Drive, Standard Cab, Eight Foot Box (1) 52105874AA Propshaft, Two-Piece, 5.2L Engine, Manual Transmission, Two Wheel Drive, Club Cab **(1) 521112OOAA Propshaft, One-Piece, 3.9L/5.2L Engine, Automatic Transmission, Two Wheel Drive, Club Cab** **1 52020302AA Crossmember, 3.9L/5.2L Engine, Automatic Transmission, Two Wheel Drive, Club Cab** **4 06504677 Bolt, Crossmember** **4 06502979 Nut, Crossmember** REPAIR PROCEDURE: 1. Place the vehicle on a hoist and shift the transmission to the neutral position. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > Customer Interest for Cross-Member: > 03-01-99A > Aug > 99 > Propeller Shaft Boot - Torn/Cut > Page 7097 2. Raise the vehicle. 3. Remove the bolts that attach the center bearing and heat shield to the crossmember. 4. Remove the bolts holding the universal joint clamps to the pinion yoke. 5. Slide the slip yoke off the transmission output shaft and remove the propeller shaft. For Manual Transmission Equipped Vehicles: 6. Slide the slip yoke of the new propeller shaft (see Parts Required section) onto the transmission output shaft. 7. Install the center bearing and heat shield onto the crossmember and attach the bearing with the bolts. Tighten the bolts to 68 N.m (50 ft. lbs.). 8. Position the universal joint into the axle yoke and attach the universal strap with the bolts. Tighten the bolts to 19 N.m (14 ft. lbs.). 9. Lower the vehicle. **For Automatic Transmission Equipped Vehicles: 10. Remove the crossmember attaching rivets and the crossmember. 11. Install the new crossmember (p/n 52020302AC). Attach the new crossmember to the vehicle frame with four (4) nuts and bolts (p/n 06504677 and 06052979). Tighten the bolts to 60 N.m (45 ft. lbs.). 12. Slide the slip yoke of the new propeller shaft (p/n 52111200AA) onto the transmission output shaft. 13. Position the universal joint into the axle yoke and attach the universal strap with the bolts. Tighten the bolts to 19 Nm (14 ft. lbs.). 14. Lower the vehicle.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 16-30-02-98 0.3 Hrs. Propeller Shaft - Replace Manual Transmission Equipped 16-30-02-99 0.6 Hrs. Propeller Shaft - Replace Automatic Trans. Equipped FAILURE CODE: PB - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cross-Member: > 03-01-99A > Aug > 99 > Propeller Shaft Boot - Torn/Cut Cross-Member: All Technical Service Bulletins Propeller Shaft Boot - Torn/Cut NUMBER: 03-01-99 Rev. A GROUP: Axle And Propshafts DATE: Aug. 13, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 03-01-99, DATED FEB. 02, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE REPLACEMENT OF THE VEHICLE CROSSMEMBER ON AUTOMATIC TRANSMISSION EQUIPPED VEHICLES. SUBJECT: Two-Piece Propeller Shaft Boot Torn OVERVIEW: ** This bulletin involves replacing of the propeller shaft assembly and, on certain applications, the replacement of the vehicle crossmember.** MODELS: 1997 - 1998 (AN) Dakota NOTE: THIS BULLETIN APPLIES TO TWO WHEEL DRIVE VEHICLES WITH THE FOLLOWING CONFIGURATIONS: ^ ALL CLUB CAB VEHICLES EQUIPPED WITH A MANUAL TRANSMISSION ^ ALL STANDARD CAB/EIGHT FOOT BOX VEHICLES EQUIPPED WITH A MANUAL TRANSMISSION ^ CLUB CAB VEHICLES EQUIPPED WITH AN AUTOMATIC TRANSMISSION BUILT BEFORE SEPTEMBER 8, 1997 (MDH 0908XX). SYMPTOM/CONDITION: Two-piece propeller shaft boot is torn. DIAGNOSIS: Raise the vehicle on a hoist and inspect the two-piece propeller shaft boot for a cut or tear in the vicinity of the crossmember. If the boot shows signs that it had been cut or torn because it may have contacted the crossmember, perform the Repair Procedure. PARTS REQUIRED: (1) 52105850AA Propshaft, Two-Piece, 2.5L/3.9L Engine, Manual Transmission, Two Wheel Drive, Standard Cab, Eight Foot Box (1) 52105851AA Propshaft, Two-Piece, 2.5L/3.9L Engine, Manual Transmission, Two Wheel Drive, Club Cab (1) 52105873AA Propshaft, Two-Piece, 5.2L Engine, Manual Transmission, Two Wheel Drive, Standard Cab, Eight Foot Box (1) 52105874AA Propshaft, Two-Piece, 5.2L Engine, Manual Transmission, Two Wheel Drive, Club Cab **(1) 521112OOAA Propshaft, One-Piece, 3.9L/5.2L Engine, Automatic Transmission, Two Wheel Drive, Club Cab** **1 52020302AA Crossmember, 3.9L/5.2L Engine, Automatic Transmission, Two Wheel Drive, Club Cab** **4 06504677 Bolt, Crossmember** **4 06502979 Nut, Crossmember** REPAIR PROCEDURE: 1. Place the vehicle on a hoist and shift the transmission to the neutral position. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cross-Member: > 03-01-99A > Aug > 99 > Propeller Shaft Boot - Torn/Cut > Page 7103 2. Raise the vehicle. 3. Remove the bolts that attach the center bearing and heat shield to the crossmember. 4. Remove the bolts holding the universal joint clamps to the pinion yoke. 5. Slide the slip yoke off the transmission output shaft and remove the propeller shaft. For Manual Transmission Equipped Vehicles: 6. Slide the slip yoke of the new propeller shaft (see Parts Required section) onto the transmission output shaft. 7. Install the center bearing and heat shield onto the crossmember and attach the bearing with the bolts. Tighten the bolts to 68 N.m (50 ft. lbs.). 8. Position the universal joint into the axle yoke and attach the universal strap with the bolts. Tighten the bolts to 19 N.m (14 ft. lbs.). 9. Lower the vehicle. **For Automatic Transmission Equipped Vehicles: 10. Remove the crossmember attaching rivets and the crossmember. 11. Install the new crossmember (p/n 52020302AC). Attach the new crossmember to the vehicle frame with four (4) nuts and bolts (p/n 06504677 and 06052979). Tighten the bolts to 60 N.m (45 ft. lbs.). 12. Slide the slip yoke of the new propeller shaft (p/n 52111200AA) onto the transmission output shaft. 13. Position the universal joint into the axle yoke and attach the universal strap with the bolts. Tighten the bolts to 19 Nm (14 ft. lbs.). 14. Lower the vehicle.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 16-30-02-98 0.3 Hrs. Propeller Shaft - Replace Manual Transmission Equipped 16-30-02-99 0.6 Hrs. Propeller Shaft - Replace Automatic Trans. Equipped FAILURE CODE: PB - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > Customer Interest for Arm Rest: > 23-006-01 > Apr > 01 > Center Armrest/Console - Binds/Sticks Arm Rest: Customer Interest Center Armrest/Console - Binds/Sticks NUMBER: 23-006-01 GROUP: Body DATE: April 13, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-24-98, DATED JUNE 19, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-99003. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODEL YEARS AND CHANGES TO THE PROCEDURE. SUBJECT: Center Armrest/Console Upper Inertia Latch Cover Broken OVERVIEW: This bulletin involves replacing the center armrest/console upper **and lower** inertia latch cover. MODELS: 1997 - **2001** (AN) Dakota 1998 - **2001** (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLE EQUIPPED WITH THE 40-20-40 SPLIT BENCH SEAT (SALES CODE CBE). SYMPTOM/CONDITION: The center armrest/console upper inertia latch cover (driver side hinge cover) is broken. DIAGNOSIS: Inspect the center armrest/console upper inertia latch/hinge cover on the driver side of the armrest (Fig. 1) at the rear flange and internal check strap for a cracked or broken condition. If the cover is cracked or broken, the arm rest may bind or stick when raising or lowering the armrest. Additionally, it the cover is broken, the leg of the cover may extend out from the rear of the armrest when the armrest is folded down. If the cover is cracked or broken, perform the Repair Procedure. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > Customer Interest for Arm Rest: > 23-006-01 > Apr > 01 > Center Armrest/Console - Binds/Sticks > Page 7113 PARTS REQUIRED: REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Move the driver seat to the full forward position with the seat back full forward. 2. Place the center armrest/console in the down position. 3. Remove the screw securing the cover to the inertia latch. 4. Remove the upper and lower inertia latch covers. 5. Place the new upper latch cover **p/n 05017734AA**, onto the inertia latch upper arm with the rear strap around the post. Ensure that the check strap loops under the stud on the side of the lower stanchion/post and that the white slip cover is over the stud and under the check strap. 6. Open the lower inertia latch cover **p/n 05016165AB**, and install the cover onto the inertia latch upper arm working it around the latch bracket. 7. Align the lower inertia latch cover, upper inertia latch cover, and latch bracket to the screw hole on the arm. 8. Secure the cover with the screw and tighten the screw to 4.15 Nm (37 in. lbs.). 9. Inspect the inertia latch, covers, and screw for proper alignment. Perform a function check by moving the center armrest/console through its full range of travel checking for freedom of movement. Adjust the center armrest/console inertia latch covers as necessary. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > Customer Interest for Arm Rest: > 23-31-97 > May > 97 > Center Armrest/Console - Upper Latch Cover Broken Arm Rest: Customer Interest Center Armrest/Console - Upper Latch Cover Broken NO: 23-31-97 GROUP: Body DATE: May 16, 1997 SUBJECT: Center Armrest/Console Upper Inertia Latch Cover Broken MODELS: 1997 (AN) Dakota SYMPTOM/CONDITION: The center armrest/console upper inertia latch cover (driver side hinge cover) is broken. DIAGNOSIS: Inspect the center armrest/console upper inertia latch/hinge cover (Figure 1) on the driver side of the armrest at the rear flange and internal check strap for a cracked or broken condition. If the cover is cracked or broken, the arm rest may bind or stick when raising or lowering the armrest. Additionally, if the cover is broken, the leg of the cover may extend out from the rear of the armrest when the armrest is folded down. If the cover is cracked or broken, perform the following Repair Procedure. PARTS REQUIRED: 1 04883530AA Cover, Center Armrest/Console Upper Inertia Latch AR (1) 04883531AA Cover, Center Armrest/Console Lower Inertia Latch REPAIR PROCEDURE: This bulletin involves replacing the center armrest/console upper inertia latch cover. Some vehicle may also have the lower cover broken which will require replacement. 1. Move the driver seat to a full forward position with the seat back full forward. 2. Place the center armrest/console in the down position. 3. Remove the screw securing the cover to the inertia latch. 4. Remove the upper and lower inertia latch covers. 5. Place the new upper latch cover, p/n 04883530AA, onto the inertia latch upper arm with the rear strap around the post. Ensure that the check strap loops under the stud on the side of the lower stanchion/post. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > Customer Interest for Arm Rest: > 23-31-97 > May > 97 > Center Armrest/Console - Upper Latch Cover Broken > Page 7118 6. Inspect the lower inertia latch cover for damage. If the cover is damaged, replace the cover with p/n 04883531AA. 7. Open the lower latch cover and install the cover onto the inertia latch upper arm working it around the latch bracket. 8. Align the lower latch cover, upper latch cover and latch bracket to the screw hole on the arm. 9. Secure the cover with the screw and torque the screw to 4.15 Nm (37 in. lbs.). 10. Inspect the inertia latch, covers, and screw for proper alignment. Perform a function check by moving the center armrest/console through its full range of travel checking for freedom of movement. Adjust the center armrest/console inertia latch covers as necessary. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-10-00-90 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > Customer Interest for Arm Rest: > 23-06-97 > Feb > 97 > Console Armrest - Hinge Bezel Cracked Arm Rest: Customer Interest Console Armrest - Hinge Bezel Cracked NO: 23-06-97 GROUP: Body DATE: Feb. 28, 1997 SUBJECT: Hinge Bezel On Front Seat Center Console/Armrest Broken MODELS: 1997 (AN) Dakota SYMPTOM/CONDITION: The front 40/20/40 seat center console/armrest hinge bezel is cracked or broken at the rear hinge. DIAGNOSIS: If the front seat center console/armrest cover is over extended upon opening, the hinge bezel may crack or break. The cracking occurs around the flexible fingers of the hinge bezel. The hinge bezel is now available as a separate part for service. Previously, the only way to obtain the hinge bezel was to purchase the front seat center console/armrest as an assembly. Inspect the area of the front seat center console/armrest near the hinge bezel. If cracking is noticed, replace the hinge bezel using the following Repair Procedure. PARTS REQUIRED: AR(1) 0RE841AZAA Front Seat Center Console/Armrest Hinge Bezel, Agate AR(1) 0RE841C3AA Front Seat Center Console/Armrest Hinge Bezel, Medium Mist Gray AR(1) 0RE841K5AA Front Seat Center Console/Armrest Hinge Bezel, Camel REPAIR PROCEDURE: This bulletin involves replacing the front seat center console/armrest hinge bezel. 1. Place the front seat center console/armrest in the down position. 2. Remove the two screws from the hinge bezel. 3. Remove plastic hinge bezel by sliding it towards the rear of the truck. 4. Slide new hinge bezel (refer to Parts Required section for proper color) onto the armrest by pushing it forward and over the vinyl ledge that is molded into the armrest. 5. Align the holes in the hinge bezel with the holes in the metal substrate of the center console/armrest. 6. Attach the hinge bezel with the two screws removed in step 2. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-14-21-90 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Arm Rest: > 23-006-01 > Apr > 01 > Center Armrest/Console Binds/Sticks Arm Rest: All Technical Service Bulletins Center Armrest/Console - Binds/Sticks NUMBER: 23-006-01 GROUP: Body DATE: April 13, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-24-98, DATED JUNE 19, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-99003. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODEL YEARS AND CHANGES TO THE PROCEDURE. SUBJECT: Center Armrest/Console Upper Inertia Latch Cover Broken OVERVIEW: This bulletin involves replacing the center armrest/console upper **and lower** inertia latch cover. MODELS: 1997 - **2001** (AN) Dakota 1998 - **2001** (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLE EQUIPPED WITH THE 40-20-40 SPLIT BENCH SEAT (SALES CODE CBE). SYMPTOM/CONDITION: The center armrest/console upper inertia latch cover (driver side hinge cover) is broken. DIAGNOSIS: Inspect the center armrest/console upper inertia latch/hinge cover on the driver side of the armrest (Fig. 1) at the rear flange and internal check strap for a cracked or broken condition. If the cover is cracked or broken, the arm rest may bind or stick when raising or lowering the armrest. Additionally, it the cover is broken, the leg of the cover may extend out from the rear of the armrest when the armrest is folded down. If the cover is cracked or broken, perform the Repair Procedure. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Arm Rest: > 23-006-01 > Apr > 01 > Center Armrest/Console Binds/Sticks > Page 7128 PARTS REQUIRED: REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Move the driver seat to the full forward position with the seat back full forward. 2. Place the center armrest/console in the down position. 3. Remove the screw securing the cover to the inertia latch. 4. Remove the upper and lower inertia latch covers. 5. Place the new upper latch cover **p/n 05017734AA**, onto the inertia latch upper arm with the rear strap around the post. Ensure that the check strap loops under the stud on the side of the lower stanchion/post and that the white slip cover is over the stud and under the check strap. 6. Open the lower inertia latch cover **p/n 05016165AB**, and install the cover onto the inertia latch upper arm working it around the latch bracket. 7. Align the lower inertia latch cover, upper inertia latch cover, and latch bracket to the screw hole on the arm. 8. Secure the cover with the screw and tighten the screw to 4.15 Nm (37 in. lbs.). 9. Inspect the inertia latch, covers, and screw for proper alignment. Perform a function check by moving the center armrest/console through its full range of travel checking for freedom of movement. Adjust the center armrest/console inertia latch covers as necessary. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Arm Rest: > 23-31-97 > May > 97 > Center Armrest/Console - Upper Latch Cover Broken Arm Rest: All Technical Service Bulletins Center Armrest/Console - Upper Latch Cover Broken NO: 23-31-97 GROUP: Body DATE: May 16, 1997 SUBJECT: Center Armrest/Console Upper Inertia Latch Cover Broken MODELS: 1997 (AN) Dakota SYMPTOM/CONDITION: The center armrest/console upper inertia latch cover (driver side hinge cover) is broken. DIAGNOSIS: Inspect the center armrest/console upper inertia latch/hinge cover (Figure 1) on the driver side of the armrest at the rear flange and internal check strap for a cracked or broken condition. If the cover is cracked or broken, the arm rest may bind or stick when raising or lowering the armrest. Additionally, if the cover is broken, the leg of the cover may extend out from the rear of the armrest when the armrest is folded down. If the cover is cracked or broken, perform the following Repair Procedure. PARTS REQUIRED: 1 04883530AA Cover, Center Armrest/Console Upper Inertia Latch AR (1) 04883531AA Cover, Center Armrest/Console Lower Inertia Latch REPAIR PROCEDURE: This bulletin involves replacing the center armrest/console upper inertia latch cover. Some vehicle may also have the lower cover broken which will require replacement. 1. Move the driver seat to a full forward position with the seat back full forward. 2. Place the center armrest/console in the down position. 3. Remove the screw securing the cover to the inertia latch. 4. Remove the upper and lower inertia latch covers. 5. Place the new upper latch cover, p/n 04883530AA, onto the inertia latch upper arm with the rear strap around the post. Ensure that the check strap loops under the stud on the side of the lower stanchion/post. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Arm Rest: > 23-31-97 > May > 97 > Center Armrest/Console - Upper Latch Cover Broken > Page 7133 6. Inspect the lower inertia latch cover for damage. If the cover is damaged, replace the cover with p/n 04883531AA. 7. Open the lower latch cover and install the cover onto the inertia latch upper arm working it around the latch bracket. 8. Align the lower latch cover, upper latch cover and latch bracket to the screw hole on the arm. 9. Secure the cover with the screw and torque the screw to 4.15 Nm (37 in. lbs.). 10. Inspect the inertia latch, covers, and screw for proper alignment. Perform a function check by moving the center armrest/console through its full range of travel checking for freedom of movement. Adjust the center armrest/console inertia latch covers as necessary. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-10-00-90 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Arm Rest: > 23-06-97 > Feb > 97 > Console Armrest - Hinge Bezel Cracked Arm Rest: All Technical Service Bulletins Console Armrest - Hinge Bezel Cracked NO: 23-06-97 GROUP: Body DATE: Feb. 28, 1997 SUBJECT: Hinge Bezel On Front Seat Center Console/Armrest Broken MODELS: 1997 (AN) Dakota SYMPTOM/CONDITION: The front 40/20/40 seat center console/armrest hinge bezel is cracked or broken at the rear hinge. DIAGNOSIS: If the front seat center console/armrest cover is over extended upon opening, the hinge bezel may crack or break. The cracking occurs around the flexible fingers of the hinge bezel. The hinge bezel is now available as a separate part for service. Previously, the only way to obtain the hinge bezel was to purchase the front seat center console/armrest as an assembly. Inspect the area of the front seat center console/armrest near the hinge bezel. If cracking is noticed, replace the hinge bezel using the following Repair Procedure. PARTS REQUIRED: AR(1) 0RE841AZAA Front Seat Center Console/Armrest Hinge Bezel, Agate AR(1) 0RE841C3AA Front Seat Center Console/Armrest Hinge Bezel, Medium Mist Gray AR(1) 0RE841K5AA Front Seat Center Console/Armrest Hinge Bezel, Camel REPAIR PROCEDURE: This bulletin involves replacing the front seat center console/armrest hinge bezel. 1. Place the front seat center console/armrest in the down position. 2. Remove the two screws from the hinge bezel. 3. Remove plastic hinge bezel by sliding it towards the rear of the truck. 4. Slide new hinge bezel (refer to Parts Required section for proper color) onto the armrest by pushing it forward and over the vinyl ledge that is molded into the armrest. 5. Align the holes in the hinge bezel with the holes in the metal substrate of the center console/armrest. 6. Attach the hinge bezel with the two screws removed in step 2. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-14-21-90 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Ash Tray > Component Information > Service and Repair Ash Tray: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Open the ash receiver. Depress the spring retainer in the center of the ash receiver to release it, then pull the ash receiver away from the pivot pins in the instrument panel lower bezel. Ash Receiver Removal/Install 3. Remove the two screws that secure the flame shield to the lower instrument panel bezel. 4. Pull the flame shield out from the instrument panel lower bezel far enough to disengage the two retaining tabs on the top, then lower the shield far enough to access the ash receiver lamp and hood. 5. Squeeze the ash receiver lamp and hood bracket to remove the unit from the mounting hole in the flame shield. 6. Remove the flame shield from the instrument panel. 7. Reverse the removal procedures to install. Tighten the flame shield mounting screws to 2.2 N.m (20 in. lbs.). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Customer Interest for Console: > 23-006-01 > Apr > 01 > Center Armrest/Console - Binds/Sticks Console: Customer Interest Center Armrest/Console - Binds/Sticks NUMBER: 23-006-01 GROUP: Body DATE: April 13, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-24-98, DATED JUNE 19, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-99003. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODEL YEARS AND CHANGES TO THE PROCEDURE. SUBJECT: Center Armrest/Console Upper Inertia Latch Cover Broken OVERVIEW: This bulletin involves replacing the center armrest/console upper **and lower** inertia latch cover. MODELS: 1997 - **2001** (AN) Dakota 1998 - **2001** (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLE EQUIPPED WITH THE 40-20-40 SPLIT BENCH SEAT (SALES CODE CBE). SYMPTOM/CONDITION: The center armrest/console upper inertia latch cover (driver side hinge cover) is broken. DIAGNOSIS: Inspect the center armrest/console upper inertia latch/hinge cover on the driver side of the armrest (Fig. 1) at the rear flange and internal check strap for a cracked or broken condition. If the cover is cracked or broken, the arm rest may bind or stick when raising or lowering the armrest. Additionally, it the cover is broken, the leg of the cover may extend out from the rear of the armrest when the armrest is folded down. If the cover is cracked or broken, perform the Repair Procedure. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Customer Interest for Console: > 23-006-01 > Apr > 01 > Center Armrest/Console - Binds/Sticks > Page 7149 PARTS REQUIRED: REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Move the driver seat to the full forward position with the seat back full forward. 2. Place the center armrest/console in the down position. 3. Remove the screw securing the cover to the inertia latch. 4. Remove the upper and lower inertia latch covers. 5. Place the new upper latch cover **p/n 05017734AA**, onto the inertia latch upper arm with the rear strap around the post. Ensure that the check strap loops under the stud on the side of the lower stanchion/post and that the white slip cover is over the stud and under the check strap. 6. Open the lower inertia latch cover **p/n 05016165AB**, and install the cover onto the inertia latch upper arm working it around the latch bracket. 7. Align the lower inertia latch cover, upper inertia latch cover, and latch bracket to the screw hole on the arm. 8. Secure the cover with the screw and tighten the screw to 4.15 Nm (37 in. lbs.). 9. Inspect the inertia latch, covers, and screw for proper alignment. Perform a function check by moving the center armrest/console through its full range of travel checking for freedom of movement. Adjust the center armrest/console inertia latch covers as necessary. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Customer Interest for Console: > 23-31-97 > May > 97 > Center Armrest/Console - Upper Latch Cover Broken Console: Customer Interest Center Armrest/Console - Upper Latch Cover Broken NO: 23-31-97 GROUP: Body DATE: May 16, 1997 SUBJECT: Center Armrest/Console Upper Inertia Latch Cover Broken MODELS: 1997 (AN) Dakota SYMPTOM/CONDITION: The center armrest/console upper inertia latch cover (driver side hinge cover) is broken. DIAGNOSIS: Inspect the center armrest/console upper inertia latch/hinge cover (Figure 1) on the driver side of the armrest at the rear flange and internal check strap for a cracked or broken condition. If the cover is cracked or broken, the arm rest may bind or stick when raising or lowering the armrest. Additionally, if the cover is broken, the leg of the cover may extend out from the rear of the armrest when the armrest is folded down. If the cover is cracked or broken, perform the following Repair Procedure. PARTS REQUIRED: 1 04883530AA Cover, Center Armrest/Console Upper Inertia Latch AR (1) 04883531AA Cover, Center Armrest/Console Lower Inertia Latch REPAIR PROCEDURE: This bulletin involves replacing the center armrest/console upper inertia latch cover. Some vehicle may also have the lower cover broken which will require replacement. 1. Move the driver seat to a full forward position with the seat back full forward. 2. Place the center armrest/console in the down position. 3. Remove the screw securing the cover to the inertia latch. 4. Remove the upper and lower inertia latch covers. 5. Place the new upper latch cover, p/n 04883530AA, onto the inertia latch upper arm with the rear strap around the post. Ensure that the check strap loops under the stud on the side of the lower stanchion/post. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Customer Interest for Console: > 23-31-97 > May > 97 > Center Armrest/Console - Upper Latch Cover Broken > Page 7154 6. Inspect the lower inertia latch cover for damage. If the cover is damaged, replace the cover with p/n 04883531AA. 7. Open the lower latch cover and install the cover onto the inertia latch upper arm working it around the latch bracket. 8. Align the lower latch cover, upper latch cover and latch bracket to the screw hole on the arm. 9. Secure the cover with the screw and torque the screw to 4.15 Nm (37 in. lbs.). 10. Inspect the inertia latch, covers, and screw for proper alignment. Perform a function check by moving the center armrest/console through its full range of travel checking for freedom of movement. Adjust the center armrest/console inertia latch covers as necessary. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-10-00-90 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Customer Interest for Console: > 23-06-97 > Feb > 97 > Console Armrest - Hinge Bezel Cracked Console: Customer Interest Console Armrest - Hinge Bezel Cracked NO: 23-06-97 GROUP: Body DATE: Feb. 28, 1997 SUBJECT: Hinge Bezel On Front Seat Center Console/Armrest Broken MODELS: 1997 (AN) Dakota SYMPTOM/CONDITION: The front 40/20/40 seat center console/armrest hinge bezel is cracked or broken at the rear hinge. DIAGNOSIS: If the front seat center console/armrest cover is over extended upon opening, the hinge bezel may crack or break. The cracking occurs around the flexible fingers of the hinge bezel. The hinge bezel is now available as a separate part for service. Previously, the only way to obtain the hinge bezel was to purchase the front seat center console/armrest as an assembly. Inspect the area of the front seat center console/armrest near the hinge bezel. If cracking is noticed, replace the hinge bezel using the following Repair Procedure. PARTS REQUIRED: AR(1) 0RE841AZAA Front Seat Center Console/Armrest Hinge Bezel, Agate AR(1) 0RE841C3AA Front Seat Center Console/Armrest Hinge Bezel, Medium Mist Gray AR(1) 0RE841K5AA Front Seat Center Console/Armrest Hinge Bezel, Camel REPAIR PROCEDURE: This bulletin involves replacing the front seat center console/armrest hinge bezel. 1. Place the front seat center console/armrest in the down position. 2. Remove the two screws from the hinge bezel. 3. Remove plastic hinge bezel by sliding it towards the rear of the truck. 4. Slide new hinge bezel (refer to Parts Required section for proper color) onto the armrest by pushing it forward and over the vinyl ledge that is molded into the armrest. 5. Align the holes in the hinge bezel with the holes in the metal substrate of the center console/armrest. 6. Attach the hinge bezel with the two screws removed in step 2. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-14-21-90 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Console: > 23-006-01 > Apr > 01 > Center Armrest/Console Binds/Sticks Console: All Technical Service Bulletins Center Armrest/Console - Binds/Sticks NUMBER: 23-006-01 GROUP: Body DATE: April 13, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-24-98, DATED JUNE 19, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-99003. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODEL YEARS AND CHANGES TO THE PROCEDURE. SUBJECT: Center Armrest/Console Upper Inertia Latch Cover Broken OVERVIEW: This bulletin involves replacing the center armrest/console upper **and lower** inertia latch cover. MODELS: 1997 - **2001** (AN) Dakota 1998 - **2001** (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLE EQUIPPED WITH THE 40-20-40 SPLIT BENCH SEAT (SALES CODE CBE). SYMPTOM/CONDITION: The center armrest/console upper inertia latch cover (driver side hinge cover) is broken. DIAGNOSIS: Inspect the center armrest/console upper inertia latch/hinge cover on the driver side of the armrest (Fig. 1) at the rear flange and internal check strap for a cracked or broken condition. If the cover is cracked or broken, the arm rest may bind or stick when raising or lowering the armrest. Additionally, it the cover is broken, the leg of the cover may extend out from the rear of the armrest when the armrest is folded down. If the cover is cracked or broken, perform the Repair Procedure. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Console: > 23-006-01 > Apr > 01 > Center Armrest/Console Binds/Sticks > Page 7164 PARTS REQUIRED: REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Move the driver seat to the full forward position with the seat back full forward. 2. Place the center armrest/console in the down position. 3. Remove the screw securing the cover to the inertia latch. 4. Remove the upper and lower inertia latch covers. 5. Place the new upper latch cover **p/n 05017734AA**, onto the inertia latch upper arm with the rear strap around the post. Ensure that the check strap loops under the stud on the side of the lower stanchion/post and that the white slip cover is over the stud and under the check strap. 6. Open the lower inertia latch cover **p/n 05016165AB**, and install the cover onto the inertia latch upper arm working it around the latch bracket. 7. Align the lower inertia latch cover, upper inertia latch cover, and latch bracket to the screw hole on the arm. 8. Secure the cover with the screw and tighten the screw to 4.15 Nm (37 in. lbs.). 9. Inspect the inertia latch, covers, and screw for proper alignment. Perform a function check by moving the center armrest/console through its full range of travel checking for freedom of movement. Adjust the center armrest/console inertia latch covers as necessary. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Console: > 23-31-97 > May > 97 > Center Armrest/Console - Upper Latch Cover Broken Console: All Technical Service Bulletins Center Armrest/Console - Upper Latch Cover Broken NO: 23-31-97 GROUP: Body DATE: May 16, 1997 SUBJECT: Center Armrest/Console Upper Inertia Latch Cover Broken MODELS: 1997 (AN) Dakota SYMPTOM/CONDITION: The center armrest/console upper inertia latch cover (driver side hinge cover) is broken. DIAGNOSIS: Inspect the center armrest/console upper inertia latch/hinge cover (Figure 1) on the driver side of the armrest at the rear flange and internal check strap for a cracked or broken condition. If the cover is cracked or broken, the arm rest may bind or stick when raising or lowering the armrest. Additionally, if the cover is broken, the leg of the cover may extend out from the rear of the armrest when the armrest is folded down. If the cover is cracked or broken, perform the following Repair Procedure. PARTS REQUIRED: 1 04883530AA Cover, Center Armrest/Console Upper Inertia Latch AR (1) 04883531AA Cover, Center Armrest/Console Lower Inertia Latch REPAIR PROCEDURE: This bulletin involves replacing the center armrest/console upper inertia latch cover. Some vehicle may also have the lower cover broken which will require replacement. 1. Move the driver seat to a full forward position with the seat back full forward. 2. Place the center armrest/console in the down position. 3. Remove the screw securing the cover to the inertia latch. 4. Remove the upper and lower inertia latch covers. 5. Place the new upper latch cover, p/n 04883530AA, onto the inertia latch upper arm with the rear strap around the post. Ensure that the check strap loops under the stud on the side of the lower stanchion/post. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Console: > 23-31-97 > May > 97 > Center Armrest/Console - Upper Latch Cover Broken > Page 7169 6. Inspect the lower inertia latch cover for damage. If the cover is damaged, replace the cover with p/n 04883531AA. 7. Open the lower latch cover and install the cover onto the inertia latch upper arm working it around the latch bracket. 8. Align the lower latch cover, upper latch cover and latch bracket to the screw hole on the arm. 9. Secure the cover with the screw and torque the screw to 4.15 Nm (37 in. lbs.). 10. Inspect the inertia latch, covers, and screw for proper alignment. Perform a function check by moving the center armrest/console through its full range of travel checking for freedom of movement. Adjust the center armrest/console inertia latch covers as necessary. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-10-00-90 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Console: > 23-06-97 > Feb > 97 > Console Armrest - Hinge Bezel Cracked Console: All Technical Service Bulletins Console Armrest - Hinge Bezel Cracked NO: 23-06-97 GROUP: Body DATE: Feb. 28, 1997 SUBJECT: Hinge Bezel On Front Seat Center Console/Armrest Broken MODELS: 1997 (AN) Dakota SYMPTOM/CONDITION: The front 40/20/40 seat center console/armrest hinge bezel is cracked or broken at the rear hinge. DIAGNOSIS: If the front seat center console/armrest cover is over extended upon opening, the hinge bezel may crack or break. The cracking occurs around the flexible fingers of the hinge bezel. The hinge bezel is now available as a separate part for service. Previously, the only way to obtain the hinge bezel was to purchase the front seat center console/armrest as an assembly. Inspect the area of the front seat center console/armrest near the hinge bezel. If cracking is noticed, replace the hinge bezel using the following Repair Procedure. PARTS REQUIRED: AR(1) 0RE841AZAA Front Seat Center Console/Armrest Hinge Bezel, Agate AR(1) 0RE841C3AA Front Seat Center Console/Armrest Hinge Bezel, Medium Mist Gray AR(1) 0RE841K5AA Front Seat Center Console/Armrest Hinge Bezel, Camel REPAIR PROCEDURE: This bulletin involves replacing the front seat center console/armrest hinge bezel. 1. Place the front seat center console/armrest in the down position. 2. Remove the two screws from the hinge bezel. 3. Remove plastic hinge bezel by sliding it towards the rear of the truck. 4. Slide new hinge bezel (refer to Parts Required section for proper color) onto the armrest by pushing it forward and over the vinyl ledge that is molded into the armrest. 5. Align the holes in the hinge bezel with the holes in the metal substrate of the center console/armrest. 6. Attach the hinge bezel with the two screws removed in step 2. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-14-21-90 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions Console: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7176 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 Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7177 Electrostatic Discharge Symbol All Electrostatic Discharge (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, especially 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. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7178 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7179 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7180 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7181 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7182 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7183 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7184 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7185 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. 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. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7186 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7187 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7188 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7189 Console: Diagnostic Aids 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 in 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 and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7190 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. 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 every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. 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 fuse circuit. 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 the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7191 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools 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 - This instrument is 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 vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. 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 non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7192 Console: Electrical Diagrams Overhead Console (Part 1 Of 2) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7193 Overhead Console (Part 2 Of 2) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Page 7194 Console: Description and Operation INTRODUCTION An overhead console featuring a mini trip computer, an electronic compass, and an outside ambient temperature thermometer are available factory-installed options on this model. The overhead console also includes two front-mounted reading and courtesy lamps, a garage door opener storage bin, and a sunglasses storage bin. Following are general descriptions of the major components used in the overhead console. SYSTEM OPERATION Trip Computer A mini trip computer is available on this model to provide several electronic functions and features. The trip computer contains a central processing unit and interfaces with other modules in the vehicle on the Chrysler Collision Detection (CCD) data bus network. The CCD data bus network allows the sharing of sensor information. This helps to reduce wire harness complexity, reduce internal controller hardware, and reduce component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. Some of the functions and features that the trip computer supports and/or controls, include the following display options: Compass and temperature - Trip odometer (ODO) - Average fuel economy (AVG ECO) - Instant fuel economy (ECO) - Distance to empty (DTE) - Elapsed time (ET) - Blank display Momentarily depressing and releasing the Step button when the ignition switch is in the On position will cause the overhead console display to step sequentially through the listed display options. Momentarily depressing and releasing the U.S./Metric button toggles the display between U.S. and Metric measurements. For more information on the trip computer features and functions, refer to the owner 5 manual in the vehicle glove box. The push button (Step and U.S./Metric) switches and the compass flux-gate unit are integral to the trip computer, compass, and thermometer display module unit. The ambient temperature sensor is hard-wired to the module. Data input for all other trip computer functions is received through CCD data bus messages. The trip computer uses its internal programming and all of these inputs to calculate and display the requested data. If the data displayed is incorrect, perform the self-diagnostic tests as described. If these tests prove inconclusive, the use of a DRB scan tool and the proper Diagnostic Procedures are recommended for further testing of the trip computer and the CCD data bus. The trip computer, compass, and thermometer display module cannot be repaired, and are only available for service as a unit. If faulty or damaged, the complete module must be replaced. Compass The compass will display the direction in which the vehicle is pointed using the eight major compass headings (Examples: north is N, northeast is NE). It does not display the headings in actual degrees. The self-calibrating compass unit requires no adjusting in normal use. The only calibration that may prove necessary is to drive the vehicle in three complete circles, on level ground, in not less than 48 seconds. This will reorient the compass unit to its vehicle. The compass unit also will compensate for magnetism the body of the vehicle may acquire during normal use. However, avoid placing anything magnetic directly on the roof of the vehicle. Magnetic mounts for an antenna, a repair order hat, or a funeral procession flag can exceed the compensating ability of the compass unit if placed on the roof panel. Magnetic bit drivers used on the fasteners that hold the assembly to the roof header can also affect compass operation. if the vehicle roof should become magnetized, the demagnetizing and calibration procedures found may be required to restore proper compass operation. The compass, trip computer, and thermometer display module cannot be repaired, and are only available for service as a unit. If faulty or damaged, the complete module must be replaced. Thermometer The thermometer displays the outside ambient temperature. The temperature display can be changed from Fahrenheit to Celsius using the U.S./ Metric button, located just rearward of the display module. The displayed temperature is not an instant reading of conditions, but an average temperature. It may take the thermometer display several minutes to respond to a major temperature change, such as driving out of a heated garage into winter temperatures. When the ignition switch is turned to the Off position, the last displayed temperature reading stays in the thermometer unit memory. When the ignition switch is turned to the On position again, the thermometer will display the memory temperature if the engine coolant temperature is above about 52 °C (125 °F). If the engine coolant temperature is below about 52 °C (125 °F), the thermometer will display the actual temperature sensed by the ambient temperature sensor. The thermometer temperature display update interval varies with the vehicle speed. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Page 7195 The thermometer function is supported by an ambient temperature sensor. The sensor is mounted outside the passenger compartment near the front and center of the vehicle and is hard-wired to the module. The ambient temperature sensor is available as a separate service item. The thermometer, compass, and trip computer display module cannot be repaired, and are only available for service as a unit. If faulty or damaged, the complete module must be replaced. Reading And Courtesy Lamp All reading and courtesy lamps located in the overhead console are activated by the door jamb switches. When the doors are closed, the lamps can be individually activated by depressing the corresponding lens. When a door is open, depressing the lamp lens switches will not turn the lamps off. The reading and courtesy lamp housing, lamp lens, bulb holders, and bulbs are available for service replacement. The reading and courtesy lamp switches are only available as part of the overhead console wire harness. If either switch is faulty or damaged, the wire harness and both switches must be replaced. Garage Door Opener Storage Bin A compartment in the overhead console is designed to hold most garage door opener remote control transmitters. The transmitter is mounted within the compartment with an adhesive-backed hook and loop fastener patch. With the transmitter mounted in the storage bin, adapter pegs located on the front of the storage bin door are selected and mounted on of several posts near the center of the storage bin door. The peg(s) selected and/or the post must be long enough to depress the button of the transmitter, when the garage door opener storage bin door is depressed. The pegs may be stacked, if necessary. Refer to the owner's manual in the vehicle glove box for more information. A transmitter mounting kit including the adhesive-backed hook and loop fastener material and a selection of pegs is available for service. The garage door opener storage bin door assembly is also available for service replacement. Sunglasses Storage Bin A sunglasses storage bin is included in the overhead console. The interior of the bin is lined with a foam padding material to protect the sunglasses from being scratched. This bin features dampening springs on the hinges for a smooth opening action. The sunglasses storage bin door assembly is available for service replacement. CIRCUIT OPERATION When the ignition switch is in the RUN or START position, circuit F12 from fuse 11, a 10 amp, in the junction block supplies power to the overhead console. When the headlamps or parking lamps are ON, circuits L7 and E2 provide voltage to the overhead console. Circuit E2 from fuse 5 in the junction block powers the illumination lamps in the overhead console. Circuit E1 from the headlamp switch feeds fuse 5 and circuit E2. Circuit Z2 provides ground for the compass. To allow the overhead console to communicate with other modules and controllers the CCD Bus is used. The circuits involved are D1 for CCD (+), and D2 for CCD (-). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Page 7196 Console: Testing and Inspection If the problem with the trip computer, compass, and thermometer display module is an inaccurate or scrambled display, use the Self-Diagnostic Test procedures. If the problem is incorrect display lighting levels, use a DRB scan tool and the proper Diagnostic Procedures to test for the correct dimming message inputs being received from the instrument cluster over the Chrysler Collision Detection (CCD) data bus. If the problem is a no-display condition, use the following procedures. 1. Check the fuses in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse(s). 2. Check for battery voltage at the fused B(+) fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the Power Distribution Center (PDC) as required. 3. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output fuse in the junction block. If OK, go to Step 4. If not OK, repair the open circuit to the ignition switch as required. 4. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Remove the overhead console as described. Check for continuity between the ground circuit cavities of the overhead console wire harness connector and a good ground. There should be continuity. If OK, go to Step 5. If not OK, repair the open circuit to ground as required. 5. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the overhead console wire harness connector. If OK, go to Step 6. If not OK, repair the open circuit to the junction block as required. 6. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output circuit cavity of the overhead console wire harness connector. If OK, proceed to the Self-Diagnostic Test for further diagnosis of the module and the CCD data bus. If not OK, repair the open circuit to the junction block as required. Self-Diagnostic Test A self-diagnostic test is used to determine that the trip computer, compass, thermometer, and all of the display module segments are operating properly electrically. Initiate the self-diagnostic test as follows: 1. With the ignition switch in the Off position, simultaneously press and hold the Step button and the U.S./Metric button. 2. Turn the ignition switch to the On position. 3. Continue to hold both buttons until the display module performs a display segment test. In this test, all of the vacuum fluorescent display segments are lighted. This test will: a. Verify that all display segments are functional b. Check the internal circuitry of the module c. Check that all of the CCD data bus messages needed are being received. 4. Respond to the respective test results as follows. If all tests are passed, the module will automatically return to normal operation. d. In the display segment test, if any segment should fail to light the unit is faulty and must be replaced. e. If the internal circuitry test is failed, the module will display "FAIL". If "FAIL" is displayed, the unit is faulty and must be replaced. f. If the CCD data bus message test is failed, the module will display "CCD". If "CCD" is displayed, the use of a DRB scan tool and the proper Diagnostic Procedures are required for further diagnosis. 5. Momentarily depress and release either button one time to exit the self-diagnostic test mode and return the trip computer, compass, and thermometer display module to normal operation. NOTE: If the compass functions, but accuracy Is suspect, it may be necessary to perform a variation adjustment. This procedure allows the compass unit to accommodate variations in the earth's magnetic field strength, based on geographic location. See the Instrument Panel, Gauges and Warning Indicators/Compass/Testing and Inspection/ProceduresCompass Variation Adjustment procedures. - If the compass reading has blanked out, and only "CAL" appears in the display module, demagnetizing may be necessary to remove excessive residual magnetic fields from the vehicle. See the Instrument Panel, Gauges and Warning Indicators/Compass/Testing and Inspection/Procedures/Compass Demagnetizing procedure. Thermometer The thermometer function is supported by a ambient temperature sensor, a wiring circuit, and a portion of the overhead console trip computer, compass, and thermometer display module display The sensor is mounted outside the passenger compartment near the front and center of the vehicle. If any portion of the ambient temperature sensor circuit fails, the thermometer display will self-diagnose the circuit. An "SC" (short circuit) will appear in the display in place of the temperature, when the sensor is exposed to temperatures above 110 °C (230 °F), or if the sensor circuit is shorted. An "OC" (open circuit) will appear in the display in place of the temperature, when the sensor is exposed to temperatures below -50 °C (-58 °F), or if the sensor circuit is open. The ambient temperature sensor circuit can also be diagnosed using the following Sensor Test, and Sensor Circuit Test. If the temperature sensor and circuit are confirmed to be OK, but the temperature display is inoperative or incorrect, see the Trip Computer, Compass, and Thermometer Display Module diagnosis in Instrument Panel, Gauges and Warning Indicators. Sensor Test 1. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Unplug the temperature sensor wire harness connector. 2. Measure the resistance of the 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, go to the Sensor Circuit Test. If not OK, Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Page 7197 replace the faulty sensor. Sensor Circuit Test 1. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Unplug the ambient temperature sensor wire harness connector and the overhead console wire harness connector. 2. Connect a jumper wire between the two terminals in the body half of the sensor wire harness connector. 3. Check for continuity between the sensor return circuit and the ambient temperature sensor signal circuit cavities of the overhead console wire harness connector. There should be continuity If OK, go to Step 4. If not OK, repair the open circuit as required. 4. Remove the jumper wire from the ambient temperature sensor wire harness connector. Check for continuity between the sensor return circuit cavity of the overhead console wire harness connector and a good ground. There should be no continuity If OK, go to Step 5. If not OK, repair the short circuit as required. 5. Check for continuity between the ambient temperature sensor signal circuit cavity of the overhead console wire harness connector and a good ground. There should be no continuity If OK, see the Trip Computer, Compass, and Thermometer Display Module diagnosis in Instrument Panel, Gauges and Warning Indicators. If not OK, repair the short circuit as required. NOTE: For complete testing, refer to Powertrain Management/Computers and Control Systems/Body Control Module/Testing and Inspection. See: Body Control Systems/Central Timer Module ( CTM ) High Option/Testing and Inspection Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Overhead Console Replacement Console: Service and Repair Overhead Console Replacement REMOVAL 1. Disconnect and isolate the battery negative cable. Overhead Console Remove/Install 2. Remove the forward mounting screw, located ahead of the display module. 3. Using a trim stick or another suitable widebladed flat tool, gently pry between the rear sides of the console housing and the headliner to release the two snap-clip retainers that secure the console to the rear of the mounting bracket. 4. Lower the overhead console far enough to access the wire harness connector, which is secured to the top of the trip computer, compass, and thermometer display module. 5. Unplug the overhead console wire harness connector. 6. Remove the overhead console from the vehicle. 7. Reverse the removal procedures to install. Tighten the overhead console mounting screw to 2 N.m (17 in. lbs.). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Overhead Console Replacement > Page 7200 Console: Service and Repair Sunglasses Storage Bin Door REMOVAL and INSTALLATION 1. Open the sunglasses storage bin door. 2. Using a trim stick or another suitable widebladed flat tool, gently pry the door hinge pins from the retainers in the overhead console housing. 3. To install, hold the door in position in the overhead console opening and press the door hinge pins gently until they snap into place. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Arming and Disarming The airbag system is a sensitive, complex electromechanical unit. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components you must first disconnect and isolate the battery negative (ground) cable. Then wait two minutes for the system capacitor to discharge before further system service. This is the only sure way to disable the airbag system. Failure to do this could result in accidental air-bag deployment and possible personal injury. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Glove Compartment Lock > Component Information > Service and Repair Glove Compartment Lock: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Open the glove box. Glove Box Latch Striker Remove/Install 3. Remove the two screws that secure the glove box latch striker to the instrument panel at the top of the glove box opening. 4. Remove the latch striker from the glove box opening. 5. Reverse the removal procedures to install. Tighten the glove box latch striker mounting screws to 2.2 N.m (20 in. lbs.). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Scuff Plate > Component Information > Technical Service Bulletins > Customer Interest for Scuff Plate: > 23-45-97 > Aug > 97 > Lower Sill Area - Mud/Dirt Accumulation Scuff Plate: Customer Interest Lower Sill Area - Mud/Dirt Accumulation NO: 23-45-97 GROUP: Body EFFECTIVE DATE: Aug. 29, 1997 SUBJECT: Mud And Debris Accumulates On Lower Sill Area MODELS: 1997 (AN) Dakota SYMPTOM/CONDITION: Dirt/mud, water and debris accumulates under the doors at the lower sill area. DIAGNOSIS: Inspect the lower sill area of the door opening for dirt/mud and debris. If dirt/mud and debris is present, perform the following Repair Procedure. PARTS REQUIRED: 2 55257342AA Seal, Lower Sill Secondary AR (1) 04318015 Mopar Super Kleen REPAIR PROCEDURE: This bulletin involves installing an additional lower sill secondary seal. 1. Open the door. 2. Wash the area and throughly clean the lower hem flange area of the door with Mopar Super Kleen, p/n 04318015. 3. Starting with the pull tab, remove the adhesive strip protective backing from the new secondary seal, p/n 55257342AA, and install the secondary seal along the bottom of the door hem flange as shown in Figure 1 starting at the forward edge of the door. The lip of the seal should overlap the outer edge of the hem flange (as shown) to help prevent interference with the original secondary seal. 4. To ensure a good bond to the door hem flange, apply pressure with a trim stick (or suitable tool) to the secondary seal starting with the forward edge of the door working your way to the rear edge of the door. NOTE: MAKE SURE THE NEW SECONDARY SEAL DOES NOT INTERFERE WITH THE ORIGINAL SECONDARY SEAL. 5. Repeat steps one through four for the other door. NOTE: THE ADHESIVE ON THE SECONDARY SEAL SHOULD BE ALLOWED TO FULLY CURE PRIOR TO EXPOSING THE SEAL TO A LOT Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Scuff Plate > Component Information > Technical Service Bulletins > Customer Interest for Scuff Plate: > 23-45-97 > Aug > 97 > Lower Sill Area - Mud/Dirt Accumulation > Page 7217 OF DIRT/MUD AND DEBRIS. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-51-08-92 0.4 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Scuff Plate > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Scuff Plate: > 23-45-97 > Aug > 97 > Lower Sill Area - Mud/Dirt Accumulation Scuff Plate: All Technical Service Bulletins Lower Sill Area - Mud/Dirt Accumulation NO: 23-45-97 GROUP: Body EFFECTIVE DATE: Aug. 29, 1997 SUBJECT: Mud And Debris Accumulates On Lower Sill Area MODELS: 1997 (AN) Dakota SYMPTOM/CONDITION: Dirt/mud, water and debris accumulates under the doors at the lower sill area. DIAGNOSIS: Inspect the lower sill area of the door opening for dirt/mud and debris. If dirt/mud and debris is present, perform the following Repair Procedure. PARTS REQUIRED: 2 55257342AA Seal, Lower Sill Secondary AR (1) 04318015 Mopar Super Kleen REPAIR PROCEDURE: This bulletin involves installing an additional lower sill secondary seal. 1. Open the door. 2. Wash the area and throughly clean the lower hem flange area of the door with Mopar Super Kleen, p/n 04318015. 3. Starting with the pull tab, remove the adhesive strip protective backing from the new secondary seal, p/n 55257342AA, and install the secondary seal along the bottom of the door hem flange as shown in Figure 1 starting at the forward edge of the door. The lip of the seal should overlap the outer edge of the hem flange (as shown) to help prevent interference with the original secondary seal. 4. To ensure a good bond to the door hem flange, apply pressure with a trim stick (or suitable tool) to the secondary seal starting with the forward edge of the door working your way to the rear edge of the door. NOTE: MAKE SURE THE NEW SECONDARY SEAL DOES NOT INTERFERE WITH THE ORIGINAL SECONDARY SEAL. 5. Repeat steps one through four for the other door. NOTE: THE ADHESIVE ON THE SECONDARY SEAL SHOULD BE ALLOWED TO FULLY CURE PRIOR TO EXPOSING THE SEAL TO A LOT Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Scuff Plate > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Scuff Plate: > 23-45-97 > Aug > 97 > Lower Sill Area - Mud/Dirt Accumulation > Page 7223 OF DIRT/MUD AND DEBRIS. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-51-08-92 0.4 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Component Information > Diagrams Door Locks: Diagrams Door Jamb Switch Connector Pinout Door Disarm Switch Connector Pinout Power Door Lock Switch Connections Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Component Information > Diagrams > Page 7228 Door Lock Actuator Connector Pinout Key-In Ignition Connector Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Receiver > Component Information > Description and Operation Keyless Entry Receiver: Description and Operation SYSTEM OPERATION The Remote Keyless Entry (RKE) receiver is a radio frequency unit contained in the high-line version of the Central Timer Module (CTM). The CTM also contains the program circuitry for the RKE system. The CTM is located under the passenger side end of the instrument panel, outboard of the glove box. The RKE receiver is energized by one of two messages from the RKE transmitter; Unlock, or Lock. The CTM circuitry responds to these messages to lock or unlock the doors by energizing the power lock motors. For diagnosis of the RKE receiver, the high-line CTM, or the CCD data bus, a DRE scan tool and the proper Diagnostic Procedures are recommended. The RKE receiver is only serviced as a unit with the high-line CTM and, if faulty or damaged, the CTM unit must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Transmitter Battery: > 08-39-97 > Nov > 97 > RKE Transmitter - Premature Battery Failure Keyless Entry Transmitter Battery: Customer Interest RKE Transmitter - Premature Battery Failure NO: 08-39-97 GROUP: Electrical DATE: Nov. 28, 1997 SUBJECT: Remote Keyless Entry Transmitter Batteries Discharge Prematurely MODELS: 1997 - 1998 (AB) Ram Van/Wagon 1997 - 1998 (AN) Dakota/Dakota Cab & Chassis 1998 (BRIBE)Ram Truck 1998 (DN) Durango 1997 (LH) Concorde/Intrepid/LHS/Vision 1997 - 1998 (NS) Town & Country/Caravan/Voyager 1997 - 1998 (PL) Neon 1997 (PR) Prowler 1997 - 1998 (ZJ) Grand Cherokee NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO AUGUST 15, 1997 (MDH 0815XX). SYMPTOM/CONDITION: Remote Keyless Entry (RKE) transmitter batteries discharge in approximately 6 weeks. DIAGNOSIS: If the vehicle operator describes the Symptom/Condition and the vehicle was built prior to MDH 0815XX, perform the Repair Procedure. PARTS REQUIRED: AR 04686366 Transmitter, RKE- NS, PL & PR AR 04759136AB Transmitter, RKE- LH AR 56007049 Transmitter, RKE- AB & 1997 AN AR 56008761 Transmitter 1, RKE- ZJ & DN AR 56008762 Transmitter 2, RKE- ZJ AR 56021903AA Transmitter, RKE- BR/BE & 1998 AN REPAIR PROCEDURE: This bulletin involves replacing the RKE transmitter(s). 1. Replace RKE transmitter(s) that have discharged batteries. 2. Program the RKE transmitter(s) to the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-28-93 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter Battery: > 08-39-97 > Nov > 97 > RKE Transmitter - Premature Battery Failure Keyless Entry Transmitter Battery: All Technical Service Bulletins RKE Transmitter - Premature Battery Failure NO: 08-39-97 GROUP: Electrical DATE: Nov. 28, 1997 SUBJECT: Remote Keyless Entry Transmitter Batteries Discharge Prematurely MODELS: 1997 - 1998 (AB) Ram Van/Wagon 1997 - 1998 (AN) Dakota/Dakota Cab & Chassis 1998 (BRIBE)Ram Truck 1998 (DN) Durango 1997 (LH) Concorde/Intrepid/LHS/Vision 1997 - 1998 (NS) Town & Country/Caravan/Voyager 1997 - 1998 (PL) Neon 1997 (PR) Prowler 1997 - 1998 (ZJ) Grand Cherokee NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO AUGUST 15, 1997 (MDH 0815XX). SYMPTOM/CONDITION: Remote Keyless Entry (RKE) transmitter batteries discharge in approximately 6 weeks. DIAGNOSIS: If the vehicle operator describes the Symptom/Condition and the vehicle was built prior to MDH 0815XX, perform the Repair Procedure. PARTS REQUIRED: AR 04686366 Transmitter, RKE- NS, PL & PR AR 04759136AB Transmitter, RKE- LH AR 56007049 Transmitter, RKE- AB & 1997 AN AR 56008761 Transmitter 1, RKE- ZJ & DN AR 56008762 Transmitter 2, RKE- ZJ AR 56021903AA Transmitter, RKE- BR/BE & 1998 AN REPAIR PROCEDURE: This bulletin involves replacing the RKE transmitter(s). 1. Replace RKE transmitter(s) that have discharged batteries. 2. Program the RKE transmitter(s) to the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-28-93 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Description and Operation Power Door Lock Actuator: Description and Operation SYSTEM OPERATION In the power lock and Remote Keyless Entry (RKE) systems, the locks are actuated by a reversible motor mounted within each door. The power lock motor direction is controlled by the battery and ground feeds from the high-line Central Timer Module (CTM). The power lock motor cannot be repaired and, if faulty or damaged, the entire motor must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Description and Operation > Page 7251 Power Door Lock Actuator: Testing and Inspection Before you proceed with this diagnosis, confirm proper power lock switch and switch circuit operation. See Power Lock Switch for the diagnostic procedures in Body and Frame/Locks/Power Locks. 1. Check each power lock motor for correct operation while moving the power lock switch to both the Lock and Unlock positions. If both of the power lock motors are inoperative, go to Step 2. If one power lock motor is inoperative, go to Step 3. 2. If both of the power lock motors are inoperative, the problem may be caused by one shorted motor. Unplugging a shorted power lock motor from the power lock circuit will allow the good power lock motor to operate. Unplug each power lock motor wire harness connector, one at a time, and recheck both the lock and unlock functions by operating the power lock switch. If both of the power lock motors are still inoperative after the above test, confirm proper Central Timer Module (CTM) operation. See Instrument Panel, Gauges and Warning Indicators/Audible Warning Device Module/Central Timer Module for the diagnostic procedures. If unplugging one power lock motor causes the other motor to become functional, go to Step 3 to test the unplugged motor. 3. Once it is determined which power lock motor is inoperative, that motor can be tested as follows. Unplug the wire harness connector at the inoperative power lock motor. Apply 12 Volts to the motor terminals to check its operation in one direction. Reverse the polarity to check the operation in the other direction. If OK, repair the short or open circuits between the power lock motor and the CTM as required. If not OK, replace the faulty power lock motor. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Description and Operation > Page 7252 Power Door Lock Actuator: Service and Repair REMOVAL 1. Raise the door window to its full up position. 2. Disconnect and isolate the battery negative cable. 3. Remove the power lock switch as described. Inside Door Latch Release Handle Pocket Screw Remove/Install 4. Pull the inside door latch release handle to the open position and remove the screw in the release handle pocket that secures the door trim panel to the inside door handle bracket. Door Trim Panel Remove/Install 5. Remove the four screws that secure the door trim panel to the inner door. 6. To disengage the stepped retainers that secure the door trim panel to the inner door, gently pull the lower edge of the trim panel away from the door while lifting the panel upwards. 7. Pull the door trim panel away from the inner door far enough to access the inside door latch release linkage rod at the back of the inside door handle. 8. Unsnap the plastic retainer clip from the inside door handle end of the latch release linkage rod, and remove the rod end from the inside door handle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Description and Operation > Page 7253 Door Trim Panel Wire Harness Connectors 9. On the driver side only, if the vehicle is so equipped, unplug the power mirror switch wire harness connector. 10. If the vehicle is so equipped, unplug the Infinity upper door speaker wire harness connector. 11. Remove the door trim panel and set it aside. Power Lock Motor And Latch Remove/Install 12. Roll the door watershield away from the bottom of the inner door panel far enough to access the power lock motor. 13. Remove the two screws that secure the lower rear door glass channel to the door. Move the channel and secure it out of the way far enough to access the power lock motor and latch. 14. Remove the three screws that secure the power lock motor and latch assembly to the door. 15. Disconnect the latch linkage rods. 16. Pull the power lock motor and latch out from the door far enough to unplug the wire harness connector. 17. Remove the power lock motor and latch assembly from the door. 18. Reverse the removal procedures to install. Tighten the mounting hardware as follows: - Power lock motor and latch screws - 11 N.m (100 in. lbs.) - Rear glass channel door latch face mounting screw - 5 N.m (45 in. lbs.) - Rear glass channel inner door panel mounting screw - 9 N.m (80 in. lbs.). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Description and Operation Power Door Lock Switch: Description and Operation SYSTEM OPERATION The power locks are controlled by a two-way switch mounted in a bezel on the trim panel of each front door. The switch controls the battery feeds to the lock and unlock sense inputs of the high-line Central Timer Module (CTM). The power lock switches cannot be repaired and, if faulty or damaged, the entire switch must be replaced. CIRCUIT OPERATION The door lock switches have two circuits that connect from the switches to the CTM. When the operator selects UNLOCK, from either switch, circuit F35 is connected to circuit P36. When the operator selects the LOCK, from either switch, voltage is passed through the CLOSED contacts in the switch to circuit P35. The CTM then process this request and supplies power and ground to the appropriate circuits. When the LOCK function is selected power is supplied on circuit P33 to all the motors. Ground is supplied on circuit P34. For the UNLOCK function the circuits are reversed. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Description and Operation > Page 7257 Power Door Lock Switch: Testing and Inspection 1. Check the fuse in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the Power Distribution Center (PDC) as required. 3. Disconnect and isolate the battery negative cable. Remove the power lock switch from the door trim panel as described. Carefully separate the wire harness connector from the switch body. 4. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the power lock switch wire harness connector. If OK, go to Step 5. If not OK, repair the open circuit to the junction block as required. Power Lock Switch Continuity 5. Test the power lock switch continuity. See the Power Lock Switch Continuity chart to determine if the continuity is correct in the Off, Lock and Unlock switch positions. If OK, repair the power lock switch sense circuit(s) from the power lock switch wire harness connector to the Central Timer Module (CTM) as required. If not OK, replace the faulty switch. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Description and Operation > Page 7258 Power Door Lock Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Power Windows And Lock Switches Remove/Install 2. Using a wide flat-bladed tool such as a trim stick, gently pry the upper edge of the power lock and power window switch bezel to release the snap-clip retainer that secures the bezel to the door trim panel. 3. Pull the switch bezel away from the door trim panel far enough to access the wire harness connectors. 4. Gently pry the locking tabs of the wire harness connectors away from the switches and carefully unplug the switches. 5. Using a wide flat-bladed tool such as a trim stick, gently pry the sides of the switch cavity on the back of the switch bezel to release the power lock switch from the bezel. 6. Reverse the removal procedures to install. When installing the switch bezel to the door trim panel, insert the rear of the bezel into the trim panel opening, then push down on the front of the bezel until the retaining tab snaps into place. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Description and Operation Power Mirror Switch: Description and Operation SYSTEM OPERATION Both the right and left power outside mirrors are controlled by a single multi-function switch unit mounted on the driver side door trim panel. The switch knob is rotated clockwise (right mirror control), or counterclockwise (left mirror control) to select the mirror to be adjusted. The switch knob is then moved in a joystick fashion to control movement of the selected mirror up, down, right, or left. The power mirror switch cannot be repaired and, if faulty or damaged, it must be replaced. The power switch knob is available for service replacement. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Description and Operation > Page 7263 Power Mirror Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Power Mirror Switch Knob Remove/Install 2. Pull the power mirror switch control knob rearward to remove it from the switch stem. Power Mirror Switch Nut 3. Remove the nut that secures the power mirror switch to the door trim panel. Inside Door Latch Release Handle Pocket Screw Remove/Install Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Description and Operation > Page 7264 4. Pull the inside door latch release handle to the open position and remove the screw in the release handle pocket that secures the door trim panel to the inside door handle bracket. Window Regulator Crank Handle Remove - Typical 5. If the vehicle is so equipped, remove the manual window regulator crank handle with a removal tool. 6. If the vehicle is so equipped, remove the power window and lock switches as follows: Power Window And Lock Switches Remove/Install a. Using a wide flat-bladed tool such as a trim stick, gently pry the upper edge of the switch bezel to release the snap-clip retainer that secures the bezel to the door trim panel. b. Pull the switch bezel away from the door trim panel far enough to access the wire harness connectors. c. Gently pry the locking tabs of the wire harness connectors away from the switches and carefully unplug the switches. Door Trim Panel Remove/Install 7. Remove the four screws that secure the door trim panel to the inner door. 8. To disengage the stepped retainers that secure the door trim panel to the inner door, gently pull the lower edge of the trim panel away from the Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Description and Operation > Page 7265 door while lifting the panel upwards. 9. Pull the door trim panel away from the inner door far enough to access the power mirror switch wire harness connector. Door Trim Panel Wire Harness Connectors 10. Unplug the power mirror switch wire harness connector. 11. Remove the power mirror switch from the back of the door trim panel. 12. When installing the power window and lock switch bezel to the door trim panel, insert the rear of the bezel into the trim panel opening, then push down on the front of the bezel until the retaining tab snaps into place. 13. Reverse the remaining removal procedures to complete the installation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Recalls: > 727 > Jun > 97 > Recall - Paint Chipping Technical Service Bulletin # 727 Date: 970601 Recall - Paint Chipping No.: 727 June, 1997 To: All Dodge Truck Dealers Subject: Customer Satisfaction Notification # 727 -- Severe Paint Chipping Models: 1997 Model Year Dodge Dakota (AN) and Ram (BR) Pickup Trucks With Radiant Red Metallic Paint (Sales Code PRF) Built Through March 23, 1997 (MDH 032300) at the Dodge City Assembly Plant ("S" in the 11th VIN position). The above vehicles may have been painted without using a full body powder anti-chip primer in the painting process. Without this anti-chip primer, severe and excessive paint chipping from normal stone contact may occur. To correct this condition, each vehicle must first be inspected. If the anti-chip primer was not applied, the vehicle must be completely stripped and repainted at a "PPG" approved repair facility. The Chrysler "Paint Resolution Group at 1-800-215-6230 will coordinate the repair. Owners of vehicles that do not meet the paint inspection criteria will be given three options: repainting, vehicle replacement, or repurchase. Details of this service action are explained in the following sections. Service Procedure Videotape No videotape of the service procedure for this notification will be provided. Dealer Notification & Vehicle List All dealers: All dealers will receive a copy of this dealer notification letter by first class mail. No VIN lists will be provided for this notification. DIAL System Functions 53, 63, 70 and VIP VIN's for all involved vehicles will be activated on DIAL System Functions 53, 63, 70 and VIP at the time of notification mailing for dealer inquiry as needed. Parts No parts are required for this service action. "Paint thickness gauges were previously distributed to certain dealers for inspecting unsold vehicles. No additional paint thickness gauges are available. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to contact the Chrysler "Paint Resolution Group at 1-800-215-6230 to locate the nearest dealer for the inspection. Owners will be instructed to make an appointment with that dealer for an inspection. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Service Procedure The paint thickness on each involved vehicle is to be measured at four locations (the roof panel, the cab outer rocker panel, the pickup bed floor, and the rocker panel of the pickup box) and each measurement recorded on DIAL function 63 per Warranty Bulletin D-97-08 (included) even if the paint thickness is acceptable. 1. Using the provided magnetic induction paint thickness gauge (Elcometer), measure the paint thickness on the roof panel and record the measurement on the ""Paint Inspection" form (included). 2. Measure the paint thickness of the cab rocker panel outer surface (outside of door opening) and record on the "Paint Inspection" form. 3. Measure the paint thickness on the floor of the pickup bed and record on the "Paint Inspection" form. This may require lifting up the bedliner to measure the paint thicknesses if equipped. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Recalls: > 727 > Jun > 97 > Recall - Paint Chipping > Page 7275 4. Measure the paint thickness on the pickup box rocker panel and record on the "Paint Inspection" form. 5. Log into DIAL, enter function 63 and follow the prompts for recording the VIN and the paint thickness measurements. 6. If the paint thickness in all four locations meets or exceeds 0.005" (5 mils), no further action is necessary. 7. If the paint thickness at any of the four locations is less than 0.005" (5 mils), inform the customer that he will be contacted by the Chrysler Paint Resolution Group regarding his three options: repainting; vehicle replacement, or vehicle repurchase. 8. Note any vehicle damage, other than normal wear and tear, and its repair cost on the paint inspection form. 9. Give a copy of the "Paint Inspection" form to the owner and telefax one to the Chrysler Paint Resolution Group at (214) 638-4054. Note: If the owner elects to have the vehicle repainted, this will be done only at a PPG approved paint facility. During the repainting period, loaner vehicles will be authorized. All repaint, replacement vehicle and repurchase vehicle elections will be handled by the Chrysler Paint Resolution Group. Completion Reporting and Reimbursement / Parts Return Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record notification service completions and provide dealer payments. Use the following labor operation number and time allowance: Labor Operation Time Number Allowance Inspect Paint Thickness 23-72-71-81 0.2 Transportation, and loaner vehicle expense should be submitted on a separate warranty claim. Note: See the Warranty Administration Manual, Recall Claim Processing Section for complete claim processing instructions. Parts Return Not applicable. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Dealer Service Instructions IMPORTANT Customer Satisfaction Notification # 727 -- Severe Paint Chipping ^ This service requirement applies only to 1997 Model Year Dodge Dakota (AN) and Ram (BR) Pickup trucks with radiant red metallic paint (Sales Code PRF) built through March 23, 1997 (MDH 032300) at the Dodge City Assembly Plant ("S" in the 11th VIN position). ^ The above vehicles may have been painted without using a full body powder anti-chip primer in the painting process. Without this anti-chip primer, severe and excessive paint chipping from normal stone contact may occur. To correct this condition, each vehicle must first be inspected. If the anti-chip primer was not applied, the vehicle must be completely stripped and repainted at a "PPG" approved repair facility. The Chrysler "Paint Resolution Group at 1-800-215-6230 will coordinate the repair. Owners of vehicles that do not meet the paint inspection criteria will be given three options: repainting, vehicle replacement, or repurchase. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Recalls: > 727 > Jun > 97 > Recall - Paint Chipping > Page 7276 ^ Dealers will inspect the paint thickness on all affected vehicles and enter their paint thickness inspection measurements of all inspected vehicles into DIAL Function 63 per Warranty Bulletin D-97-08 (even if the paint thickness is acceptable). If the paint is thicker than 5 mils at all four inspection locations, no further action is required. ^ The dealer must telefax the inspection results of vehicles not meeting the inspection criteria and any vehicle damage beyond normal wear and tear to the Chrysler Paint Resolution Group. CPRG will be responsible for notifying all owners of inspected vehicles, which do not satisfy minimum paint thickness requirements of their options. ^ During the repainting period, loaner vehicles will be authorized. Owner Letter/ Inspect the Paint on Truck Dear Dodge Dakota or Ram Truck Owner: The satisfaction of our customers is very important to Chrysler. Because of this, we are requesting owners of some radiant red metallic 1997 Dodge Dakota and Ram trucks, to return them to their dealer for inspection. The problem is... A step in the painting process on your radiant red metallic 1997 Dodge Dakota or Ram truck (identified on the enclosed form) may have been omitted and severe paint chipping may occur. What Chrysler and your dealer will do... Chrysler will inspect the paint on your truck free of charge. The inspection will take about a half hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. If the inspection determines that the paint was applied properly, no further action is necessary. If it is determined that the paint was not applied properly, the Chrysler Paint Resolution Group will contact you regarding details of repainting, replacement or repurchase of your vehicle. What you must do... ^ Simply contact the Chrysler Paint Resolution Group at 1-800-215-6230. They will inform you which dealer in your area you should contact to schedule a paint inspection appointment. Not all dealers have the necessary equipment for the inspection. ^ Chrysler's offer to repaint, replace or repurchase your vehicle is for a limited time only. Your vehicle must be inspected before November 1, 1997. Chrysler's customer satisfaction offer expires November 1, 1997 if not accepted by you by that date. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Recalls: > 727 > Jun > 97 > Recall - Paint Chipping > Page 7277 ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required inspection to your dealer. We're sorry for any inconvenience, but we believe that this special service will help to ensure your continuing satisfaction with your truck. Thanks for your attention to this important matter. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 727 > Jun > 97 > Recall - Paint Chipping Technical Service Bulletin # 727 Date: 970601 Recall - Paint Chipping No.: 727 June, 1997 To: All Dodge Truck Dealers Subject: Customer Satisfaction Notification # 727 -- Severe Paint Chipping Models: 1997 Model Year Dodge Dakota (AN) and Ram (BR) Pickup Trucks With Radiant Red Metallic Paint (Sales Code PRF) Built Through March 23, 1997 (MDH 032300) at the Dodge City Assembly Plant ("S" in the 11th VIN position). The above vehicles may have been painted without using a full body powder anti-chip primer in the painting process. Without this anti-chip primer, severe and excessive paint chipping from normal stone contact may occur. To correct this condition, each vehicle must first be inspected. If the anti-chip primer was not applied, the vehicle must be completely stripped and repainted at a "PPG" approved repair facility. The Chrysler "Paint Resolution Group at 1-800-215-6230 will coordinate the repair. Owners of vehicles that do not meet the paint inspection criteria will be given three options: repainting, vehicle replacement, or repurchase. Details of this service action are explained in the following sections. Service Procedure Videotape No videotape of the service procedure for this notification will be provided. Dealer Notification & Vehicle List All dealers: All dealers will receive a copy of this dealer notification letter by first class mail. No VIN lists will be provided for this notification. DIAL System Functions 53, 63, 70 and VIP VIN's for all involved vehicles will be activated on DIAL System Functions 53, 63, 70 and VIP at the time of notification mailing for dealer inquiry as needed. Parts No parts are required for this service action. "Paint thickness gauges were previously distributed to certain dealers for inspecting unsold vehicles. No additional paint thickness gauges are available. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to contact the Chrysler "Paint Resolution Group at 1-800-215-6230 to locate the nearest dealer for the inspection. Owners will be instructed to make an appointment with that dealer for an inspection. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Service Procedure The paint thickness on each involved vehicle is to be measured at four locations (the roof panel, the cab outer rocker panel, the pickup bed floor, and the rocker panel of the pickup box) and each measurement recorded on DIAL function 63 per Warranty Bulletin D-97-08 (included) even if the paint thickness is acceptable. 1. Using the provided magnetic induction paint thickness gauge (Elcometer), measure the paint thickness on the roof panel and record the measurement on the ""Paint Inspection" form (included). 2. Measure the paint thickness of the cab rocker panel outer surface (outside of door opening) and record on the "Paint Inspection" form. 3. Measure the paint thickness on the floor of the pickup bed and record on the "Paint Inspection" form. This may require lifting up the bedliner to measure the paint thicknesses if equipped. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 727 > Jun > 97 > Recall - Paint Chipping > Page 7283 4. Measure the paint thickness on the pickup box rocker panel and record on the "Paint Inspection" form. 5. Log into DIAL, enter function 63 and follow the prompts for recording the VIN and the paint thickness measurements. 6. If the paint thickness in all four locations meets or exceeds 0.005" (5 mils), no further action is necessary. 7. If the paint thickness at any of the four locations is less than 0.005" (5 mils), inform the customer that he will be contacted by the Chrysler Paint Resolution Group regarding his three options: repainting; vehicle replacement, or vehicle repurchase. 8. Note any vehicle damage, other than normal wear and tear, and its repair cost on the paint inspection form. 9. Give a copy of the "Paint Inspection" form to the owner and telefax one to the Chrysler Paint Resolution Group at (214) 638-4054. Note: If the owner elects to have the vehicle repainted, this will be done only at a PPG approved paint facility. During the repainting period, loaner vehicles will be authorized. All repaint, replacement vehicle and repurchase vehicle elections will be handled by the Chrysler Paint Resolution Group. Completion Reporting and Reimbursement / Parts Return Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record notification service completions and provide dealer payments. Use the following labor operation number and time allowance: Labor Operation Time Number Allowance Inspect Paint Thickness 23-72-71-81 0.2 Transportation, and loaner vehicle expense should be submitted on a separate warranty claim. Note: See the Warranty Administration Manual, Recall Claim Processing Section for complete claim processing instructions. Parts Return Not applicable. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Dealer Service Instructions IMPORTANT Customer Satisfaction Notification # 727 -- Severe Paint Chipping ^ This service requirement applies only to 1997 Model Year Dodge Dakota (AN) and Ram (BR) Pickup trucks with radiant red metallic paint (Sales Code PRF) built through March 23, 1997 (MDH 032300) at the Dodge City Assembly Plant ("S" in the 11th VIN position). ^ The above vehicles may have been painted without using a full body powder anti-chip primer in the painting process. Without this anti-chip primer, severe and excessive paint chipping from normal stone contact may occur. To correct this condition, each vehicle must first be inspected. If the anti-chip primer was not applied, the vehicle must be completely stripped and repainted at a "PPG" approved repair facility. The Chrysler "Paint Resolution Group at 1-800-215-6230 will coordinate the repair. Owners of vehicles that do not meet the paint inspection criteria will be given three options: repainting, vehicle replacement, or repurchase. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 727 > Jun > 97 > Recall - Paint Chipping > Page 7284 ^ Dealers will inspect the paint thickness on all affected vehicles and enter their paint thickness inspection measurements of all inspected vehicles into DIAL Function 63 per Warranty Bulletin D-97-08 (even if the paint thickness is acceptable). If the paint is thicker than 5 mils at all four inspection locations, no further action is required. ^ The dealer must telefax the inspection results of vehicles not meeting the inspection criteria and any vehicle damage beyond normal wear and tear to the Chrysler Paint Resolution Group. CPRG will be responsible for notifying all owners of inspected vehicles, which do not satisfy minimum paint thickness requirements of their options. ^ During the repainting period, loaner vehicles will be authorized. Owner Letter/ Inspect the Paint on Truck Dear Dodge Dakota or Ram Truck Owner: The satisfaction of our customers is very important to Chrysler. Because of this, we are requesting owners of some radiant red metallic 1997 Dodge Dakota and Ram trucks, to return them to their dealer for inspection. The problem is... A step in the painting process on your radiant red metallic 1997 Dodge Dakota or Ram truck (identified on the enclosed form) may have been omitted and severe paint chipping may occur. What Chrysler and your dealer will do... Chrysler will inspect the paint on your truck free of charge. The inspection will take about a half hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. If the inspection determines that the paint was applied properly, no further action is necessary. If it is determined that the paint was not applied properly, the Chrysler Paint Resolution Group will contact you regarding details of repainting, replacement or repurchase of your vehicle. What you must do... ^ Simply contact the Chrysler Paint Resolution Group at 1-800-215-6230. They will inform you which dealer in your area you should contact to schedule a paint inspection appointment. Not all dealers have the necessary equipment for the inspection. ^ Chrysler's offer to repaint, replace or repurchase your vehicle is for a limited time only. Your vehicle must be inspected before November 1, 1997. Chrysler's customer satisfaction offer expires November 1, 1997 if not accepted by you by that date. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 727 > Jun > 97 > Recall - Paint Chipping > Page 7285 ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required inspection to your dealer. We're sorry for any inconvenience, but we believe that this special service will help to ensure your continuing satisfaction with your truck. Thanks for your attention to this important matter. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 236996 > Nov > 96 > Paint - Fallout Damage Repair Paint: All Technical Service Bulletins Paint - Fallout Damage Repair NO: 23-69-96 GROUP: Body DATE: Nov. 22, 1996 SUBJECT: Repair Of Fallout Damaged Paint MODELS: 1997 (AB) Ram Van/Wagon 1997 (AN) Dakota 1997 (BR) Ram Pickup 1997 (FJ) Sebring/Avenger/Talon 1997 (GS) Chrysler Voyager (International Market) 1997 (JA) Cirrus/Stratus/Breeze 1997 (JX) Sebring Convertible 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1997 (NS) Town & Country/Caravan/Voyager 1997 (PL) Neon 1997 (SR) Viper/Viper GTS 1997 (TJ) Wrangler 1997 (XJ) Cherokee 1997 (ZG) Grand Cherokee (International Market) 1997 (ZJ) Grand Cherokee NOTE: THE MOPAR FALLOUT REMOVAL KIT CAN BE USED ON ANY CURRENT OR PAST MODEL YEAR CHRYSLER VEHICLE. DISCUSSION: Mopar Parts has released a new product, Mopar Fallout Removal Kit (p/n 04882417) for correcting paint damage due to industrial fallout, rail dust, over-spray and volcanic ash. The Mopar Fallout Removal Kit does not use a compounding process or acid wash and is the current Chrysler preferred method for correcting fallout damage. This product uses a clay polymer material and a liquid that are safer and better than other fallout removal methods. The Mopar Fallout Removal Kit is easier to use and less expensive than other methods. Some vehicles that would have been repainted in the past have been saved from that time consuming and expensive process with the Mopar Fallout Removal Kit. NOTE: WHEN ALL OF THE FALLOUT REPAIR LIQUID HAS BEEN USED, DISCARD THE CLAY POLYMER MATERIAL. CONTINUED USE OF THE CLAY POLYMER AFTER ALL OF THE FALLOUT REPAIR LIQUID HAS BEEN USED CAN CAUSE MINOR SCRATCHING OF THE PAINT FINISH. THE AMOUNT OF FALLOUT REPAIR LIQUID PROVIDED IN THE KIT WAS ESTABLISHED BY DETERMINING THE AMOUNT OF FALLOUT THE CLAY POLYMER COULD ABSORB BEFORE IT BECAME OVER SATURATED WITH FALLOUT AND WOULD CAUSE DAMAGE TO THE PAINT FINISH. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 236996 > Nov > 96 > Paint - Fallout Damage Repair Paint: All Technical Service Bulletins Paint - Fallout Damage Repair NO: 23-69-96 GROUP: Body DATE: Nov. 22, 1996 SUBJECT: Repair Of Fallout Damaged Paint MODELS: 1997 (AB) Ram Van/Wagon 1997 (AN) Dakota 1997 (BR) Ram Pickup 1997 (FJ) Sebring/Avenger/Talon 1997 (GS) Chrysler Voyager (International Market) 1997 (JA) Cirrus/Stratus/Breeze 1997 (JX) Sebring Convertible 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1997 (NS) Town & Country/Caravan/Voyager 1997 (PL) Neon 1997 (SR) Viper/Viper GTS 1997 (TJ) Wrangler 1997 (XJ) Cherokee 1997 (ZG) Grand Cherokee (International Market) 1997 (ZJ) Grand Cherokee NOTE: THE MOPAR FALLOUT REMOVAL KIT CAN BE USED ON ANY CURRENT OR PAST MODEL YEAR CHRYSLER VEHICLE. DISCUSSION: Mopar Parts has released a new product, Mopar Fallout Removal Kit (p/n 04882417) for correcting paint damage due to industrial fallout, rail dust, over-spray and volcanic ash. The Mopar Fallout Removal Kit does not use a compounding process or acid wash and is the current Chrysler preferred method for correcting fallout damage. This product uses a clay polymer material and a liquid that are safer and better than other fallout removal methods. The Mopar Fallout Removal Kit is easier to use and less expensive than other methods. Some vehicles that would have been repainted in the past have been saved from that time consuming and expensive process with the Mopar Fallout Removal Kit. NOTE: WHEN ALL OF THE FALLOUT REPAIR LIQUID HAS BEEN USED, DISCARD THE CLAY POLYMER MATERIAL. CONTINUED USE OF THE CLAY POLYMER AFTER ALL OF THE FALLOUT REPAIR LIQUID HAS BEEN USED CAN CAUSE MINOR SCRATCHING OF THE PAINT FINISH. THE AMOUNT OF FALLOUT REPAIR LIQUID PROVIDED IN THE KIT WAS ESTABLISHED BY DETERMINING THE AMOUNT OF FALLOUT THE CLAY POLYMER COULD ABSORB BEFORE IT BECAME OVER SATURATED WITH FALLOUT AND WOULD CAUSE DAMAGE TO THE PAINT FINISH. POLICY: Information Only Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 7295 Paint: By Symptom Technical Service Bulletin # 727 Date: 970601 Recall - Paint Chipping No.: 727 June, 1997 To: All Dodge Truck Dealers Subject: Customer Satisfaction Notification # 727 -- Severe Paint Chipping Models: 1997 Model Year Dodge Dakota (AN) and Ram (BR) Pickup Trucks With Radiant Red Metallic Paint (Sales Code PRF) Built Through March 23, 1997 (MDH 032300) at the Dodge City Assembly Plant ("S" in the 11th VIN position). The above vehicles may have been painted without using a full body powder anti-chip primer in the painting process. Without this anti-chip primer, severe and excessive paint chipping from normal stone contact may occur. To correct this condition, each vehicle must first be inspected. If the anti-chip primer was not applied, the vehicle must be completely stripped and repainted at a "PPG" approved repair facility. The Chrysler "Paint Resolution Group at 1-800-215-6230 will coordinate the repair. Owners of vehicles that do not meet the paint inspection criteria will be given three options: repainting, vehicle replacement, or repurchase. Details of this service action are explained in the following sections. Service Procedure Videotape No videotape of the service procedure for this notification will be provided. Dealer Notification & Vehicle List All dealers: All dealers will receive a copy of this dealer notification letter by first class mail. No VIN lists will be provided for this notification. DIAL System Functions 53, 63, 70 and VIP VIN's for all involved vehicles will be activated on DIAL System Functions 53, 63, 70 and VIP at the time of notification mailing for dealer inquiry as needed. Parts No parts are required for this service action. "Paint thickness gauges were previously distributed to certain dealers for inspecting unsold vehicles. No additional paint thickness gauges are available. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to contact the Chrysler "Paint Resolution Group at 1-800-215-6230 to locate the nearest dealer for the inspection. Owners will be instructed to make an appointment with that dealer for an inspection. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Service Procedure The paint thickness on each involved vehicle is to be measured at four locations (the roof panel, the cab outer rocker panel, the pickup bed floor, and the rocker panel of the pickup box) and each measurement recorded on DIAL function 63 per Warranty Bulletin D-97-08 (included) even if the paint thickness is acceptable. 1. Using the provided magnetic induction paint thickness gauge (Elcometer), measure the paint thickness on the roof panel and record the measurement on the ""Paint Inspection" form (included). 2. Measure the paint thickness of the cab rocker panel outer surface (outside of door opening) and record on the "Paint Inspection" form. 3. Measure the paint thickness on the floor of the pickup bed and record on the "Paint Inspection" form. This may require lifting up the bedliner to Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 7296 measure the paint thicknesses if equipped. 4. Measure the paint thickness on the pickup box rocker panel and record on the "Paint Inspection" form. 5. Log into DIAL, enter function 63 and follow the prompts for recording the VIN and the paint thickness measurements. 6. If the paint thickness in all four locations meets or exceeds 0.005" (5 mils), no further action is necessary. 7. If the paint thickness at any of the four locations is less than 0.005" (5 mils), inform the customer that he will be contacted by the Chrysler Paint Resolution Group regarding his three options: repainting; vehicle replacement, or vehicle repurchase. 8. Note any vehicle damage, other than normal wear and tear, and its repair cost on the paint inspection form. 9. Give a copy of the "Paint Inspection" form to the owner and telefax one to the Chrysler Paint Resolution Group at (214) 638-4054. Note: If the owner elects to have the vehicle repainted, this will be done only at a PPG approved paint facility. During the repainting period, loaner vehicles will be authorized. All repaint, replacement vehicle and repurchase vehicle elections will be handled by the Chrysler Paint Resolution Group. Completion Reporting and Reimbursement / Parts Return Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record notification service completions and provide dealer payments. Use the following labor operation number and time allowance: Labor Operation Time Number Allowance Inspect Paint Thickness 23-72-71-81 0.2 Transportation, and loaner vehicle expense should be submitted on a separate warranty claim. Note: See the Warranty Administration Manual, Recall Claim Processing Section for complete claim processing instructions. Parts Return Not applicable. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Dealer Service Instructions IMPORTANT Customer Satisfaction Notification # 727 -- Severe Paint Chipping ^ This service requirement applies only to 1997 Model Year Dodge Dakota (AN) and Ram (BR) Pickup trucks with radiant red metallic paint (Sales Code PRF) built through March 23, 1997 (MDH 032300) at the Dodge City Assembly Plant ("S" in the 11th VIN position). ^ The above vehicles may have been painted without using a full body powder anti-chip primer in the painting process. Without this anti-chip primer, severe and excessive paint chipping from normal stone contact may occur. To correct this condition, each vehicle must first be inspected. If the anti-chip primer was not applied, the vehicle must be completely stripped and repainted at a "PPG" approved repair facility. The Chrysler "Paint Resolution Group at 1-800-215-6230 will coordinate the repair. Owners of vehicles that do not meet the paint inspection criteria will be given three Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 7297 options: repainting, vehicle replacement, or repurchase. ^ Dealers will inspect the paint thickness on all affected vehicles and enter their paint thickness inspection measurements of all inspected vehicles into DIAL Function 63 per Warranty Bulletin D-97-08 (even if the paint thickness is acceptable). If the paint is thicker than 5 mils at all four inspection locations, no further action is required. ^ The dealer must telefax the inspection results of vehicles not meeting the inspection criteria and any vehicle damage beyond normal wear and tear to the Chrysler Paint Resolution Group. CPRG will be responsible for notifying all owners of inspected vehicles, which do not satisfy minimum paint thickness requirements of their options. ^ During the repainting period, loaner vehicles will be authorized. Owner Letter/ Inspect the Paint on Truck Dear Dodge Dakota or Ram Truck Owner: The satisfaction of our customers is very important to Chrysler. Because of this, we are requesting owners of some radiant red metallic 1997 Dodge Dakota and Ram trucks, to return them to their dealer for inspection. The problem is... A step in the painting process on your radiant red metallic 1997 Dodge Dakota or Ram truck (identified on the enclosed form) may have been omitted and severe paint chipping may occur. What Chrysler and your dealer will do... Chrysler will inspect the paint on your truck free of charge. The inspection will take about a half hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. If the inspection determines that the paint was applied properly, no further action is necessary. If it is determined that the paint was not applied properly, the Chrysler Paint Resolution Group will contact you regarding details of repainting, replacement or repurchase of your vehicle. What you must do... ^ Simply contact the Chrysler Paint Resolution Group at 1-800-215-6230. They will inform you which dealer in your area you should contact to schedule a paint inspection appointment. Not all dealers have the necessary equipment for the inspection. ^ Chrysler's offer to repaint, replace or repurchase your vehicle is for a limited time only. Your vehicle must be inspected before November 1, 1997. Chrysler's customer satisfaction offer expires November 1, 1997 if not accepted by you by that date. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 7298 ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required inspection to your dealer. We're sorry for any inconvenience, but we believe that this special service will help to ensure your continuing satisfaction with your truck. Thanks for your attention to this important matter. Technical Service Bulletin # 727 Date: 970601 Recall - Paint Chipping No.: 727 June, 1997 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 7299 To: All Dodge Truck Dealers Subject: Customer Satisfaction Notification # 727 -- Severe Paint Chipping Models: 1997 Model Year Dodge Dakota (AN) and Ram (BR) Pickup Trucks With Radiant Red Metallic Paint (Sales Code PRF) Built Through March 23, 1997 (MDH 032300) at the Dodge City Assembly Plant ("S" in the 11th VIN position). The above vehicles may have been painted without using a full body powder anti-chip primer in the painting process. Without this anti-chip primer, severe and excessive paint chipping from normal stone contact may occur. To correct this condition, each vehicle must first be inspected. If the anti-chip primer was not applied, the vehicle must be completely stripped and repainted at a "PPG" approved repair facility. The Chrysler "Paint Resolution Group at 1-800-215-6230 will coordinate the repair. Owners of vehicles that do not meet the paint inspection criteria will be given three options: repainting, vehicle replacement, or repurchase. Details of this service action are explained in the following sections. Service Procedure Videotape No videotape of the service procedure for this notification will be provided. Dealer Notification & Vehicle List All dealers: All dealers will receive a copy of this dealer notification letter by first class mail. No VIN lists will be provided for this notification. DIAL System Functions 53, 63, 70 and VIP VIN's for all involved vehicles will be activated on DIAL System Functions 53, 63, 70 and VIP at the time of notification mailing for dealer inquiry as needed. Parts No parts are required for this service action. "Paint thickness gauges were previously distributed to certain dealers for inspecting unsold vehicles. No additional paint thickness gauges are available. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to contact the Chrysler "Paint Resolution Group at 1-800-215-6230 to locate the nearest dealer for the inspection. Owners will be instructed to make an appointment with that dealer for an inspection. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Service Procedure The paint thickness on each involved vehicle is to be measured at four locations (the roof panel, the cab outer rocker panel, the pickup bed floor, and the rocker panel of the pickup box) and each measurement recorded on DIAL function 63 per Warranty Bulletin D-97-08 (included) even if the paint thickness is acceptable. 1. Using the provided magnetic induction paint thickness gauge (Elcometer), measure the paint thickness on the roof panel and record the measurement on the ""Paint Inspection" form (included). 2. Measure the paint thickness of the cab rocker panel outer surface (outside of door opening) and record on the "Paint Inspection" form. 3. Measure the paint thickness on the floor of the pickup bed and record on the "Paint Inspection" form. This may require lifting up the bedliner to measure the paint thicknesses if equipped. 4. Measure the paint thickness on the pickup box rocker panel and record on the "Paint Inspection" form. 5. Log into DIAL, enter function 63 and follow the prompts for recording the VIN and the paint thickness measurements. 6. If the paint thickness in all four locations meets or exceeds 0.005" (5 mils), no further action is necessary. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 7300 7. If the paint thickness at any of the four locations is less than 0.005" (5 mils), inform the customer that he will be contacted by the Chrysler Paint Resolution Group regarding his three options: repainting; vehicle replacement, or vehicle repurchase. 8. Note any vehicle damage, other than normal wear and tear, and its repair cost on the paint inspection form. 9. Give a copy of the "Paint Inspection" form to the owner and telefax one to the Chrysler Paint Resolution Group at (214) 638-4054. Note: If the owner elects to have the vehicle repainted, this will be done only at a PPG approved paint facility. During the repainting period, loaner vehicles will be authorized. All repaint, replacement vehicle and repurchase vehicle elections will be handled by the Chrysler Paint Resolution Group. Completion Reporting and Reimbursement / Parts Return Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record notification service completions and provide dealer payments. Use the following labor operation number and time allowance: Labor Operation Time Number Allowance Inspect Paint Thickness 23-72-71-81 0.2 Transportation, and loaner vehicle expense should be submitted on a separate warranty claim. Note: See the Warranty Administration Manual, Recall Claim Processing Section for complete claim processing instructions. Parts Return Not applicable. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Dealer Service Instructions IMPORTANT Customer Satisfaction Notification # 727 -- Severe Paint Chipping ^ This service requirement applies only to 1997 Model Year Dodge Dakota (AN) and Ram (BR) Pickup trucks with radiant red metallic paint (Sales Code PRF) built through March 23, 1997 (MDH 032300) at the Dodge City Assembly Plant ("S" in the 11th VIN position). ^ The above vehicles may have been painted without using a full body powder anti-chip primer in the painting process. Without this anti-chip primer, severe and excessive paint chipping from normal stone contact may occur. To correct this condition, each vehicle must first be inspected. If the anti-chip primer was not applied, the vehicle must be completely stripped and repainted at a "PPG" approved repair facility. The Chrysler "Paint Resolution Group at 1-800-215-6230 will coordinate the repair. Owners of vehicles that do not meet the paint inspection criteria will be given three options: repainting, vehicle replacement, or repurchase. ^ Dealers will inspect the paint thickness on all affected vehicles and enter their paint thickness inspection measurements of all inspected vehicles into DIAL Function 63 per Warranty Bulletin D-97-08 (even if the paint thickness is acceptable). If the paint is thicker than 5 mils at all four inspection locations, no further action is required. ^ The dealer must telefax the inspection results of vehicles not meeting the inspection criteria and any vehicle damage beyond normal wear and tear to Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 7301 the Chrysler Paint Resolution Group. CPRG will be responsible for notifying all owners of inspected vehicles, which do not satisfy minimum paint thickness requirements of their options. ^ During the repainting period, loaner vehicles will be authorized. Owner Letter/ Inspect the Paint on Truck Dear Dodge Dakota or Ram Truck Owner: The satisfaction of our customers is very important to Chrysler. Because of this, we are requesting owners of some radiant red metallic 1997 Dodge Dakota and Ram trucks, to return them to their dealer for inspection. The problem is... A step in the painting process on your radiant red metallic 1997 Dodge Dakota or Ram truck (identified on the enclosed form) may have been omitted and severe paint chipping may occur. What Chrysler and your dealer will do... Chrysler will inspect the paint on your truck free of charge. The inspection will take about a half hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. If the inspection determines that the paint was applied properly, no further action is necessary. If it is determined that the paint was not applied properly, the Chrysler Paint Resolution Group will contact you regarding details of repainting, replacement or repurchase of your vehicle. What you must do... ^ Simply contact the Chrysler Paint Resolution Group at 1-800-215-6230. They will inform you which dealer in your area you should contact to schedule a paint inspection appointment. Not all dealers have the necessary equipment for the inspection. ^ Chrysler's offer to repaint, replace or repurchase your vehicle is for a limited time only. Your vehicle must be inspected before November 1, 1997. Chrysler's customer satisfaction offer expires November 1, 1997 if not accepted by you by that date. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 7302 ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required inspection to your dealer. We're sorry for any inconvenience, but we believe that this special service will help to ensure your continuing satisfaction with your truck. Thanks for your attention to this important matter. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time Child Seat: Technical Service Bulletins Child Seat - Tether Anchor Part Numbers & Labor Time NUMBER: 23-008-00 Rev. B GROUP: Body DATE: Nov. 24, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. A, DATED JULY 7, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND PARTS. SUBJECT: Child Seat Tether Anchors MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 2000 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1993 (AJ) Lebaron Coupe 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2000 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1990 - 1994 (BD) Laser/Talon 1994 - 2001 (BR/BE) Ram Truck 1989 - 1992 (B2) Colt/Summit 1992 - 1995 (B3) Colt Vista 1989 (B5) Conquest 1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada) 1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon 1993 - 1994 (B9) Colt/Summit 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 JA Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GTS **2000 (TJ) Wrangler** 1999 - 2000 (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1993 - 1998 (WJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND LABOR OPERATION NUMBERS NECESSARY TO INSTALL A CHILD SEAT TETHER ANCHOR. DAIMLERCHRYSLER WILL REIMBURSE YOU FOR THE ANCHORS AND LABOR TO INSTALL THEM. THIS IS BEING DONE IN THE INTEREST OF CUSTOMER SATISFACTION. REFER TO GLOBAL WARRANTY ADMINISTRATION BULLETIN # D-99-23 FOR COMPLETE REIMBURSEMENT INSTRUCTIONS. DISCUSSION: User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model Year, and in light trucks in the 2001 Model Year. Tether straps improve the performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit for a Kid" Program, owners of earlier products are expected to approach dealers for the free provision and installation of the anchor hardware. DaimlerChrysler Corporation is offering child seat tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary parts and a detailed instruction sheet. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 7308 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 7309 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 7310 PARTS REQUIRED: POLICY: Customer Satisfaction Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 7311 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 7312 TIME ALLOWANCE: FAILURE CODE: Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Description and Operation Hood Sensor/Switch (For Alarm): Description and Operation CIRCUIT OPERATION Circuit G71 connects from the Central Timer Module to the hood switch. The hood switch is normally OPEN when the hood is CLOSED. When the hood is OPENED the switch CLOSES completing a path to ground on circuit Z1. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Description and Operation Power Door Lock Switch: Description and Operation SYSTEM OPERATION The power locks are controlled by a two-way switch mounted in a bezel on the trim panel of each front door. The switch controls the battery feeds to the lock and unlock sense inputs of the high-line Central Timer Module (CTM). The power lock switches cannot be repaired and, if faulty or damaged, the entire switch must be replaced. CIRCUIT OPERATION The door lock switches have two circuits that connect from the switches to the CTM. When the operator selects UNLOCK, from either switch, circuit F35 is connected to circuit P36. When the operator selects the LOCK, from either switch, voltage is passed through the CLOSED contacts in the switch to circuit P35. The CTM then process this request and supplies power and ground to the appropriate circuits. When the LOCK function is selected power is supplied on circuit P33 to all the motors. Ground is supplied on circuit P34. For the UNLOCK function the circuits are reversed. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Description and Operation > Page 7321 Power Door Lock Switch: Testing and Inspection 1. Check the fuse in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the Power Distribution Center (PDC) as required. 3. Disconnect and isolate the battery negative cable. Remove the power lock switch from the door trim panel as described. Carefully separate the wire harness connector from the switch body. 4. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the power lock switch wire harness connector. If OK, go to Step 5. If not OK, repair the open circuit to the junction block as required. Power Lock Switch Continuity 5. Test the power lock switch continuity. See the Power Lock Switch Continuity chart to determine if the continuity is correct in the Off, Lock and Unlock switch positions. If OK, repair the power lock switch sense circuit(s) from the power lock switch wire harness connector to the Central Timer Module (CTM) as required. If not OK, replace the faulty switch. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Description and Operation > Page 7322 Power Door Lock Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Power Windows And Lock Switches Remove/Install 2. Using a wide flat-bladed tool such as a trim stick, gently pry the upper edge of the power lock and power window switch bezel to release the snap-clip retainer that secures the bezel to the door trim panel. 3. Pull the switch bezel away from the door trim panel far enough to access the wire harness connectors. 4. Gently pry the locking tabs of the wire harness connectors away from the switches and carefully unplug the switches. 5. Using a wide flat-bladed tool such as a trim stick, gently pry the sides of the switch cavity on the back of the switch bezel to release the power lock switch from the bezel. 6. Reverse the removal procedures to install. When installing the switch bezel to the door trim panel, insert the rear of the bezel into the trim panel opening, then push down on the front of the bezel until the retaining tab snaps into place. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Description and Operation Power Mirror Switch: Description and Operation SYSTEM OPERATION Both the right and left power outside mirrors are controlled by a single multi-function switch unit mounted on the driver side door trim panel. The switch knob is rotated clockwise (right mirror control), or counterclockwise (left mirror control) to select the mirror to be adjusted. The switch knob is then moved in a joystick fashion to control movement of the selected mirror up, down, right, or left. The power mirror switch cannot be repaired and, if faulty or damaged, it must be replaced. The power switch knob is available for service replacement. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Description and Operation > Page 7326 Power Mirror Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Power Mirror Switch Knob Remove/Install 2. Pull the power mirror switch control knob rearward to remove it from the switch stem. Power Mirror Switch Nut 3. Remove the nut that secures the power mirror switch to the door trim panel. Inside Door Latch Release Handle Pocket Screw Remove/Install Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Description and Operation > Page 7327 4. Pull the inside door latch release handle to the open position and remove the screw in the release handle pocket that secures the door trim panel to the inside door handle bracket. Window Regulator Crank Handle Remove - Typical 5. If the vehicle is so equipped, remove the manual window regulator crank handle with a removal tool. 6. If the vehicle is so equipped, remove the power window and lock switches as follows: Power Window And Lock Switches Remove/Install a. Using a wide flat-bladed tool such as a trim stick, gently pry the upper edge of the switch bezel to release the snap-clip retainer that secures the bezel to the door trim panel. b. Pull the switch bezel away from the door trim panel far enough to access the wire harness connectors. c. Gently pry the locking tabs of the wire harness connectors away from the switches and carefully unplug the switches. Door Trim Panel Remove/Install 7. Remove the four screws that secure the door trim panel to the inner door. 8. To disengage the stepped retainers that secure the door trim panel to the inner door, gently pull the lower edge of the trim panel away from the Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Description and Operation > Page 7328 door while lifting the panel upwards. 9. Pull the door trim panel away from the inner door far enough to access the power mirror switch wire harness connector. Door Trim Panel Wire Harness Connectors 10. Unplug the power mirror switch wire harness connector. 11. Remove the power mirror switch from the back of the door trim panel. 12. When installing the power window and lock switch bezel to the door trim panel, insert the rear of the bezel into the trim panel opening, then push down on the front of the bezel until the retaining tab snaps into place. 13. Reverse the remaining removal procedures to complete the installation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 23-52-99 > Nov > 99 > Window - Squeak Noise When Rolled Down Weatherstrip: Customer Interest Window - Squeak Noise When Rolled Down NUMBER: 23-52-99 GROUP: Body DATE: Nov. 12, 1999 SUBJECT: Squeak Is Heard When The Window Is Rolled Down OVERVIEW: This bulletin involves installing a new door glass inner belt weatherstrip. MODELS: 1997 - 2000 (AN) Dakota 1998 - 2000 (DN) Durango SYMPTOM/CONDITION: A squeak is heard coming from the window area as the window is rolled down. DIAGNOSIS: 1. Roll each window down and up several times. If a squeak is heard, continue on to the next step for each door that emits a squeak. 2. Release the door latch and open the door. 3. Roll the window down. 4. If equipped, remove the window crank. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 23-52-99 > Nov > 99 > Window - Squeak Noise When Rolled Down > Page 7337 5. Remove the screws attaching the door trim panel to the door (Figures 1 and 2). CAUTION: DO NOT FORCIBLY PULL THE TRIM PANEL FROM DOOR. DAMAGE TO THE DOOR TRIM PANEL COULD RESULT. THE DOOR TRIM PANEL USES HOOKS TO SECURE THE LOWER PORTION OF THE DOOR TRIM TO THE DOOR INNER PANEL AND DOES NOT USE ANY CHRISTMAS TREE FASTENERS. 6. Simultaneously lift upward and outward to release retainer hooks from inner door panel (Figure 3). Allow the door trim panel to hang on the door handle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 23-52-99 > Nov > 99 > Window - Squeak Noise When Rolled Down > Page 7338 7. Peel the door inner belt weather strip seal from the door (Figure 4 and Figure 5). 8. Roll each window down and up several times again. If the squeak is still heard, further diagnosis is required. If the squeak is gone, perform the Repair Procedure. PARTS REQUIRED: AR (2) 55255888AD Seal, Front Door Glass Belt Inner Weather Strip, Dakota AR (2) 55256706AD Seal, Front Door Glass Belt Inner Weather Strip, Durango AR (2) 55256868AD Seal, Rear Door Glass Belt Inner Weather Strip REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. With the inner belt weatherstrip already removed, slide the new weather strip seal (see Parts Required section) into position onto the door. 2. Align the trim panel hooks with the receptacles on the inner door panel and slide the trim panel into place. 3. Secure the trim panel to the door with the screws. 4. If equipped, install the window crank. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-51-17-96 Weatherstrip, Door Window Belt Replace, Front Door, One Side 0.3 Hrs. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 23-52-99 > Nov > 99 > Window - Squeak Noise When Rolled Down > Page 7339 23-51-17-97 Weatherstrip, Door Window Belt Replace, Rear Door, One Side 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 23-45-97 > Aug > 97 > Lower Sill Area - Mud/Dirt Accumulation Weatherstrip: Customer Interest Lower Sill Area - Mud/Dirt Accumulation NO: 23-45-97 GROUP: Body EFFECTIVE DATE: Aug. 29, 1997 SUBJECT: Mud And Debris Accumulates On Lower Sill Area MODELS: 1997 (AN) Dakota SYMPTOM/CONDITION: Dirt/mud, water and debris accumulates under the doors at the lower sill area. DIAGNOSIS: Inspect the lower sill area of the door opening for dirt/mud and debris. If dirt/mud and debris is present, perform the following Repair Procedure. PARTS REQUIRED: 2 55257342AA Seal, Lower Sill Secondary AR (1) 04318015 Mopar Super Kleen REPAIR PROCEDURE: This bulletin involves installing an additional lower sill secondary seal. 1. Open the door. 2. Wash the area and throughly clean the lower hem flange area of the door with Mopar Super Kleen, p/n 04318015. 3. Starting with the pull tab, remove the adhesive strip protective backing from the new secondary seal, p/n 55257342AA, and install the secondary seal along the bottom of the door hem flange as shown in Figure 1 starting at the forward edge of the door. The lip of the seal should overlap the outer edge of the hem flange (as shown) to help prevent interference with the original secondary seal. 4. To ensure a good bond to the door hem flange, apply pressure with a trim stick (or suitable tool) to the secondary seal starting with the forward edge of the door working your way to the rear edge of the door. NOTE: MAKE SURE THE NEW SECONDARY SEAL DOES NOT INTERFERE WITH THE ORIGINAL SECONDARY SEAL. 5. Repeat steps one through four for the other door. NOTE: THE ADHESIVE ON THE SECONDARY SEAL SHOULD BE ALLOWED TO FULLY CURE PRIOR TO EXPOSING THE SEAL TO A LOT Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 23-45-97 > Aug > 97 > Lower Sill Area - Mud/Dirt Accumulation > Page 7344 OF DIRT/MUD AND DEBRIS. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-51-08-92 0.4 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 23-52-99 > Nov > 99 > Window - Squeak Noise When Rolled Down Weatherstrip: All Technical Service Bulletins Window - Squeak Noise When Rolled Down NUMBER: 23-52-99 GROUP: Body DATE: Nov. 12, 1999 SUBJECT: Squeak Is Heard When The Window Is Rolled Down OVERVIEW: This bulletin involves installing a new door glass inner belt weatherstrip. MODELS: 1997 - 2000 (AN) Dakota 1998 - 2000 (DN) Durango SYMPTOM/CONDITION: A squeak is heard coming from the window area as the window is rolled down. DIAGNOSIS: 1. Roll each window down and up several times. If a squeak is heard, continue on to the next step for each door that emits a squeak. 2. Release the door latch and open the door. 3. Roll the window down. 4. If equipped, remove the window crank. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 23-52-99 > Nov > 99 > Window - Squeak Noise When Rolled Down > Page 7350 5. Remove the screws attaching the door trim panel to the door (Figures 1 and 2). CAUTION: DO NOT FORCIBLY PULL THE TRIM PANEL FROM DOOR. DAMAGE TO THE DOOR TRIM PANEL COULD RESULT. THE DOOR TRIM PANEL USES HOOKS TO SECURE THE LOWER PORTION OF THE DOOR TRIM TO THE DOOR INNER PANEL AND DOES NOT USE ANY CHRISTMAS TREE FASTENERS. 6. Simultaneously lift upward and outward to release retainer hooks from inner door panel (Figure 3). Allow the door trim panel to hang on the door handle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 23-52-99 > Nov > 99 > Window - Squeak Noise When Rolled Down > Page 7351 7. Peel the door inner belt weather strip seal from the door (Figure 4 and Figure 5). 8. Roll each window down and up several times again. If the squeak is still heard, further diagnosis is required. If the squeak is gone, perform the Repair Procedure. PARTS REQUIRED: AR (2) 55255888AD Seal, Front Door Glass Belt Inner Weather Strip, Dakota AR (2) 55256706AD Seal, Front Door Glass Belt Inner Weather Strip, Durango AR (2) 55256868AD Seal, Rear Door Glass Belt Inner Weather Strip REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. With the inner belt weatherstrip already removed, slide the new weather strip seal (see Parts Required section) into position onto the door. 2. Align the trim panel hooks with the receptacles on the inner door panel and slide the trim panel into place. 3. Secure the trim panel to the door with the screws. 4. If equipped, install the window crank. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-51-17-96 Weatherstrip, Door Window Belt Replace, Front Door, One Side 0.3 Hrs. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 23-52-99 > Nov > 99 > Window - Squeak Noise When Rolled Down > Page 7352 23-51-17-97 Weatherstrip, Door Window Belt Replace, Rear Door, One Side 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 23-45-97 > Aug > 97 > Lower Sill Area - Mud/Dirt Accumulation Weatherstrip: All Technical Service Bulletins Lower Sill Area - Mud/Dirt Accumulation NO: 23-45-97 GROUP: Body EFFECTIVE DATE: Aug. 29, 1997 SUBJECT: Mud And Debris Accumulates On Lower Sill Area MODELS: 1997 (AN) Dakota SYMPTOM/CONDITION: Dirt/mud, water and debris accumulates under the doors at the lower sill area. DIAGNOSIS: Inspect the lower sill area of the door opening for dirt/mud and debris. If dirt/mud and debris is present, perform the following Repair Procedure. PARTS REQUIRED: 2 55257342AA Seal, Lower Sill Secondary AR (1) 04318015 Mopar Super Kleen REPAIR PROCEDURE: This bulletin involves installing an additional lower sill secondary seal. 1. Open the door. 2. Wash the area and throughly clean the lower hem flange area of the door with Mopar Super Kleen, p/n 04318015. 3. Starting with the pull tab, remove the adhesive strip protective backing from the new secondary seal, p/n 55257342AA, and install the secondary seal along the bottom of the door hem flange as shown in Figure 1 starting at the forward edge of the door. The lip of the seal should overlap the outer edge of the hem flange (as shown) to help prevent interference with the original secondary seal. 4. To ensure a good bond to the door hem flange, apply pressure with a trim stick (or suitable tool) to the secondary seal starting with the forward edge of the door working your way to the rear edge of the door. NOTE: MAKE SURE THE NEW SECONDARY SEAL DOES NOT INTERFERE WITH THE ORIGINAL SECONDARY SEAL. 5. Repeat steps one through four for the other door. NOTE: THE ADHESIVE ON THE SECONDARY SEAL SHOULD BE ALLOWED TO FULLY CURE PRIOR TO EXPOSING THE SEAL TO A LOT Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 23-45-97 > Aug > 97 > Lower Sill Area - Mud/Dirt Accumulation > Page 7357 OF DIRT/MUD AND DEBRIS. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-51-08-92 0.4 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation Brake Switch (Cruise Control): Description and Operation SYSTEM OPERATION Vehicles equipped with the speed control option use a dual function stop lamp switch. The switch is mounted in the same location as the conventional stop lamp switch, on the brake pedal mounting bracket under the instrument panel. The PCM monitors the state of the dual function stop lamp switch. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Technical Service Bulletins > Customer Interest for Cruise Control Servo: > 08-18-97A > Jul > 97 > Instrument Panel - Clicking/Tapping Noise Cruise Control Servo: Customer Interest Instrument Panel - Clicking/Tapping Noise NO: 08-18-97 Rev. A GROUP: Electrical DATE: Jul. 3, 1997 SUBJECT: Clicking/Tapping Noise Coming From Under Instrument Panel THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-18-97, DATED MAY 2, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES. THE SPEED CONTROL BRACKET HAS BEEN REVISED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1997 (AN) Dakota NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH SPEED CONTROL BUILT BEFORE APRIL 14, 1997 (MDH 0414XX). SYMPTOM/CONDITION: A clicking or tapping noise is heard coming from under the instrument panel while the speed control is engaged. DIAGNOSIS: Road test the vehicle on a smooth surfaced road. When conditions permit, engage the speed control and listen for a clicking/tapping noise coming from under the instrument panel. Then, dis-engage the speed control and listen again for the noise. If a clicking/tapping noise is heard coming from under the instrument panel while the speed control is engaged but disappears when the speed control is disengaged, perform the following Repair Procedure. If the noise does not appear and disappear when the speed control is engaged and disengaged then, further diagnosis will be required. PARTS REQUIRED: 1 **05010825AA** Bracket, Speed Control Servo REPAIR PROCEDURE: This bulletin involves installing a revised speed control servo bracket. 1. Record the radio station presets. 2. Disconnect and isolate the battery negative cable. 3. Disconnect the vacuum hose from the servo. 4. Remove the two servo bracket nuts that secure the servo assembly to the cowl panel. Then, remove the **ground strap and** speed control servo (Figure 1). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Technical Service Bulletins > Customer Interest for Cruise Control Servo: > 08-18-97A > Jul > 97 > Instrument Panel - Clicking/Tapping Noise > Page 7370 5. Unplug the electrical connector from the servo. 6. Remove two mounting nuts holding the cable sleeve to the mounting bracket. 7. Block the throttle to the full open position. 8. Pull speed control servo sleeve away from the servo to expose the hairpin (retaining) clip (Figure 2). 9. Remove clip attaching cable to servo. 10. Remove servo from mounting bracket. 11. Install the new speed control servo bracket **(p/n 05010825AA)** onto the speed control servo. 12. With the throttle blocked to its full open position, install the speed control cable onto the pin of the servo. Align the retaining clip hole of the cable with the retaining clip hole of the servo pin then, install the hairpin (retaining) clip. CAUTION: MAKE SURE THE HAIRPIN (RETAINING) CLIP IS INSERTED INTO THE HOLE OF THE SPEED CONTROL CABLE AND SERVO PIN ASSEMBLY AND IS FULLY SEATED ONTO THE SPEED CONTROL SERVO CABLE (FIGURE 2). 13. Return the throttle to the closed position. 14. Install the servo cable sleeve onto the servo and secure with the two nuts. Tighten the nuts to 8.5 Nm (75 in. lbs.) of torque. 15. **Attach the speed control servo mounting bracket to the mounting studs on the cowl panel. Install the ground strap onto the speed control servo bracket mounting stud. Secure the servo bracket with the two nuts and tighten the nuts to 8.5 Nm (75 in. lbs.) of torque.** 16. Connect the speed control servo electrical connector. 17. Connect the vacuum hose to the speed control servo. 18. Operate the accelerator pedal to ensure that there isn't any binding in the cable. 19. Connect the battery negative cable. 20. Reprogram the radio to the stations recorded in step one and reset the clock. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 14-20-03-96 0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Servo: > 08-18-97A > Jul > 97 > Instrument Panel - Clicking/Tapping Noise Cruise Control Servo: All Technical Service Bulletins Instrument Panel - Clicking/Tapping Noise NO: 08-18-97 Rev. A GROUP: Electrical DATE: Jul. 3, 1997 SUBJECT: Clicking/Tapping Noise Coming From Under Instrument Panel THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-18-97, DATED MAY 2, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES. THE SPEED CONTROL BRACKET HAS BEEN REVISED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: 1997 (AN) Dakota NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH SPEED CONTROL BUILT BEFORE APRIL 14, 1997 (MDH 0414XX). SYMPTOM/CONDITION: A clicking or tapping noise is heard coming from under the instrument panel while the speed control is engaged. DIAGNOSIS: Road test the vehicle on a smooth surfaced road. When conditions permit, engage the speed control and listen for a clicking/tapping noise coming from under the instrument panel. Then, dis-engage the speed control and listen again for the noise. If a clicking/tapping noise is heard coming from under the instrument panel while the speed control is engaged but disappears when the speed control is disengaged, perform the following Repair Procedure. If the noise does not appear and disappear when the speed control is engaged and disengaged then, further diagnosis will be required. PARTS REQUIRED: 1 **05010825AA** Bracket, Speed Control Servo REPAIR PROCEDURE: This bulletin involves installing a revised speed control servo bracket. 1. Record the radio station presets. 2. Disconnect and isolate the battery negative cable. 3. Disconnect the vacuum hose from the servo. 4. Remove the two servo bracket nuts that secure the servo assembly to the cowl panel. Then, remove the **ground strap and** speed control servo (Figure 1). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Servo: > 08-18-97A > Jul > 97 > Instrument Panel - Clicking/Tapping Noise > Page 7376 5. Unplug the electrical connector from the servo. 6. Remove two mounting nuts holding the cable sleeve to the mounting bracket. 7. Block the throttle to the full open position. 8. Pull speed control servo sleeve away from the servo to expose the hairpin (retaining) clip (Figure 2). 9. Remove clip attaching cable to servo. 10. Remove servo from mounting bracket. 11. Install the new speed control servo bracket **(p/n 05010825AA)** onto the speed control servo. 12. With the throttle blocked to its full open position, install the speed control cable onto the pin of the servo. Align the retaining clip hole of the cable with the retaining clip hole of the servo pin then, install the hairpin (retaining) clip. CAUTION: MAKE SURE THE HAIRPIN (RETAINING) CLIP IS INSERTED INTO THE HOLE OF THE SPEED CONTROL CABLE AND SERVO PIN ASSEMBLY AND IS FULLY SEATED ONTO THE SPEED CONTROL SERVO CABLE (FIGURE 2). 13. Return the throttle to the closed position. 14. Install the servo cable sleeve onto the servo and secure with the two nuts. Tighten the nuts to 8.5 Nm (75 in. lbs.) of torque. 15. **Attach the speed control servo mounting bracket to the mounting studs on the cowl panel. Install the ground strap onto the speed control servo bracket mounting stud. Secure the servo bracket with the two nuts and tighten the nuts to 8.5 Nm (75 in. lbs.) of torque.** 16. Connect the speed control servo electrical connector. 17. Connect the vacuum hose to the speed control servo. 18. Operate the accelerator pedal to ensure that there isn't any binding in the cable. 19. Connect the battery negative cable. 20. Reprogram the radio to the stations recorded in step one and reset the clock. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 14-20-03-96 0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Technical Service Bulletins > Page 7377 Speed Control Servo Components Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Technical Service Bulletins > Page 7378 Speed Control Servo Connector Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Technical Service Bulletins > Page 7379 Cruise Control Servo: Description and Operation SYSTEM OPERATION The speed control servo is mounted to a bracket located in the rear of the engine compartment. The servo unit consists of a solenoid valve body, a vacuum servo and the mounting bracket. The PCM controls the solenoid valve body The solenoid valve body controls the application and release of vacuum to the diaphragm of the vacuum servo. The servo unit cannot be repaired and is serviced only as a complete assembly. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Technical Service Bulletins > Page 7380 Cruise Control Servo: Testing and Inspection For complete speed control system diagnosis, refer to the appropriate Powertrain Diagnostic Procedures and the DRB scan tool in Powertrain Management/Computers and Control Systems. To test the speed control servo only, refer to the following: The engine must be started and running for the following voltage tests. 1. Start engine. 2. Disconnect 4-way electrical connector at servo. 3. Turn speed control switch to ON position. Fig. 4 Servo Harness Connector 4. Check for battery voltage at pin-3 of wiring harness 4-way connector. This is the 12 volt feed from the stoplamp switch. When the brake pedal is depressed, voltage should not be present at pin-3. If voltage is not present with brake pedal not depressed, check for continuity between servo and stop lamp switch. Also check stop lamp switch adjustment. 5. Connect a small gauge jumper wire between the disconnected servo harness 4-way connector pin-3, and pin-3 on the servo. Check for battery voltage at pins-1, 2 and 4 of the servo. If battery voltage is not at these pins, replace the servo. 6. Turn ignition switch to OFF position. Check for continuity between disconnected servo harness 4-way connector pin-4 and a good ground. There should be continuity. If not OK, repair open circuit to ground as required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Technical Service Bulletins > Page 7381 Cruise Control Servo: Service and Repair REMOVAL 1. Disconnect negative battery cable at battery. 2. Disconnect vacuum hose at servo. 3. Unplug electrical connector at servo. 4. Remove 2 servo mounting nuts holding cable sleeve to mounting bracket. 5. Block throttle to full open position. Speed Control Cable 6. Pull speed control cable sleeve away from servo to expose cable hairpin (retaining) clip. 7. Remove clip attaching cable to servo. 8. Remove servo from mounting bracket. INSTALLATION 1. Position servo to mounting bracket. 2. Block throttle to full open position to align hole in cable connector with hole in servo pin. Install cable-to-servo retaining clip. 3. Install servo mounting nuts and tighten to 8.5 N.m (75 in. lbs.). 4. Connect vacuum hose at servo. 5. Connect electrical connector at servo. 6. Remove throttle block. 7. Connect negative battery cable to battery. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Description and Operation Cruise Control Servo Cable: Description and Operation SYSTEM OPERATION The speed control servo cable is connected between the speed control vacuum servo diaphragm and the throttle body control linkage. This cable causes the throttle control linkage to open or close the throttle valve in response to movement of the vacuum servo diaphragm. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Description and Operation > Page 7385 Cruise Control Servo Cable: Service and Repair REMOVAL 1. Disconnect negative battery cable at battery Servo Cable Remove/Install 2. Using finger pressure only, remove speed control cable connector at throttle body bell crank by pushing connector rearward off the bellcrank pin. DO NOT try to pull connector off perpendicular to the bell crank pin. Connector will be broken. 3. Squeeze 2 tabs on sides of speed control cable at throttle body mounting bracket (locking plate) and push out of bracket. 4. Remove servo cable from servo. INSTALLATION 1. Install end of cable to speed control servo. 2. Install cable into throttle body mounting bracket (snaps in). 3. Install speed control cable connector at throttle body bellcrank pin (snaps on). 4. Connect negative battery cable at battery. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations Cruise Control Switch: Locations Speed Control Switches Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Page 7389 Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Page 7390 Cruise Control Switch: Description and Operation SYSTEM OPERATION Two separate speed control switch modules are mounted on the steering wheel to the left and right side of the driver's airbag module. Within the two switch modules, five momentary contact switches, supporting seven different speed control functions are used. The outputs from these switches are filtered into one input. The Powertrain Control Module (PCM) determines which output has been applied through resistive multiplexing. The input circuit voltage is measured by the PCM to determine which switch function has been selected. A speed control indicator lamp, located on the instrument panel cluster is energized by the PCM via the CCD Bus. This occurs when speed control system power has been turned ON, and the engine is running. The two switch modules are labeled: ON/OFF, SET, RESUME/ACCEL, CANCEL and COAST. 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 individual switch fails, the switch module must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Page 7391 Cruise Control Switch: Testing and Inspection For complete speed control system diagnosis, refer to the appropriate Powertrain Diagnostic Procedures service and the DRB scan tool in Powertrain Management/Computers and Control Systems. To test the speed control switch only, refer to the following: WARNING: BEFORE ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL AND STEERING COLUMN COMPONENTS, YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. WAIT 2 MINUTES FOR SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. FAILURE TO DO SO COULD RESULT IN ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect negative battery cable. Wait 2 minutes for airbag system capacitor to discharge. 2. Remove speed control switch module from steering wheel. Refer to the removal/installation for procedures. Speed Control Switch Continuity (Typical Switch Shown) 3. Check speed control switch module continuity as shown in chart. If OK, reinstall switch. If not OK, replace switch module assembly The individual switches and the indicator lamp can not be serviced separately. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Page 7392 Cruise Control Switch: Service and Repair REMOVAL WARNING: BEFORE BEGINNING ANY AIRBAG SYSTEM COMPONENT REMOVAL OR INSTALLATION, REMOVE AND ISOLATE THE NEGATIVE (-) CABLE FROM THE BATTERY. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. THEN WAIT TWO MINUTES FOR SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE INJURY. 1. Disconnect and isolate negative battery cable. 2. Remove airbag module. Refer to Air Bags And Seat Belts/Air Bags for procedures. Speed Control Switches 3. Remove switch-to-steering wheel mounting screws. 4. Remove switch. 5. Remove electrical connector at switch. INSTALLATION 1. Install electrical connector to switch. 2. Install switch and mounting screws. 3. Tighten screws to 1.5 N.m (14 in. lbs.) torque. 4. Install airbag module. Refer to Air Bags And Seat Belts/Air Bags for procedures. 5. Connect negative battery cable. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Description and Operation Cruise Control Vacuum Reservoir: Description and Operation SYSTEM OPERATION The vacuum reservoir is located under the cowl intake air screen in the cowl plenum. The reservoir contains a one-way check valve to trap engine vacuum in the reservoir. When engine vacuum drops, as in climbing a grade while driving, the reservoir supplies the vacuum needed to maintain proper speed control operation. The vacuum reservoir cannot be repaired and must be replaced if faulty. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation Brake Switch (Cruise Control): Description and Operation SYSTEM OPERATION Vehicles equipped with the speed control option use a dual function stop lamp switch. The switch is mounted in the same location as the conventional stop lamp switch, on the brake pedal mounting bracket under the instrument panel. The PCM monitors the state of the dual function stop lamp switch. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations Cruise Control Switch: Locations Speed Control Switches Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 7403 Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 7404 Cruise Control Switch: Description and Operation SYSTEM OPERATION Two separate speed control switch modules are mounted on the steering wheel to the left and right side of the driver's airbag module. Within the two switch modules, five momentary contact switches, supporting seven different speed control functions are used. The outputs from these switches are filtered into one input. The Powertrain Control Module (PCM) determines which output has been applied through resistive multiplexing. The input circuit voltage is measured by the PCM to determine which switch function has been selected. A speed control indicator lamp, located on the instrument panel cluster is energized by the PCM via the CCD Bus. This occurs when speed control system power has been turned ON, and the engine is running. The two switch modules are labeled: ON/OFF, SET, RESUME/ACCEL, CANCEL and COAST. 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 individual switch fails, the switch module must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 7405 Cruise Control Switch: Testing and Inspection For complete speed control system diagnosis, refer to the appropriate Powertrain Diagnostic Procedures service and the DRB scan tool in Powertrain Management/Computers and Control Systems. To test the speed control switch only, refer to the following: WARNING: BEFORE ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL AND STEERING COLUMN COMPONENTS, YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. WAIT 2 MINUTES FOR SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. FAILURE TO DO SO COULD RESULT IN ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect negative battery cable. Wait 2 minutes for airbag system capacitor to discharge. 2. Remove speed control switch module from steering wheel. Refer to the removal/installation for procedures. Speed Control Switch Continuity (Typical Switch Shown) 3. Check speed control switch module continuity as shown in chart. If OK, reinstall switch. If not OK, replace switch module assembly The individual switches and the indicator lamp can not be serviced separately. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 7406 Cruise Control Switch: Service and Repair REMOVAL WARNING: BEFORE BEGINNING ANY AIRBAG SYSTEM COMPONENT REMOVAL OR INSTALLATION, REMOVE AND ISOLATE THE NEGATIVE (-) CABLE FROM THE BATTERY. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. THEN WAIT TWO MINUTES FOR SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE INJURY. 1. Disconnect and isolate negative battery cable. 2. Remove airbag module. Refer to Air Bags And Seat Belts/Air Bags for procedures. Speed Control Switches 3. Remove switch-to-steering wheel mounting screws. 4. Remove switch. 5. Remove electrical connector at switch. INSTALLATION 1. Install electrical connector to switch. 2. Install switch and mounting screws. 3. Tighten screws to 1.5 N.m (14 in. lbs.) torque. 4. Install airbag module. Refer to Air Bags And Seat Belts/Air Bags for procedures. 5. Connect negative battery cable. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer Cruise Control > Component Information > Description and Operation Vehicle Speed Sensor/Transducer - Cruise Control: Description and Operation SYSTEM OPERATION The Vehicle Speed Sensor (VSS) is a pulse generator mounted to an adapter near the transmission output shaft. The sensor is driven through the adapter by a speedometer pinion gear. The VSS pulse signal to the speedometer/odometer is monitored by the PCM speed control circuitry to determine vehicle speed and to maintain speed control set speed. Refer to the appropriate Powertrain Diagnostic Procedures in Powertrain Management/Computer and Control Systems for diagnosis and testing of this component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Description and Operation Vehicle Speed Sensor/Transducer - Cruise Control: Description and Operation SYSTEM OPERATION The Vehicle Speed Sensor (VSS) is a pulse generator mounted to an adapter near the transmission output shaft. The sensor is driven through the adapter by a speedometer pinion gear. The VSS pulse signal to the speedometer/odometer is monitored by the PCM speed control circuitry to determine vehicle speed and to maintain speed control set speed. Refer to the appropriate Powertrain Diagnostic Procedures in Powertrain Management/Computer and Control Systems for diagnosis and testing of this component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Description and Operation ABS Light: Description and Operation The amber anti-lock warning lamp is controlled by the vehicle's "smart" instrument cluster. This cluster has direct control over the Anti-Lock Brake System (ABS) warning lamp. The cluster will periodically transmit a message over the Chrysler Collision Detection (CCD) bus relating to diagnostics and current lamp status for the ABS lamp. If the Controller Anti-Lock Brake (CAB) does not receive this message for a period of three seconds, it will assume that either the CCD bus or the instrument cluster is not operational and will turn on the red brake lamp in the event a fault is set. Likewise, the cluster will expect a periodic message from the CAB indicating whether the lamp should be turned on or off. In the event that no signal is received from the CAB for a certain number of ignition cycles, the cluster will turn on the ABS warning lamp. The lamp detects system related problems and indicates the start of diagnostic action. SYSTEM OPERATION The Anti-Lock Brake System (ABS) lamp gives an indication when the ABS system is faulty or inoperative. The lamp is controlled by the instrument cluster circuitry based upon messages received from the Controller Anti-lock Brake (CAB) on the Chrysler Collision Detection (CCD) data bus. The lamp is turned on by the CAB for about two seconds when the ignition switch is turned to the On position as a bulb test. After the bulb test, the CAB turns the lamp on or off based upon the results of the ABS self-tests. The CAB continually monitors the ABS circuits and sensors to decide whether the system is in good operating condition. The CAB then sends the proper message to the instrument cluster on the CCD data bus to turn the lamp on or off. If the CAB turns the lamp on after the bulb test, it indicates that the CAB has detected a system malfunction and/or that the ABS system has become inoperative. If only the amber ABS lamp is illuminated, and the red brake warning lamp remains off, the base brake system will operate normally Each time the instrument cluster circuitry receives a lamp-on message from the CAB, it will light the lamp for the duration of the ABS malfunction. The CAB will also flash this lamp during the diagnostic mode, unless a hard fault is present. If a hard fault is present, the ABS lamp will illuminate without flashing. Rear Wheel Anti-Lock Brake System Lamp The Rear Wheel Anti-Lock (RWAL) brake system lamp gives an indication when the RWAL system is faulty or inoperative. The lamp is controlled by a hard-wired input to the instrument cluster from the RWAL Controller Anti-lock Brake (CAB). The lamp is turned on by the CAB for about four seconds when the ignition switch is turned to the On position as a bulb test. After the bulb test, the CAB turns the lamp on or off based upon the results of the RWAL system self-tests. The CAB continually monitors the RWAL system circuits and sensors to decide whether the system is in good operating condition. The CAB then switches the ground circuit to the lamp in the instrument cluster to turn the lamp on or off. If the CAB turns the lamp on after the bulb test, it indicates that the CAB has detected an RWAL system malfunction and/or that the RWAL system has become inoperative. If only the amber RWAL lamp is illuminated, and the red brake warning lamp remains off, the base brake system will operate normally. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Description and Operation > Page 7417 ABS Light: Testing and Inspection The diagnosis found here addresses an inoperative Anti-lock Brake System (ABS) lamp condition. If the ABS lamp stays on with the ignition switch in the On position, or comes on and stays on while driving, refer to Brakes and Traction Control/Brakes/Anti-Lock Brakes for diagnosis. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. If the ABS lamp fails to light when the ignition switch is turned to the On position, replace the ABS lamp bulb with a known good unit. If the ABS lamp still fails to operate, diagnosis of the ABS system and the Chrysler Collision Detection (CCD) data bus should be performed with a DRB scan tool as described in the proper Diagnostic Procedures. For diagnosis of the ABS lamp and the instrument cluster circuitry, see Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Instrument Cluster. Rear Wheel Anti-Lock Brake System Lamp The diagnosis found here addresses an inoperative Rear Wheel Anti-Lock (RWAL) brake system lamp condition. If the RWAL lamp stays on with the ignition switch in the On position, or comes on and stays on while driving, refer to Brakes and Traction Control/Brakes/Anti-Lock Brakes for diagnosis. If no RWAL system problem is found, the following procedure will help locate a short or open in the RWAL lamp circuit. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check the fuse in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Turn the ignition switch to the On position. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the ignition switch as required. 3. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Remove the instrument cluster bezel and the cluster as described. Unplug the wire harness connector from the RWAL Controller Anti-lock Brake (CAB). Check for continuity between the RWAL indicator control circuit cavity of the CAB wire harness connector and a good ground. There should be no continuity. If OK, go to Step 4. If not OK, repair the short circuit as required. 4. Check for continuity between the HWAL indicator control circuit cavities of the CAB wire harness connector and the cluster wire harness connector. There should be continuity. If OK, replace the faulty bulb. If not OK, repair the open circuit as required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation Audible Warning Device: Description and Operation CHIME SYSTEM The chime system is built into the CTM. The system also supports an external chime request from the instrument cluster. This feature allows the instrument cluster to request a chime from the CTM for gauge problems and tell-tale warnings. There are two chime rates, Low; 50 chimes per minute for reminders and High; 180 chimes per minute for serious conditions that require immediate attention. The high rate chime sounds when the key is left in the ignition and the doors are open or the headlights are left on. The low rate chime sounds for any of the other conditions. There is a variable rate feature that allows the chime to sound continuously for key-in and headlamp warning as long as the door is open. The seat belt warning chime is activated for six seconds, and all other chime conditions will activate the chime once at the time the warning light on the cluster is illuminated. The chime will sound for the following conditions: ^ Ignition oft, key in ignition, driver's door open ^ Ignition oft, headlamps on, driver's door open ^ Seat belt warning ^ Check engine lamp illuminated (after prove-out) ^ Airbag lamp illuminated (after prove-out) ^ Anti-lock lamp illuminated (after prove-out if equipped) ^ Check gauges lamp illuminated ^ Low fuel ^ Low washer fluid ^ Engine temp critical ^ Engine oil press too low CIRCUIT OPERATION Seat Belt Warning Chime The seat belt chime is used to indicate to the operator that the seat belt is not fastened when the ignition switch is in the RUN position. The seat belt switch is normally OPEN with the seat belt buckled. Circuit G10 is connected between the Central Timer Module (CTM) and the switch. Ground for the switch is provided on circuit Z1. Exterior Lamp-On Warning Chime The exterior lamp ON chime is used to indicate to the operator that the lamps are ON with the drivers door OPEN and the key removed from the ignition. The Central Timer Module (CTM) uses information from circuit G26 to determine if the lamps are ON, and circuit G16 for drivers door ajar. Key-In Ignition Warning Chime The Key-In chime is used to indicate to the operator that the key is in the ignition with the driver's door OPEN. If the key is in the ignition, a ground path is completed from the G26 circuit at the Central Timer Module (CTM), through the CLOSED switch, to the Z1 circuit. The Z1 circuit is the ground circuit. When the driver's door is open the normally OPEN door ajar switch CLOSES completing a path to ground on circuit G16. The CTM processes this information and turns on the chime. For additional information on the Central Timer Module, refer to Powertrain Management / Computers and Control Systems / Body Control Module. See: Body and Frame/Body Control Systems/Central Timer Module ( CTM ) High Option/Description and Operation Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Locations Central Timer Module ( CTM ) Low Option: Locations Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions Central Timer Module ( CTM ) Low Option: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7426 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 Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7427 Electrostatic Discharge Symbol All Electrostatic Discharge (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, especially 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. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7428 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7429 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7430 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7431 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7432 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7433 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7434 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7435 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. 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. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7436 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7437 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7438 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7439 Central Timer Module ( CTM ) Low Option: Diagnostic Aids 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 in 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 and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7440 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. 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 every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. 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 fuse circuit. 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 the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7441 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools 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 - This instrument is 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 vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. 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 non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7442 Central Timer Module ( CTM ) Low Option: Connector Views Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7443 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7444 Central Timer Module ( CTM ) Low Option: Electrical Diagrams Central Timer Module (Part 1 Of 10) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7445 Central Timer Module (Part 2 Of 10) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7446 Central Timer Module (Part 3 Of 10) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7447 Central Timer Module (Part 4 Of 10) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7448 Central Timer Module (Part 5 Of 10) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7449 Central Timer Module (Part 6 Of 10) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7450 Central Timer Module (Part 7 Of 10) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7451 Central Timer Module (Part 8 Of 10) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7452 Central Timer Module (Part 9 Of 10) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7453 Central Timer Module (Part 10 Of 10) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Page 7454 Central Timer Module ( CTM ) Low Option: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR- BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY . Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Page 7455 Central Timer Module ( CTM ) Low Option: Description and Operation CENTRAL TIMER MODULE Two versions of the Central Timer Module (CTM) are available on this vehicle a base version and a high-line version. The base version of the CTM is used on base models of the vehicle. The base version of the CTM combines the functions of a chime/buzzer module an intermittent wipe module and an ignition lamp time delay relay in a single unit. The high-line version of the CTM is used on high-line vehicles. The high-line CTM provides all of the functions of the base version CTM but also is used to control and integrate many of the additional electronic functions and features included on the high-line models. The high-line version of the CTM contains a central processing unit and interfaces with other modules in the vehicle on the Chrysler Collision Detection (CCD) data bus network. The CCD data bus network allows the sharing of sensor information. This helps to reduce wire harness complexity reduce internal controller hardware and reduce component sensor current loads. At the same time this system provides increased reliability enhanced diagnostics and allows the addition of many new feature capabilities. Some of the functions and features that the CTM supports or controls include: Chimes for the following conditions: ^ Headl amps on with ignition off and driver door open warning ^ Key in ignition with ignition off and driver door open warning ^ ABS lamp warning (if the vehicle is so equipped) ^ Airbag lamp warning ^ Check engine lamp warning ^ Check gauges lamp warning ^ Low fuel lamp warning ^ Low washer fluid lamp warning ^ Seat belt reminder lamp warning ^ Transmission oil temperature lamp warning ^ Ignition key lamp timer ^ Intermittent wipe control ^ Courtesy lamp time-out (high-line only) ^ Enhanced accident response (high-line only) ^ Horn chirp upon door lock with RKE (programmable) (high-line only) ^ Illuminated entry (high-line only) ^ Power door lock control (high-line only) ^ Power lock inhibit (high-line only) ^ Remote Keyless Entry (RKE) (high-line only) ^ Rolling door locks (programmable) (high-line only) ^ Speed sensitive intermittent wipe (high-line only) ^ Vehicle Theft Security System (VTSS) (high-line only) (if the vehicle is so equipped) Both versions of the CTM are mounted under the passenger side end of the instrument panel behind the instrument panel top cover and outboard of the glove box opening. For diagnosis of the base version of the CTM Refer to Chime/Buzzer Warning Systems. See: Audible Warning Device For diagnosis of the high-line version of the CTM or the CCD data bus, the use of a DRB scan tool and the proper Diagnostic Procedures manual are recommended. The CTM cannot be repaired and if faulty or dam aged it must be replaced. For additional information on the Central Timer Module, See: Body and Frame/Body Control Systems/Central Timer Module ( CTM ) High Option Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Page 7456 Central Timer Module ( CTM ) Low Option: Testing and Inspection NOTE: The following tests may not prove conclusive in the diagnosis of the high-line version of the Central Timer Module (CTM). The most reliable, efficient, and accurate means to diagnose the high-line CTM requires the use of a DRB scan tool. For additional information on the Central Timer Module, refer to Powertrain Management / Computers and Control Systems / Body Control Module. See: Body and Frame/Body Control Systems/Central Timer Module ( CTM ) High Option 1. Check the fuses in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the Power Distribution Center (PDC) as required. 3. Disconnect and isolate the battery negative cable. Remove the Central Timer Module (CTM) from its mounting bracket to access the CTM wire harness connectors. 4. Unplug the wire harness connectors from the CTM. Check the wire harness connectors and the receptacles in the CTM for loose, corroded, or damaged terminals and pins. If OK, go to Step 5. If not OK, repair as required. 5. Probe the ground circuit cavity of the 14-way CTM wire harness connector and check for continuity to a good ground. Repeat the check between the ground circuit cavity of the 18-way CTM wire harness connector and a good ground. In each case, there should be continuity. If OK, go to Step 6. If not OK, repair the open circuit(s) to ground as required. 6. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the 14-way CTM wire harness connector. If OK, go to Step 7. If not OK, repair the open circuit to the junction block as required. 7. Probe the door lock switch output (lock) circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as you actuate each power lock switch to the Lock position. If OK, go to Step 8. If not OK, repair the open circuit from either or both power lock switch(es) to the CTM as required. 8. Probe the door lock switch output (unlock) circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as you actuate each power lock switch to the Unlock position. If OK, go to Step 9. If not OK, repair the open circuit from either or both power lock switch(es) to the CTM as required. 9. Plug the wire harness connectors back into the CTM. Backprobe the door lock driver circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as either power lock switch is moved to the Lock position. Repeat the test pressing the Lock button of the Remote Keyless Entry (RKE) transmitter. If OK, go to Step 10. If not OK using the power lock switch, but OK with the RKE transmitter, see the test for the Power Lock Switch in Body and Frame/Locks/Power Locks. If not OK using the RKE transmitter, but OK with the power lock switch, see the test for the Remote Keyless Entry Transmitter in Body and Frame/Locks/Keyless Entry. If not OK, with the power lock switch or the RKE transmitter, replace the faulty CTM. 10. Backprobe the door unlock driver circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as the power lock switch is moved to the Unlock position. Repeat the test pressing the Unlock button of the RKE transmitter. If OK, see the test for the Power Lock Motors in Body and Frame/Locks/Power Locks. If not OK using the power lock switch, but OK with the RKE transmitter, see the test for the Power Lock Switch. If not OK using the RKE transmitter, but OK with the power lock switch, see the test for the Remote Keyless Entry Transmitter in Body and Frame/Locks/Keyless Entry. If not OK, with the power lock switch or the RKE transmitter, replace the faulty CTM. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Page 7457 Central Timer Module ( CTM ) Low Option: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the glove box as described. Central Timer Module Remove/Install 3. Remove the three screws that secure the outboard glove box opening bracket to the instrument panel. 4. Remove the two screws that secure the Central Timer Module (CTM) mounting bracket to the outboard glove box opening bracket. 5. Remove the outboard glove box opening bracket from the instrument panel through the glove box opening. 6. Pull the CTM and mounting bracket into the glove box opening far enough to disengage the wire harness retainer from the CTM mounting bracket. 7. Unplug the wire harness connector(s) (one connector for low-line models, two connectors for high-line models) from the CTM. 8. Remove the CTM from the instrument panel. 9. Reverse the removal procedures to install. Be certain to engage the mounting tab on the outboard side of the CTM mounting bracket with the slot in the instrument panel end bracket. Tighten the CTM and mounting bracket screws to 2.2 N.m (20 in. lbs.). NOTE: If a new high-line Central Timer Module is installed, the programmable features must be enabled and/or disabled to the customer's preferred settings. Use a DRB scan tool and the proper Diagnostic Procedures to perform these operations. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Technical Service Bulletins > Brakes - Teves Mark IV/Teves Mark 20 ABS Revisions Brake Warning Indicator: Technical Service Bulletins Brakes - Teves Mark IV/Teves Mark 20 ABS Revisions NUMBER: 26-12-97F GROUP: Miscellaneous DATE: December, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997-1998 Teves Mark IV, Teves Mark 20 ABS Diagnostic Manual - Publication Number 81-699-97012 DESCRIPTION OF CHANGES Revisions to the ABS warning light procedure Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Technical Service Bulletins > Brakes - Teves Mark IV/Teves Mark 20 ABS Revisions > Page 7462 244 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Technical Service Bulletins > Brakes - Teves Mark IV/Teves Mark 20 ABS Revisions > Page 7463 245 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Technical Service Bulletins > Page 7464 Brake Warning Indicator: Description and Operation ANTI-LOCK BRAKE SYSTEM (ABS) WARNING INDICATORS Rear Wheel Anti-Lock (RWAL) Brake System In the RWAL brake system, as in other brake systems, the brake warning lamp (red) is used to alert the driver of a hydraulic fault or that the parking brake is applied. However, in the RWAL system, the brake warning lamp is also used to alert the driver that there is a problem with the RWAL system. There is also an ABS warning lamp (amber). The ABS warning lamp is only used to alert the driver of RWAL malfunctions and to identify Diagnostic Trouble Codes (DTCs) stored in the Controller Anti-Lock Brake (CAB) memory. The ABS warning lamp illuminates when ignition voltage is supplied to the bulb and a ground is provided for the bulb. The bulb has ignition voltage supplied to it any time the ignition switch is in the Run or Start positions. A ground for the bulb is provided by the CAB only. A circuit in the CAB monitors the brake warning lamp switch and the ignition switch bulb check circuit (grounds the brake warning lamp bulb while in the Start position). When the CAB identifies a ground on this circuit, the CAB illuminates the ABS warning lamp. Four Wheel Anti-Lock Brake System The amber ABS warning lamp is located in the instrument cluster. The lamp illuminates at start-up to perform a self check. The lamp goes out when the self check program determines the system is operating normal. If an ABS component exhibits a fault, the CAB will illuminate the lamp and register a trouble code in the microprocessor. The lamp is controlled by the vehicle's "smart" instrument cluster and by the CAB. The CAB activates the lamp by directly grounding the circuit. The CAB checks the brake warning light circuit at the beginning of each ignition cycle. If the CAB detects high voltage when it attempts to ground the light circuit, it determines that a short exists. Diagnostic action for this detected condition includes setting an (88) Indicator Lamp (Red) Circuit diagnostic trouble code. ABS operation will not be inhibited. BASE BRAKE WARNING INDICATOR Purpose A red warning lamp is used for the service brake portion of the hydraulic system. The lamp is located in the instrument cluster. The lamp alerts the driver when a pressure differential exists between the front and rear hydraulic systems or when the parking brakes are applied. Operation The red brake warning lamp is connected to the parking brake switch and to the pressure differential warning switch in the combination valve. The red light illuminates for approximately 2-4 seconds at engine start up. This is a self test feature designed to check bulb operation. The lamp also illuminates when the parking brake is applied. It also illuminates if a fluid pressure drop occurs in either the front or rear brake hydraulic circuit. A pressure drop moves the valve in the combination valve toward the low pressure side. When the valve moves, it pushes the pressure differential switch contact plunger upward. This closes the contacts and completes the circuit to the lamp. The lamp will remain on until repairs are made and normal fluid pressure is restored. CIRCUIT OPERATION Brake Warning Lamp The Controller Antilock Brakes (CAB) provides ground for the instrument cluster. Check Antilock warning lamp on circuit G19. ABS Warning Lamp Operation of the Anti-Lock Brake System (ABS) warning lamp is controller by the DPA switch. If a pressure problem is detected in the system the DPA switch CLOSES connecting circuits B9 and Z1. The B9 circuit connects from the instrument cluster and the Controller Anti-Lock Brake (CAB) to the DPA switch. Circuit Z1 provides the ground path for the switch. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Technical Service Bulletins > Page 7465 Brake Warning Indicator: Testing and Inspection Brake Warning Lamp The diagnosis found here addresses an inoperative brake warning lamp condition. If the brake warning lamp stays on with the ignition switch in the On position and the parking brake released, or comes on while driving, refer to Brakes and Traction Control/Brakes/Anti-Lock Brakes for diagnosis. If no service brake or parking brake problem is found, the following procedure will help locate a faulty hard-wired circuit or switch. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check the fuse in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component and replace the faulty fuse. 2. Turn the ignition switch to the On position. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the ignition switch as required. 3. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Unplug the wire harness connector at the park brake switch. With the park brake released, check for continuity between the park brake switch terminal and a good ground. There should be no continuity If OK, go to Step 4. If not OK, adjust or replace the faulty park brake switch. 4. Unplug the wire harness connector at the brake warning switch. Check for continuity between the two terminals of the brake warning switch. There should be no continuity If OK, go to Step 5. If not OK, replace the faulty brake warning switch. 5. Check for continuity between the ground circuit cavity of the brake warning switch wire harness connector and a good ground. There should be continuity If OK, go to Step 6. If not OK, repair the circuit to ground as required. 6. Remove the instrument cluster bezel and the cluster as described. With both the park brake switch and the brake warning switch wire harness connectors are still unplugged, check for continuity between the park brake switch wire harness connector cavity and a good ground. There should be no continuity If OK, go to Step 7. If not OK, repair the short circuit as required. 7. With the ignition switch held in the Start position, check for continuity between the brake warning switch sense cavity of the brake warning switch wire harness connector and a good ground. There should be continuity If OK, go to Step 8. If not OK, refer to Starting and Charging/Starting System for diagnosis of the ignition switch. 8. Turn the ignition switch to the Off position. Check for continuity between the brake warning switch sense circuit cavity of the cluster wire harness connector and a good ground. There should be no continuity If OK, go to Step 9. If not OK, repair the short circuit as required. 9. Check for continuity between the brake warning switch sense circuit cavities of the cluster wire harness connector and the brake warning switch wire harness connector. There should be continuity If OK, go to Step 10. If not OK, repair the open circuit as required. 10. With the park brake switch wire harness connector still unplugged, check for continuity between the park brake switch sense circuit cavity of the cluster wire harness connector and a good ground. There should be no continuity If OK, go to Step 11. If not OK, repair the short circuit as required. 11. Check for continuity between the park brake switch sense circuit cavities of the cluster wire harness connector and the park brake switch wire harness connector. There should be continuity If OK, see Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Instrument Cluster to test the brake warning lamp and the instrument cluster circuitry If not OK, repair the open circuit as required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Check Gauges Lamp > Component Information > Description and Operation Check Gauges Lamp: Description and Operation SYSTEM OPERATION The check gauges lamp gives an indication when certain gauges reflect a condition requiring immediate attention. The lamp is turned on by the instrument cluster circuitry for about three seconds after the ignition switch is turned to the On position as a bulb test. After the bulb test, the lamp is controlled by the instrument cluster circuitry based upon gauge data messages received from the Powertrain Control Module (PCM) on the Chrysler Collision Detection (CCD) data bus. The PCM uses several inputs to decide what gauge data messages are required. The PCM then sends the proper message to the instrument cluster on the CCD data bus. When the instrument cluster circuitry receives a gauge data message that requires the check gauges lamp be turned on, it also sends a chime tone request to the Central Timer Module (CTM). The gauge data messages for which the instrument cluster is programmed to turn on the check gauges lamp are: Engine coolant temperature is high - Engine oil pressure is low - System voltage is high or low. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Check Gauges Lamp > Component Information > Description and Operation > Page 7469 Check Gauges Lamp: Testing and Inspection The diagnosis found here addresses an inoperative check gauges lamp condition. If the check gauges lamp stays on with the ignition switch in the On position, or comes on while driving with no unusual gauge readings evident, diagnosis of the Powertrain Control Module (PCM) and the Chrysler Collision Detection (CCD) data bus should be performed with a DRB scan tool. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. If the coolant temperature gauge, oil pressure gauge, or voltmeter are giving an indication that should trigger the check gauges lamp, but the check gauges lamp fails to operate, see Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Instrument Cluster for diagnosis of the instrument cluster circuitry. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7474 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 Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7475 Electrostatic Discharge Symbol All Electrostatic Discharge (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, especially 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. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7476 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7477 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7478 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7479 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7480 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7481 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7482 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7483 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. 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. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7484 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7485 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7486 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7487 Cigarette Lighter: Diagnostic Aids 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 in 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 and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7488 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. 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 every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. 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 fuse circuit. 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 the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7489 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools 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 - This instrument is 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 vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. 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 non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7490 Cigarette Lighter: Electrical Diagrams Horn/Cigar Lighter/Power Outlet (Part 1 Of 2) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7491 Horn/Cigar Lighter/Power Outlet (Part 2 Of 2) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Page 7492 Cigarette Lighter: Description and Operation CIRCUIT OPERATION In the ACCESSORY or RUN position, the ignition switch supplies voltage to fuse 15 in the junction block on circuit A31. Fuse 15 feeds circuit X22 which connects to the cigar lighter. When the lighter is depressed, the contacts inside of the lighter element CLOSE and voltage flows to ground on circuit Z1. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Page 7493 Cigarette Lighter: Testing and Inspection - Check the 15 Amp fuse located in the junction block. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Page 7494 Cigarette Lighter: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the lower instrument panel bezel as described. Cigar Lighter And Power Outlet 3. Pull the cigar lighter knob and element out of the cigar lighter base, or remove the power outlet cap from the power outlet base. Cigar Lighter And Power Outlet Remove/Install 4. Look inside the cigar lighter or power outlet base and note the position of the rectangular retaining bosses of the mount that secures the base to the instrument panel lower bezel. 5. Insert a pair of external snap ring pliers into the cigar lighter or power outlet base and engage the tips of the pliers with the retaining bosses. 6. Squeeze the pliers to disengage the retaining bosses from the base, and using a gentle rocking motion pull the pliers and the base out of the mount. 7. Remove the cigar lighter or power outlet mount from the instrument panel lower bezel. 8. Reverse the removal procedures to install. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Locations Module Locations Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Locations > Page 7498 Compass: Diagrams Overhead Console Compass/Mini-Trip Computer Pinout Ambient Temperature Sensor Connector Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Locations > Page 7499 Compass: Description and Operation SYSTEM OPERATION The compass will display the direction in which the vehicle is pointed using the eight major compass headings (Examples: north is N, northeast is NE). It does not display the headings in actual degrees. The self-calibrating compass unit requires no adjusting in normal use. The only calibration that may prove necessary is to drive the vehicle in three complete circles, on level ground, in not less than 48 seconds. This will reorient the compass unit to its vehicle. The compass unit also will compensate for magnetism the body of the vehicle may acquire during normal use. However, avoid placing anything magnetic directly on the roof of the vehicle. Magnetic mounts for an antenna, a repair order hat, or a funeral procession flag can exceed the compensating ability of the compass unit if placed on the roof panel. Magnetic bit drivers used on the fasteners that hold the assembly to the roof header can also affect compass operation. if the vehicle roof should become magnetized, the demagnetizing and calibration procedures found may be required to restore proper compass operation. The compass, trip computer, and thermometer display module cannot be repaired, and are only available for service as a unit. If faulty or damaged, the complete module must be replaced. The trip computer, compass, and thermometer display module cannot be repaired, and are only available for service as a unit. If faulty or damaged, the complete module must be replaced. COMPASS MINI-TRIP COMPUTER (CMTC) This system, located in the overhead console, displays information on outside temperature, compass direction and trip information. Compass And Temperature Display This display provides the outside temperature and one of eight compass readings to indicate the direction the vehicle is facing. Trip Odometer (ODO) Shows the distance travelled since the last reset. Average Fuel Economy (AVE ECO) Shows the average fuel economy in MPG (miles per gallon) or L/100Km since the last reset. Instantaneous Fuel Economy Shows the fuel economy for the last few seconds in MPG or L/100Km. Distance to Empty (DTE) Shows the estimated distance that can be travelled with the fuel remaining in the tank. This is calibrated using the MPG for the last few minutes. Elapsed Time (ET) Shows the accumulated ignition on time since the last reset. Step Button Press this button to cycle through all the mini-trip computer displays. US/M Button Press this button to convert all vehicle displays from US to metric to US. To Reset the Display Press the Step and US/M buttons simultaneously for at least two seconds and all resettable conditions will be rest. This will occur only if a resettable function (AVG ECO, ECO, ET) is currently being displayed. Automatic Compass Calibration This compass is self-calibrating which eliminates the need to manually set the compass. When the vehicle is new, the compass may appear erratic and the CAL symbol will be displayed. After completing three 360° turns in an area free from large metal or metallic objects, the CAL symbol will turn off and the compass will function normally. Compass Variance Compass Variance is the difference between Magnetic North and Geographic North. In some areas of the country, the difference between Magnetic and Geographic North is great enough to cause the compass to give false readings. If this occurs, the compass variance must be set. Enhanced Accident Response (Highline CTM only) If the Airbag Control Module (ACM) deploys the airbags, a message is transmitted over the CCD bus to the CTM module to unlock the doors. The interior lights will be turned on when the vehicle speed message on the CCD bus indicates 0 mph or the message is not present. In addition to unlocking the doors, the door lock feature will be disabled for a predetermined amount of time following the deployment. Once the ignition key Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Locations > Page 7500 has been cycled to the "off" position, normal operation will resume. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Component Tests and General Diagnostics Compass: Component Tests and General Diagnostics If the problem with the trip computer, compass, and thermometer display module is an inaccurate or scrambled display, use the Self-Diagnostic Test procedures. If the problem is incorrect display lighting levels, use a DRB scan tool and the proper Diagnostic Procedures to test for the correct dimming message inputs being received from the instrument cluster over the Chrysler Collision Detection (CCD) data bus. If the problem is a no-display condition, use the following procedures. 1. Check the fuses in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse(s). 2. Check for battery voltage at the fused B(+) fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the Power Distribution Center (PDC) as required. 3. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output fuse in the junction block. If OK, go to Step 4. If not OK, repair the open circuit to the ignition switch as required. 4. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Remove the overhead console as described. Check for continuity between the ground circuit cavities of the overhead console wire harness connector and a good ground. There should be continuity. If OK, go to Step 5. If not OK, repair the open circuit to ground as required. 5. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the overhead console wire harness connector. If OK, go to Step 6. If not OK, repair the open circuit to the junction block as required. 6. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output circuit cavity of the overhead console wire harness connector. If OK, proceed to the Self-Diagnostic Test for further diagnosis of the module and the CCD data bus. If not OK, repair the open circuit to the junction block as required. Self-Diagnostic Test A self-diagnostic test is used to determine that the trip computer, compass, thermometer, and all of the display module segments are operating properly electrically. Initiate the self-diagnostic test as follows: 1. With the ignition switch in the Off position, simultaneously press and hold the Step button and the U.S./Metric button. 2. Turn the ignition switch to the On position. 3. Continue to hold both buttons until the display module performs a display segment test. In this test, all of the vacuum fluorescent display segments are lighted. This test will: a. Verify that all display segments are functional b. Check the internal circuitry of the module c. Check that all of the CCD data bus messages needed are being received. 4. Respond to the respective test results as follows. If all tests are passed, the module will automatically return to normal operation. d. In the display segment test, if any segment should fail to light the unit is faulty and must be replaced. e. If the internal circuitry test is failed, the module will display "FAIL". If "FAIL" is displayed, the unit is faulty and must be replaced. f. If the CCD data bus message test is failed, the module will display "CCD". If "CCD" is displayed, the use of a DRB scan tool and the proper Diagnostic Procedures are required for further diagnosis. 5. Momentarily depress and release either button one time to exit the self-diagnostic test mode and return the trip computer, compass, and thermometer display module to normal operation. NOTE: If the compass functions, but accuracy Is suspect, it may be necessary to perform a variation adjustment. This procedure allows the compass unit to accommodate variations in the earth's magnetic field strength, based on geographic location. See the Instrument Panel, Gauges and Warning Indicators/Compass/Adjustments/Compass Variation Adjustment procedures. - If the compass reading has blanked out, and only "CAL" appears in the display module, demagnetizing may be necessary to remove excessive residual magnetic fields from the vehicle. See the Instrument Panel, Gauges and Warning Indicators /Compass/Adjustments/Compass Demagnetizing procedure. Thermometer The thermometer function is supported by a ambient temperature sensor, a wiring circuit, and a portion of the overhead console trip computer, compass, and thermometer display module display The sensor is mounted outside the passenger compartment near the front and center of the vehicle. If any portion of the ambient temperature sensor circuit fails, the thermometer display will self-diagnose the circuit. An "SC" (short circuit) will appear in the display in place of the temperature, when the sensor is exposed to temperatures above 110 °C (230 °F), or if the sensor circuit is shorted. An "OC" (open circuit) will appear in the display in place of the temperature, when the sensor is exposed to temperatures below -50 °C (-58 °F), or if the sensor circuit is open. The ambient temperature sensor circuit can also be diagnosed using the following Sensor Test, and Sensor Circuit Test. If the temperature sensor and circuit are confirmed to be OK, but the temperature display is inoperative or incorrect, see the Trip Computer, Compass, and Thermometer Display Module diagnosis in Instrument Panel, Gauges and Warning Indicators. Sensor Test 1. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Unplug the temperature sensor wire harness connector. 2. Measure the resistance of the 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, go to the Sensor Circuit Test. If not OK, Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 7503 replace the faulty sensor. Sensor Circuit Test 1. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Unplug the ambient temperature sensor wire harness connector and the overhead console wire harness connector. 2. Connect a jumper wire between the two terminals in the body half of the sensor wire harness connector. 3. Check for continuity between the sensor return circuit and the ambient temperature sensor signal circuit cavities of the overhead console wire harness connector. There should be continuity If OK, go to Step 4. If not OK, repair the open circuit as required. 4. Remove the jumper wire from the ambient temperature sensor wire harness connector. Check for continuity between the sensor return circuit cavity of the overhead console wire harness connector and a good ground. There should be no continuity If OK, go to Step 5. If not OK, repair the short circuit as required. 5. Check for continuity between the ambient temperature sensor signal circuit cavity of the overhead console wire harness connector and a good ground. There should be no continuity If OK, see the Trip Computer, Compass, and Thermometer Display Module diagnosis in Instrument Panel, Gauges and Warning Indicators. If not OK, repair the short circuit as required. NOTE: For complete testing, refer to Powertrain Management/Computers and Control Systems/Body Control Module/Testing and Inspection. See: Body and Frame/Body Control Systems/Central Timer Module ( CTM ) High Option/Testing and Inspection Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Adjustments > Setting the Compass Compass: Adjustments Setting the Compass SETTING THE COMPASS The compass/mini-trip module is self-calibrated and requires no adjustment. The word CAL will be displayed to indicate that the compass is in the fast calibrating mode. CAL will turn off after the vehicle has gone in three complete circles without stopping, in an area free of magnetic disturbance. If the module displays the temperature while the compass is blank or shows a false reading, the vehicle must be demagnetized. If the compass still goes blank after the vehicle is demagnetized, the compass/mini-trip module must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Adjustments > Setting the Compass > Page 7506 Compass: Adjustments Setting the Variance SETTING THE VARIANCE Setting The Variance Variance is the difference between magnetic north and geographic north. To determine the variance for the area you are in, refer to the zone map provided. The number shown for your area is the variance number for your area. 1. Set the Compass/Mini-Trip Console (CMTC) to compass/temperature mode. 2. Press and hold down the reset button for 5 seconds. NOTE: If the buttons are held for 10 seconds instead of 5, the CMTC will set the variance to 8 and enter the fast calibration mode. 3. The VAR light will come on and the last variance setting will be displayed. 4. Press the STEP button to set the zone number. 5. Press the US/M button and resume normal operation. NOTE: Do not attach any magnetic device such as a magnetic CB antenna to the vehicle. This can cause the compass to give false readings. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Adjustments > Setting the Compass > Page 7507 Compass: Adjustments Calibration and Demagnetization COMPASS CALIBRATION CAUTION: Do not place any external magnets, such as magnetic root mount antennas, in the vicinity of the compass. Do not use magnetic tools when servicing the overhead console. The electronic compass unit features a self-calibrating design, which simplifies the calibration procedure. This feature automatically updates the compass calibration while the vehicle is being driven. This allows the compass unit to compensate for small changes in the residual magnetism that the vehicle may acquire during normal use. Do not attempt to calibrate the compass near large metal objects such as other vehicles, large buildings, or bridges. NOTE: Whenever the compass is calibrated manually, the variation number must also be reset. See the Instrument Panel, Gauges and Warning Indicators/Compass/Adjustment/Compass Variation Adjustment procedure. Calibrate the compass manually as follows: 1. Start the engine. If the compass/temperature data is not currently being displayed, momentarily depress and release the Step button to step through the display options until you have reached the compass/temperature display. 2. Depress both the U.S./Metric, and the Step buttons. Hold the buttons down until "CAL" appears in the display This takes about ten seconds, and appears about five seconds after "VAR" is displayed. 3. Release both of the buttons. 4. Drive the vehicle on a level surface, away from large metal objects, through three or more complete circles in not less than 48 seconds. The "CAL" message will disappear from the display to indicate that the compass is now calibrated. NOTE: If the "CAL" message remains in the display, either there Is excessive magnetism near the compass, or the unit Is faulty. Repeat the demagnetizing and calibration procedures at least one more time. - If the wrong direction is still indicated in the compass display, the area selected for calibration may be too close to a strong magnetic field. Repeat the calibration procedure in another location. COMPASS DEMAGNETIZING A degaussing tool (Special Tool 6029) is used to demagnetize, or degauss, the overhead console forward mounting screw and the roof panel. Equivalent units must be rated as continuous duty for 110/115 volts and 60 Hz. They must also have a field strength of over 350 gauss at 7 millimeters (0.25 inch) beyond the tip of the probe. To demagnetize the roof panel and the overhead console forward mounting screw, proceed as follows: 1. Be certain the ignition switch is in the Off position, before you begin the demagnetizing procedure. 2. Plug in the degaussing tool, while keeping the tool at least 61 centimeters (2 feet) away from the compass unit. 3. Slowly approach the head of the overhead console forward mounting screw with the degaussing tool plugged in. 4. Contact the head of the screw with the plastic coated tip of the degaussing tool for about two seconds. 5. With the degaussing tool still energized, slowly back it away from the screw. When the tip of the tool is at least 61 centimeters (2 feet) from the screw head, unplug the tool. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Adjustments > Setting the Compass > Page 7508 Roof Demagnetizing Pattern 6. Place a piece of paper approximately 22 by 28 centimeters (8.5 by 11 inches), oriented on the vehicle lengthwise from front to rear, on the center line of the roof at the windshield header. The purpose of the paper is to protect the roof panel from scratches, and to define the area to be demagnetized. 7. Plug in the degaussing tool, while keeping the tool at least 61 centimeters (2 feet) away from the compass unit. 8. Slowly approach the center line of the roof panel at the windshield header, with the degaussing tool plugged in. 9. Contact the roof panel with the plastic coated tip of the degaussing tool. Be sure the template is in place to avoid scratching the roof panel. Using a slow, back-and-forth sweeping motion, and allowing 13 millimeters (0.50 inch) between passes, move the tool at least 11 centimeters (4 inches) to each side of the roof center line, and 28 centimeters (11 inches) back from the windshield header. 10. With the degaussing tool still energized, slowly back it away from the roof panel. When the tip of the tool is at least 61 centimeters (2 feet) from the roof panel, unplug the tool. 11. Calibrate the compass and adjust the compass variance as described. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Adjustments > Page 7509 Compass: Service and Repair REMOVAL 1. Remove the overhead console as described. Trip Computer, Compass, And Thermometer Display Module Remove/Install 2. Remove the four screws that secure the trip computer, compass, and thermometer display module to the overhead console housing. 3. Release the clip that secures the overhead console wire harness connector to the top of the display module housing and remove the connector. 4. Unplug the display module wire harness connector from the right side of the display module. 5. Remove the display module from the overhead console housing. 6. Remove the display module lens and bezel from the overhead console housing. 7. Reverse the removal procedures to install. Tighten the display module mounting screws to 2.2 N.m (20 in. lbs.). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cruise Control Indicator Lamp > Component Information > Description and Operation Cruise Control Indicator Lamp: Description and Operation SYSTEM OPERATION The cruise-on indicator lamp gives an indication when the vehicle speed control system is turned on, even when the system is not currently engaged. The lamp is turned on by the instrument cluster circuitry for about two seconds when the ignition switch is turned to the On position as a bulb test. After the bulb test, the lamp is controlled by the instrument cluster circuitry based upon a message received from the Powertrain Control Module (PCM) on the Chrysler Collision Detection (CCD) data bus. The PCM uses an input from the analog resistor-multiplexed vehicle speed control switches in the steering wheel to decide whether to turn the lamp on or off. The PCM then sends the proper message to the instrument cluster on the CCD data bus. CIRCUIT OPERATION Cruise (Vehicle Speed Control) Engaged Lamp The Cruise lamp is used to indicate to the operator when the vehicle speed control is ON. The signal to illuminate the lamp is carried over the CCD Bus from the Central Timer Module (CTM). The CTM receives information on vehicle speed control engagement from the PCM over the CCD Bus. This lamp also is illuminated, for a few seconds, when the ignition switch is moved from the OFF to the RUN position as a bulb check. The bulb check operation is controlled by the PCM. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cruise Control Indicator Lamp > Component Information > Description and Operation > Page 7513 Cruise Control Indicator Lamp: Testing and Inspection The diagnosis found here addresses an inoperative cruise-on indicator lamp condition. If the problem being diagnosed is an inaccurate cruise-on indicator lamp, refer to Vehicle Speed Control for diagnosis of the vehicle speed control system. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. If the cruise-on indicator lamp fails to light during the bulb test (about two seconds after the ignition switch is turned to the On position), replace the cruise-on indicator lamp bulb with a known good unit. If the cruise-on lamp still fails to operate, diagnosis of the Powertrain Control Module (PCM) and the Chrysler Collision Detection (CCD) data bus should be performed with a DRB scan tool. For diagnosis of the cruise-on indicator lamp and the instrument cluster circuitry, see Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Instrument Cluster. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Arming and Disarming The airbag system is a sensitive, complex electromechanical unit. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components you must first disconnect and isolate the battery negative (ground) cable. Then wait two minutes for the system capacitor to discharge before further system service. This is the only sure way to disable the airbag system. Failure to do this could result in accidental air-bag deployment and possible personal injury. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Description and Operation Door/Trunk Ajar Indicator/Lamp: Description and Operation CIRCUIT OPERATION This feature is used to alert the operator the drivers door is ajar while the vehicle is in motion. The Central Timer Module (CTM) uses information on vehicle speed from the CCD Bus and circuit G16 which connects to the drivers door ajar switch. Circuit G16 connects between the right and left door ajar switches and the Central Timer Module (CTM). The switches are normally OPEN with the doors closed. When the door is ajar the switch CLOSES completing a path to ground on circuit Z1. The CTM senses the ground path and sends a message to the instrument cluster over the CCD Bus for lamp illumination. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four-Wheel Drive (4WD) Indicator Lamp <--> [Four Wheel Drive Indicator Lamp] > Component Information > Description and Operation Four-Wheel Drive (4WD) Indicator Lamp: Description and Operation SYSTEM OPERATION On vehicles equipped with the optional four-wheel drive system, a four-wheel drive indicator lamp is located in the transfer case shift bezel on the floor pan transmission tunnel. This lamp lights any time the transfer case is engaged in a four-wheel drive operating mode. When the ignition switch is in the On position, battery voltage is supplied to one side of the indicator lamp bulb. A normally-open, plunger-type, four-wheel drive switch in the transfer case is hard-wired in series between the other side of the indicator lamp bulb and ground. When the transfer case is shifted into the 4L or 4H positions, the plunger of the four-wheel drive switch is moved, closing the switch and providing a path to ground. This causes the four-wheel drive indicator lamp bulb to light. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four-Wheel Drive (4WD) Indicator Lamp <--> [Four Wheel Drive Indicator Lamp] > Component Information > Description and Operation > Page 7524 Four-Wheel Drive (4WD) Indicator Lamp: Testing and Inspection NOTE: For complete testing, refer to Powertrain Management/Computers and Control Systems/Body Control Module/Testing and Inspection. See: Body and Frame/Body Control Systems/Central Timer Module ( CTM ) High Option/Testing and Inspection The diagnosis found here addresses an inoperative four-wheel drive indicator lamp condition. If the problem being diagnosed is related to lamp accuracy, be certain to confirm that the problem is with the lamp or switch and not with a damaged or inoperative transfer case or transfer case linkage. If no transfer case problem is found, the following procedure will help locate a short or open in the indicator lamp circuit. 1. Check the fuse in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component and replace the faulty fuse. 2. Turn the ignition switch to the On position. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the ignition switch as required. 3. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Unplug the transfer case switch wire harness connector. Check for continuity between the ground circuit cavity of the transfer case switch wire harness connector and a good ground. There should be continuity. if OK, go to Step 4. If not OK, repair the open circuit to ground as required. 4. Connect the battery negative cable. Turn the ignition switch to the On position. Install a jumper wire between the 4WD sense circuit cavity of the transfer case switch wire harness connector and a good ground. The four-wheel drive indicator lamp should light. If OK, replace the faulty transfer case switch. If not OK, go to Step 5. 5. Turn the ignition switch to the Off position. Remove the transfer case shifter bezel, and unplug the four-wheel drive indicator lamp wire harness connector. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output circuit cavity of the four-wheel drive indicator lamp wire harness connector. If OK, go to Step 6. If not OK, repair the open circuit to the junction block as required. 6. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. With the transfer case switch wire harness connector still unplugged, check for continuity between the 4WD sense circuit cavity of the four-wheel drive indicator lamp wire harness connector and a good ground. There should be no continuity If OK, go to Step 7. If not OK, repair the short circuit as required. 7. Check for continuity between the 4WD sense circuit cavities of the four-wheel drive indicator lamp wire harness connector and the transfer case switch wire harness connector. There should be continuity If OK, replace the faulty bulb. If not OK, repair the open circuit as required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Description and Operation Fuel Gauge: Description and Operation SYSTEM OPERATION The fuel gauge gives an indication of the level of fuel in the fuel tank. The instrument cluster circuitry controls the gauge pointer position. The instrument cluster circuitry calculates the proper gauge pointer position based upon a fuel level message received from the Powertrain Control Module (PCM) on the Chrysler Collision Detection (CCD) data bus. The PCM uses an input from the fuel gauge sending unit and internal programming to decide what fuel level message is required. The PCM then sends the proper message to the instrument cluster on the CCD data bus. If the PCM messages indicate that the fuel level is below one-eighth of a full tank for more than ten seconds, the instrument cluster circuitry turns on the low fuel warning lamp and sends a chime tone request to the Central Timer Module (CTM). The fuel gauge sending unit is mounted to the electric fuel pump module located inside the fuel tank. The sending unit has a float attached to the end of a swing-arm. The float moves up or down within the fuel tank as the fuel level changes. As the float moves, an electrical contact on the pivot end of the swing-arm wipes across a resistor coil, which changes the internal electrical resistance of the sending unit. CIRCUIT OPERATION The Central Timer Module (CTM) calculates the pointer position of the fuel gauge based on the input of the fuel tank gauge level sending unit relative to fuel tank ground. The G4 circuit sends the signal to the CTM. The fuel pump module, located in the fuel tank, contains the fuel pump and the variable resistor for the fuel gauge. Ground for the resistor is located on the left rear quarter panel. As the position of the float arm changes, the resistor changes the current flow through the G4 circuit. The change in current flow is then measured by the CTM and pointer position is adjusted to reflect the fuel tank level. The signal is sent over the CCD Bus to the instrument cluster. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Description and Operation > Page 7528 Fuel Gauge: Testing and Inspection If the problem being diagnosed is related to fuel gauge accuracy, be certain to confirm that the problem is with the gauge or sending unit and not with the fuel tank. Inspect the fuel tank for signs of damage or distortion that could affect the sending unit performance before you proceed with gauge diagnosis. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Diagnosis of the fuel gauge sending unit and circuit, the Chrysler Collision Detection (CCD) data bus, and/or the Powertrain Control Module (PCM) should be performed with a DRB scan tool. For diagnosis of the fuel gauge and the instrument cluster circuitry, see Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Instrument Cluster. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Description and Operation Fuel Gauge Sender: Description and Operation Fig 31 Fuel Gauge Sending Unit Location - Typical Module Fig 32 Fuel Gauge Sending Unit Lock Tab/Tracks 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). The resistor track is used to send electrical signals to the Powertrain Control Module (PCM) for fuel gauge operation and for OBD II emission requirements. For fuel gauge operation: As fuel level increases, the float and arm move up. This decreases the sending unit resistance, causing the fuel gauge to read full. As fuel level decreases, the float and arm move down. This increases the sending unit resistance causing the fuel gauge to read empty. After this fuel level signal is sent to the PCM, the PCM will transmit the data across the CCD bus circuits to the instrument panel. Here it is translated into the appropriate fuel gauge level reading. For OBD II emission requirements: The voltage signal is sent from the resistor track to the PCM to indicate fuel level. The purpose of this feature is to prevent a false setting of misfire and fuel system monitor trouble codes. This is if the fuel level in the tank is less than approximately 15 percent of its rated capacity. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Description and Operation > Page 7532 Fuel Gauge Sender: Testing and Inspection The fuel gauge sending unit contains a variable resistor (track). As the float moves up or down, electrical resistance will change. 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 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 Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Description and Operation > Page 7533 Fuel Gauge Sender: Service and Repair Fig 31 Fuel Gauge Sending Unit Location - Typical Module Fig 32 Fuel Gauge Sending Unit Lock Tab/Tracks The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module. The fuel pump module is located inside of fuel tank. REMOVAL 1. Remove fuel tank. Refer to Fuel Tank Removal/ Installation. 2. Remove fuel pump module. Refer to Fuel Pump Module Removal/Installation. 3. Unplug 6-way electrical connector. 4. Disconnect 2 sending unit wires at 6-way connector. The locking collar of connector must be removed before wires can be released from connector. Note location of wires within 6-way connector. 5. The sending unit is retained to pump module with a small lock tab and notch. Carefully push lock tab to the side and away from notch while sliding sending unit downward on tracks for removal. Note wire routing while removing unit from module. INSTALLATION 1. Position sending unit into tracks. Note wire routing. 2. Push unit on tracks until lock tab snaps into notch. 3. Connect 2 sending unit wires into 6-way connector and install locking collar. 4. Connect 6-way electrical connector to module. 5. Carefully connect lower section of pump module to upper section (3 tabs lock upper section to lower section). 6. Install fuel pump module. Refer to Fuel Pump Module Removal/Installation. 7. Install fuel tank. Refer to Fuel Tank Removal/ Installation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Arming and Disarming The airbag system is a sensitive, complex electromechanical unit. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components you must first disconnect and isolate the battery negative (ground) cable. Then wait two minutes for the system capacitor to discharge before further system service. This is the only sure way to disable the airbag system. Failure to do this could result in accidental air-bag deployment and possible personal injury. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Description and Operation Low Fuel Lamp/Indicator: Description and Operation SYSTEM OPERATION The low fuel warning lamp gives an indication when the fuel level in the fuel tank has fallen below about one-eighth of a full tank, as registered on the fuel gauge. The instrument cluster circuitry lights the lamp for about two seconds when the ignition switch is turned to the On position as a bulb test. After the bulb test, the instrument cluster circuitry controls the lamp based upon fuel level and vehicle speed messages received from the Powertrain Control Module (PCM) on the Chrysler Collision Detection (CCD) data bus. The PCM uses inputs from the fuel gauge sending unit, the vehicle speed sensor, and internal programming to decide what messages are required. The PCM then sends the proper messages to the instrument cluster on the CCD data bus. If the PCM messages indicate that the fuel level is below one-eighth of a full tank for more than ten seconds, and that the vehicle is not moving, the instrument cluster circuitry turns on the low fuel warning lamp and sends a chime tone request to the Central Timer Module (CTM). To reduce the effects of fuel sloshing, if the vehicle speed message indicates that the vehicle is moving, the fuel level message must remain below one-eighth of a full tank for more than sixty seconds before the lamp will be illuminated. The fuel gauge sending unit is mounted to the electric fuel pump module inside the fuel tank. The sending unit has a float attached to the end of a swing-arm. The float moves up or down within the fuel tank as the fuel level changes. As the float moves, an electrical contact on the pivot end of the swing-arm wipes across a resistor coil, which changes the resistance of the sending unit. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Description and Operation > Page 7541 Low Fuel Lamp/Indicator: Testing and Inspection The diagnosis found here addresses an inoperative low fuel warning lamp condition. If the problem being diagnosed is related to lamp accuracy, be certain to confirm the problem is the with the low fuel warning lamp and not with the fuel gauge circuit. See the diagnosis for the Fuel Gauge. If no fuel gauge problem is found, refer to the Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Testing and Inspection/Procedure/Instrument Cluster diagnosis. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. If the low fuel warning lamp fails to light during the bulb test (about two seconds after the ignition switch is turned to the On position), replace the low fuel warning lamp bulb with a known good unit. If the indicator lamp still fails to operate, diagnosis of the fuel gauge sending unit and circuit, the Powertrain Control Module (PCM), and the Chrysler Collision Detection (CCD) data bus should be performed with a DRB scan tool. For diagnosis of the low fuel warning lamp and the instrument cluster circuitry, see Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Instrument Cluster. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation MALFUNCTION INDICATOR LAMP (MIL) As a functional test, the MIL (check engine) illuminates at key-on before engine cranking. Whenever the Powertrain Control Module (PCM) sets a Diagnostic Trouble Code (DTC) that affects vehicle emissions, it illuminates the MIL. If a problem is detected, the PCM sends a message to the instrument cluster to illuminate the lamp. The PCM illuminates the MIL only for DTC's that affect vehicle emissions. There are some monitors that may take two consecutive trips, with a detected fault, before the MIL is illuminated. The MIL stays on continuously when the PCM has entered a Limp-In mode or identified a failed emission component. Also, the MIL either flashes or illuminates continuously when the PCM detects active engine misfire. Refer to Misfire Monitoring. Additionally, the PCM may reset (turn off) the MIL when one of the following occur: PCM does not detect the malfunction for 3 consecutive trips (except misfire and Fuel system Monitors). - PCM does not detect a malfunction while performing three successive engine misfire or fuel system tests. The PCM performs these tests while the engine is operating within +/- 375 RPM of and within 10% of the load of the operating condition at which the malfunction was first detected. BULB CHECK Each time the ignition key is turned to the ON position, the malfunction indicator (check engine) lamp on the instrument panel should illuminate for approximately 2 seconds then go out. This is done for a bulb check. CIRCUIT OPERATION The Powertrain Control Module (PCM) provides ground for the MIL on circuit G3. Circuit G3 connects to cavity C17 of the PCM. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 7545 Malfunction Indicator Lamp: Testing and Inspection The diagnosis found here addresses an inoperative malfunction indicator lamp condition. If the malfunction indicator lamp comes on and stays on with the engine running, refer to Instrument Panel, Gauges and Warning Indicators for diagnosis. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. If the malfunction indicator lamp fails to light during the bulb test (about two seconds after the ignition switch is turned to the On position), replace the malfunction indicator lamp bulb with a known good unit. If the indicator lamp still fails to operate, diagnosis of the Powertrain Control Module (PCM) and the Chrysler Collision Detection (CCD) data bus should be performed with a DRB scan tool. For diagnosis of the malfunction indicator lamp and the instrument cluster circuitry, see Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Instrument Cluster. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Description and Operation Odometer: Description and Operation SYSTEM OPERATION The odometer and the trip odometer share the same Liquid Crystal Display (LCD) on the instrument cluster circuit board. Each gives an indication of the distance the vehicle has travelled. However by depressing the reset knob on the face of the instrument cluster, the display can be switched from the odometer to the trip odometer mode. Depressing the reset knob for longer than two seconds while in the trip odometer mode will reset the trip odometer to zero. The odometer and trip odometer display values are based on distance pulse messages received from the Powertrain Control Module (PCM) on the Chrysler Collision Detection (CCD) data bus. The PCM uses an input from the Vehicle Speed Sensor (VSS) and internal programming to decide what distance pulse signal is required. The PCM then sends the proper message to the instrument cluster circuitry on the CCD data bus. The instrument cluster stores both the odometer and trip odometer distance information and displays the proper value based upon ignition key-on and trip odometer reset knob inputs. If the instrument cluster is not receiving distance information on the CCD data bus when the ignition switch is turned to the On position, the odometer display will flash on and off. The VSS is a hall-effect sensor that is installed in the transmission (two-wheel drive) or transfer case (four-wheel drive), and is driven by the output shaft through a speedometer pinion gear. Incorrect tire size, incorrect axle ratio, a faulty or incorrect speedometer pinion gear, or a faulty VSS can each result in inaccurate odometer readings. CIRCUIT OPERATION The Odometer function of the instrument cluster is controlled by the Central Timer Module (CTM). To calculate the proper milage for the vehicle the CTM receives information from the Powertrain Control Module (PCM) over the CCD Bus. It then calculates this information and sends the proper signal over the CCD Bus to the instrument cluster. Trip Odometer The trip odometer function of the instrument cluster is controlled by the Central Timer Module (CTM). All information is sent across the CCD Bus. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Description and Operation > Page 7549 Odometer: Testing and Inspection If the problem being diagnosed is related to odometer and/or trip odometer accuracy, be certain to confirm that the problem is with the gauge and not with an incorrect speedometer pinion gear, axle ratio, or tire size. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Diagnosis of the vehicle speed sensor and circuit, the Chrysler Collision Detection (CCD) data bus, and/or the Powertrain Control Module (PCM) should be performed with a DRB scan tool. For diagnosis of the odometer and/or trip odometer and the instrument cluster circuitry, see Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Instrument Cluster. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Description and Operation Oil Pressure Gauge: Description and Operation SYSTEM OPERATION The oil pressure gauge gives an indication of the engine oil pressure. The instrument cluster circuitry controls the gauge pointer position. The instrument cluster circuitry calculates the proper gauge pointer position based upon an engine oil pressure message received from the Powertrain Control Module (PCM) on the Chrysler Collision Detection (CCD) data bus. The PCM uses an input from the engine oil pressure sensor and internal programming to decide what engine oil pressure message is required. The PCM then sends the proper message to the instrument cluster on the CCD data bus. If the PCM message indicates that oil pressure is too low, the instrument cluster circuitry moves the gauge needle to the 0 PSI graduation on the gauge face, turns on the Check Gauges lamp, and sends a chime tone request to the Central Timer Module (CTM). If the PCM message indicates that oil pressure is too high, the instrument cluster circuitry moves the gauge needle to 110 PSI graduation on the gauge face. The engine oil pressure sensor is installed in a threaded hole that penetrates an oil passage of the engine. The engine oil pressure sensor contains a flexible diaphragm and a variable resistor coil. The diaphragm moves in response to changes in the engine oil pressure, which changes the internal electrical resistance of the sensor. CIRCUIT OPERATION The instrument cluster micro-processor calculates engine oil pressure gauge needle position based on the oil pressure data received over the CCD bus. The Powertrain Control Module (PCM) transmits the data over the CCD bus. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Description and Operation > Page 7553 Oil Pressure Gauge: Testing and Inspection If the problem being diagnosed is related to oil pressure gauge accuracy, be certain to confirm that the problem is with the gauge and not with the engine oiling system performance. The actual engine oil pressure should be checked with a test gauge and compared to the instrument cluster gauge readings before you proceed with gauge diagnosis. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.v Diagnosis of the oil pressure sensor and circuit, the Chrysler Collision Detection (CCD) data bus, and/or the Powertrain Control Module (PCM) should be performed with a DRB scan tool. For diagnosis of the oil pressure gauge and the instrument cluster circuitry, see Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Instrument Cluster. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Overdrive Indicator Lamp > Component Information > Description and Operation Overdrive Indicator Lamp: Description and Operation SYSTEM OPERATION The overdrive-off indicator lamp gives the driver an indication that the automatic transmission overdrive has been locked out. The lamp is controlled by the Powertrain Control Module (PCM) on a hard-wired circuit to instrument cluster. The PCM uses an input from the momentary overdrive lockout switch on the end of the automatic transmission gearshift selector lever to decide whether to turn the lamp on or off. The PCM then controls the lamp ground based upon the overdrive lockout switch input and its internal programming. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Overdrive Indicator Lamp > Component Information > Description and Operation > Page 7557 Overdrive Indicator Lamp: Testing and Inspection The diagnosis found here addresses an inoperative overdrive-off indicator lamp condition. If the overdrive-off indicator lamp comes on and stays on with the engine running, refer to the proper Diagnostic Procedures for diagnosis of the Powertrain Control Module (PCM) in Powertrain Management /Computer and Control Systems and the transmission control system circuits in Transmission and Drivetrain. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check the fuse in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Turn the ignition switch to the On position. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the ignition switch as required. 3. Disconnect and isolate the battery negative cable. Unplug the gray PCM wire harness connector. Install a jumper wire between the overdrive lamp driver circuit cavity of the gray PCM wire harness connector and a good ground. Connect the battery negative cable. Turn the ignition switch to the On position. The overdrive-off indicator lamp should light. Remove the jumper wire and the lamp should turn off. If OK, refer to the proper Diagnostic Procedures for diagnosis of the Powertrain Control Module (PCM) in Powertrain Management/Computer and Control Systems and the transmission control system circuits in Transmission and Drivetrain. If not OK, go to Step 4. 4. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Remove the instrument cluster bezel and the cluster as described. Check for continuity between the overdrive lamp driver circuit cavity of the gray PCM wire harness connector and a good ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the short circuit as required. 5. Check for continuity between the overdrive lamp driver circuit cavities of the gray PCM wire harness connector and the cluster wire harness connector. There should be continuity If OK, replace the faulty bulb. If not OK, repair the open circuit as required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Lamp > Component Information > Description and Operation Parking Brake Warning Lamp: Description and Operation CIRCUIT OPERATION Ground for the park brake lamp is supplied through the case grounded park brake switch on circuit G11. If the vehicle is equipped with Rear Wheel Antilock (RWAL) brakes, circuit G11 provides an input to the Controller, Antilock Brakes (CAB) and splices to circuit G9. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Description and Operation Parking Brake Warning Switch: Description and Operation CIRCUIT OPERATION On circuit G11, the Controller, Antilock Brakes (CAB) senses when the park brake switch closes. Circuit G11 also connects to the park brake lamp in the instrument cluster and through a diode to circuit G9. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Locations Central Timer Module ( CTM ) Low Option: Locations Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions Central Timer Module ( CTM ) Low Option: Diagram Information and Instructions Circuit Function Circuit Identification All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Wire Code Identification Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7570 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 Information Connector Identification Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placed next to the arrows to indicate the connector number. For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector Locations Index, which uses the connector identification number from the wiring diagrams to provide a figure number reference. Electrostatic Discharge (ESD) Sensitive Devices Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7571 Electrostatic Discharge Symbol All Electrostatic Discharge (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, especially 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. Fasteners Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7572 - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Symbols Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7573 Symbol Identification Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart. Take-Outs The abbreviation T/O is used in the Component Location group to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7574 Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Connector and Splice Identification The connector and Splice numbering used in the vehicle has a letter prefix to identity what harness the connector/splice is located in. A list of these letter designations follows: - B - Body or EDW harness - C - Dome harness - D - Door harness - E - Engine harness - F - Fuel rail harness - J - Jumper harness - L - Liftgate harness - P - Instrument panel harness - S - Seat harness - T - Trailer tow harness When looking at a splice reference the alpha code for what harness the splice is located in will come first, then an S to indicate a splice, and finally the splice number. An example of this would be ESO2. - E - Indicates splice is in the engine harness - S - Indicates a splice - 02 - Indicates what splice it is in harness Wire Color Codes Wire Color Code Identification Wire Color Code Chart Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7575 Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. The color is shown as a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer and it is a standard color, an asterisk will follow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color. Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7576 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7577 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7578 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7579 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. 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. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7580 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7581 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7582 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7583 Central Timer Module ( CTM ) Low Option: Diagnostic Aids 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 in 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 and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 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. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7584 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. 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 every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. 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 fuse circuit. 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 the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7585 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools 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 - This instrument is 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 vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. 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 non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7586 Central Timer Module ( CTM ) Low Option: Connector Views Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7587 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7588 Central Timer Module ( CTM ) Low Option: Electrical Diagrams Central Timer Module (Part 1 Of 10) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7589 Central Timer Module (Part 2 Of 10) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7590 Central Timer Module (Part 3 Of 10) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7591 Central Timer Module (Part 4 Of 10) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7592 Central Timer Module (Part 5 Of 10) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7593 Central Timer Module (Part 6 Of 10) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7594 Central Timer Module (Part 7 Of 10) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7595 Central Timer Module (Part 8 Of 10) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7596 Central Timer Module (Part 9 Of 10) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 7597 Central Timer Module (Part 10 Of 10) NOTE: To view sheets referred to in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Page 7598 Central Timer Module ( CTM ) Low Option: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIRBAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR- BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY . Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Page 7599 Central Timer Module ( CTM ) Low Option: Description and Operation CENTRAL TIMER MODULE Two versions of the Central Timer Module (CTM) are available on this vehicle a base version and a high-line version. The base version of the CTM is used on base models of the vehicle. The base version of the CTM combines the functions of a chime/buzzer module an intermittent wipe module and an ignition lamp time delay relay in a single unit. The high-line version of the CTM is used on high-line vehicles. The high-line CTM provides all of the functions of the base version CTM but also is used to control and integrate many of the additional electronic functions and features included on the high-line models. The high-line version of the CTM contains a central processing unit and interfaces with other modules in the vehicle on the Chrysler Collision Detection (CCD) data bus network. The CCD data bus network allows the sharing of sensor information. This helps to reduce wire harness complexity reduce internal controller hardware and reduce component sensor current loads. At the same time this system provides increased reliability enhanced diagnostics and allows the addition of many new feature capabilities. Some of the functions and features that the CTM supports or controls include: Chimes for the following conditions: ^ Headl amps on with ignition off and driver door open warning ^ Key in ignition with ignition off and driver door open warning ^ ABS lamp warning (if the vehicle is so equipped) ^ Airbag lamp warning ^ Check engine lamp warning ^ Check gauges lamp warning ^ Low fuel lamp warning ^ Low washer fluid lamp warning ^ Seat belt reminder lamp warning ^ Transmission oil temperature lamp warning ^ Ignition key lamp timer ^ Intermittent wipe control ^ Courtesy lamp time-out (high-line only) ^ Enhanced accident response (high-line only) ^ Horn chirp upon door lock with RKE (programmable) (high-line only) ^ Illuminated entry (high-line only) ^ Power door lock control (high-line only) ^ Power lock inhibit (high-line only) ^ Remote Keyless Entry (RKE) (high-line only) ^ Rolling door locks (programmable) (high-line only) ^ Speed sensitive intermittent wipe (high-line only) ^ Vehicle Theft Security System (VTSS) (high-line only) (if the vehicle is so equipped) Both versions of the CTM are mounted under the passenger side end of the instrument panel behind the instrument panel top cover and outboard of the glove box opening. For diagnosis of the base version of the CTM Refer to Chime/Buzzer Warning Systems. See: Audible Warning Device For diagnosis of the high-line version of the CTM or the CCD data bus, the use of a DRB scan tool and the proper Diagnostic Procedures manual are recommended. The CTM cannot be repaired and if faulty or dam aged it must be replaced. For additional information on the Central Timer Module, See: Body and Frame/Body Control Systems/Central Timer Module ( CTM ) High Option Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Page 7600 Central Timer Module ( CTM ) Low Option: Testing and Inspection NOTE: The following tests may not prove conclusive in the diagnosis of the high-line version of the Central Timer Module (CTM). The most reliable, efficient, and accurate means to diagnose the high-line CTM requires the use of a DRB scan tool. For additional information on the Central Timer Module, refer to Powertrain Management / Computers and Control Systems / Body Control Module. See: Body and Frame/Body Control Systems/Central Timer Module ( CTM ) High Option 1. Check the fuses in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the Power Distribution Center (PDC) as required. 3. Disconnect and isolate the battery negative cable. Remove the Central Timer Module (CTM) from its mounting bracket to access the CTM wire harness connectors. 4. Unplug the wire harness connectors from the CTM. Check the wire harness connectors and the receptacles in the CTM for loose, corroded, or damaged terminals and pins. If OK, go to Step 5. If not OK, repair as required. 5. Probe the ground circuit cavity of the 14-way CTM wire harness connector and check for continuity to a good ground. Repeat the check between the ground circuit cavity of the 18-way CTM wire harness connector and a good ground. In each case, there should be continuity. If OK, go to Step 6. If not OK, repair the open circuit(s) to ground as required. 6. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the 14-way CTM wire harness connector. If OK, go to Step 7. If not OK, repair the open circuit to the junction block as required. 7. Probe the door lock switch output (lock) circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as you actuate each power lock switch to the Lock position. If OK, go to Step 8. If not OK, repair the open circuit from either or both power lock switch(es) to the CTM as required. 8. Probe the door lock switch output (unlock) circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as you actuate each power lock switch to the Unlock position. If OK, go to Step 9. If not OK, repair the open circuit from either or both power lock switch(es) to the CTM as required. 9. Plug the wire harness connectors back into the CTM. Backprobe the door lock driver circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as either power lock switch is moved to the Lock position. Repeat the test pressing the Lock button of the Remote Keyless Entry (RKE) transmitter. If OK, go to Step 10. If not OK using the power lock switch, but OK with the RKE transmitter, see the test for the Power Lock Switch in Body and Frame/Locks/Power Locks. If not OK using the RKE transmitter, but OK with the power lock switch, see the test for the Remote Keyless Entry Transmitter in Body and Frame/Locks/Keyless Entry. If not OK, with the power lock switch or the RKE transmitter, replace the faulty CTM. 10. Backprobe the door unlock driver circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as the power lock switch is moved to the Unlock position. Repeat the test pressing the Unlock button of the RKE transmitter. If OK, see the test for the Power Lock Motors in Body and Frame/Locks/Power Locks. If not OK using the power lock switch, but OK with the RKE transmitter, see the test for the Power Lock Switch. If not OK using the RKE transmitter, but OK with the power lock switch, see the test for the Remote Keyless Entry Transmitter in Body and Frame/Locks/Keyless Entry. If not OK, with the power lock switch or the RKE transmitter, replace the faulty CTM. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Central Timer Module ( CTM ) Low Option <--> [Audible Warning Device Control Module] > Component Information > Diagrams > Page 7601 Central Timer Module ( CTM ) Low Option: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the glove box as described. Central Timer Module Remove/Install 3. Remove the three screws that secure the outboard glove box opening bracket to the instrument panel. 4. Remove the two screws that secure the Central Timer Module (CTM) mounting bracket to the outboard glove box opening bracket. 5. Remove the outboard glove box opening bracket from the instrument panel through the glove box opening. 6. Pull the CTM and mounting bracket into the glove box opening far enough to disengage the wire harness retainer from the CTM mounting bracket. 7. Unplug the wire harness connector(s) (one connector for low-line models, two connectors for high-line models) from the CTM. 8. Remove the CTM from the instrument panel. 9. Reverse the removal procedures to install. Be certain to engage the mounting tab on the outboard side of the CTM mounting bracket with the slot in the instrument panel end bracket. Tighten the CTM and mounting bracket screws to 2.2 N.m (20 in. lbs.). NOTE: If a new high-line Central Timer Module is installed, the programmable features must be enabled and/or disabled to the customer's preferred settings. Use a DRB scan tool and the proper Diagnostic Procedures to perform these operations. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Description and Operation Seat Belt Reminder Lamp: Description and Operation SYSTEM OPERATION The seat belt reminder lamp gives a visual reminder to the vehicle occupants to fasten their seat belts. The lamp is turned on by the instrument cluster circuitry for about seven seconds when the ignition switch is turned to the On position. The instrument cluster also receives a hard-wired input from the driver seat belt switch. If the driver seat belt switch is closed (seat belt is not buckled), the instrument cluster will send a chime request to the Central Timer Module (CTM) lasting the duration of the seat belt reminder lamp illumination. The chime warning will stop when the driver seat belt switch is open (seat belt is buckled). The driver seat belt switch is integral to the driver seat belt tip-half retractor assembly The normally open switch monitors the amount of seat belt webbing wound onto the seat belt retractor spool. When the seat belt tip-half webbing is pulled out of the retractor far enough to engage the seat belt bucklehalf, the switch closes. The seat belt reminder lamp also serves as a backup for the airbag indicator lamp. About twenty seconds after the ignition switch is turned to the On position, if an inoperative airbag indicator lamp circuit was detected during the bulb test sequence, the instrument cluster circuitry will flash the seat belt reminder lamp on and off for about thirty seconds. If the seat belt reminder lamp stays on after flashing for thirty seconds, or comes on at any time other than about twenty seconds after the initial ignition-on sequence, it indicates an airbag system fault has been detected and that the airbag indicator lamp is inoperative. CIRCUIT OPERATION Circuit G13 connects between the instrument cluster and the seat belt switch. The seat belt switch is normally OPEN with the seat belt buckled. When the seat belt is not buckled a ground path is completed on circuit F12 through the CLOSED contacts in the switch to circuit G13. The instrument cluster senses this ground path and illuminates the lamp in the instrument cluster. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Description and Operation > Page 7605 Seat Belt Reminder Lamp: Testing and Inspection The diagnosis found here addresses an inoperative seat belt reminder lamp condition. If the lamp comes on and flashes following its display function (for about seven seconds after the ignition switch is turned to the On position), refer to the diagnosis for the airbag indicator lamp in Air Bags and Seat Belts /Air Bags. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check the fuse in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Turn the ignition switch to the On position. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the ignition switch as required. 3. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Unplug the wire harness connector from the seat belt switch in the driver side seat belt retractor. Check for continuity between the fused ignition switch output circuit cavity of the body half of the seat belt switch wire harness connector and the fuse in the junction block. There should be continuity If OK, go to Step 4. If not OK, repair the open circuit as required. 4. Check for continuity between the two cavities of the seat belt retractor half of the seat belt switch wire harness connector. There should be no continuity with the seat belt webbing wound on the retractor spool, and continuity with the seat belt webbing pulled out of the retractor. If OK, go to Step 5. If not OK, replace the faulty seat belt and retractor assembly 5. Remove the instrument cluster bezel and the instrument cluster. Check for continuity between the seat belt switch sense circuit cavities of the cluster wire harness connector and the body half of the seat belt switch wire harness connector. There should be continuity. If OK, see Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Instrument Cluster for diagnosis of the seat belt reminder lamp and the instrument cluster circuitry. If not OK, repair the open circuit as required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation Fuel Gauge Sender: Description and Operation Fig 31 Fuel Gauge Sending Unit Location - Typical Module Fig 32 Fuel Gauge Sending Unit Lock Tab/Tracks 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). The resistor track is used to send electrical signals to the Powertrain Control Module (PCM) for fuel gauge operation and for OBD II emission requirements. For fuel gauge operation: As fuel level increases, the float and arm move up. This decreases the sending unit resistance, causing the fuel gauge to read full. As fuel level decreases, the float and arm move down. This increases the sending unit resistance causing the fuel gauge to read empty. After this fuel level signal is sent to the PCM, the PCM will transmit the data across the CCD bus circuits to the instrument panel. Here it is translated into the appropriate fuel gauge level reading. For OBD II emission requirements: The voltage signal is sent from the resistor track to the PCM to indicate fuel level. The purpose of this feature is to prevent a false setting of misfire and fuel system monitor trouble codes. This is if the fuel level in the tank is less than approximately 15 percent of its rated capacity. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Page 7610 Fuel Gauge Sender: Testing and Inspection The fuel gauge sending unit contains a variable resistor (track). As the float moves up or down, electrical resistance will change. 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 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 Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Page 7611 Fuel Gauge Sender: Service and Repair Fig 31 Fuel Gauge Sending Unit Location - Typical Module Fig 32 Fuel Gauge Sending Unit Lock Tab/Tracks The fuel gauge sending unit (fuel level sensor) and float assembly is located on the side of fuel pump module. The fuel pump module is located inside of fuel tank. REMOVAL 1. Remove fuel tank. Refer to Fuel Tank Removal/ Installation. 2. Remove fuel pump module. Refer to Fuel Pump Module Removal/Installation. 3. Unplug 6-way electrical connector. 4. Disconnect 2 sending unit wires at 6-way connector. The locking collar of connector must be removed before wires can be released from connector. Note location of wires within 6-way connector. 5. The sending unit is retained to pump module with a small lock tab and notch. Carefully push lock tab to the side and away from notch while sliding sending unit downward on tracks for removal. Note wire routing while removing unit from module. INSTALLATION 1. Position sending unit into tracks. Note wire routing. 2. Push unit on tracks until lock tab snaps into notch. 3. Connect 2 sending unit wires into 6-way connector and install locking collar. 4. Connect 6-way electrical connector to module. 5. Carefully connect lower section of pump module to upper section (3 tabs lock upper section to lower section). 6. Install fuel pump module. Refer to Fuel Pump Module Removal/Installation. 7. Install fuel tank. Refer to Fuel Tank Removal/ Installation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Description and Operation Parking Brake Warning Switch: Description and Operation CIRCUIT OPERATION On circuit G11, the Controller, Antilock Brakes (CAB) senses when the park brake switch closes. Circuit G11 also connects to the park brake lamp in the instrument cluster and through a diode to circuit G9. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Shift Indicator > Component Information > Description and Operation Shift Indicator: Description and Operation SYSTEM OPERATION Vehicles equipped with a manual transmission have an upshift indicator lamp. The upshift indicator lamp gives an indication when the driver should shift to the next highest gear for the best fuel economy The lamp is turned on by the instrument cluster circuitry for about three seconds when the ignition switch is turned to the On position as a bulb test. After the bulb test, the lamp is controlled by the instrument cluster circuitry based upon a message received from the Powertrain Control Module (PCM) on the Chrysler Collision Detection (CCD) data bus. The PCM uses inputs from many sensors and its internal programming to decide whether the engine speed and load conditions are proper for a transmission upshift. The PCM then sends the proper message to the instrument cluster on the CCD data bus to turn the lamp on or off. The PCM will send a lamp-off message three to five seconds after a lamp-on message, if an upshift is not performed. The lamp will then remain off until the vehicle stops accelerating and is brought back into the range of lamp operation, or until the transmission is shifted into another gear. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Shift Indicator > Component Information > Description and Operation > Page 7618 Shift Indicator: Testing and Inspection NOTE: For complete testing, refer to Powertrain Management/Computers and Control Systems/Body Control Module/Testing and Inspection. See: Body and Frame/Body Control Systems/Central Timer Module ( CTM ) High Option/Testing and Inspection The diagnosis found here addresses an inoperative upshift indicator lamp condition. If lamp accuracy is suspect, diagnosis should be performed with a DRB scan tool. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. If the upshift indicator lamp fails to light during the bulb test (about three seconds after the ignition switch is turned to the On position), replace the upshift indicator lamp bulb with a known good unit. If the indicator lamp still fails to operate, diagnosis of the Powertrain Control Module (PCM) and the Chrysler Collision Detection (CCD) data bus should be performed with a DRB scan tool. For diagnosis of the upshift indicator lamp and the instrument cluster circuitry, see Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Instrument Cluster. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Description and Operation Speedometer Head: Description and Operation SYSTEM OPERATION The speedometer gives an indication of the current vehicle speed. The instrument cluster circuitry controls the gauge pointer position. The instrument cluster circuitry calculates the proper gauge pointer position based upon a vehicle speed message received from the Powertrain Control Module (PCM) on the Chrysler Collision Detection (CCD) data bus. The PCM uses an input from the Vehicle Speed Sensor (VSS) and internal programming to decide what vehicle speed message is required. The PCM then sends the proper message to the instrument cluster on the CCD data bus. The VSS is a hall-effect sensor that is installed in the transmission (two-wheel drive) or transfer case (four-wheel drive), and is driven by the output shaft through a speedometer pinion gear. Incorrect tire size, incorrect axle ratio, a faulty or incorrect speedometer pinion gear, or a faulty VSS can each result in inaccurate speedometer readings. CIRCUIT OPERATION The speedometer receives its information across the CCD Bus from the Central Timer Module (CTM). Information on vehicle speed is transmitted from the Powertrain Control Module (PCM) across the CCD Bus to the CTM. The PCM receives its information on vehicle speed on the G7 circuit from the Vehicle Speed Sensor (VSS). The CTM calculates the position of the speedometer pointer based on the input from the PCM and adjusts the position of the gauge pointer as necessary This signal is sent over the CCD Bus to the instrument cluster. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Description and Operation Tachometer: Description and Operation SYSTEM OPERATION The tachometer gives an indication of the engine speed in revolutions-per-minute (RPM). The instrument cluster circuitry controls the gauge pointer position. The instrument cluster circuitry calculates the proper gauge pointer position based upon an engine speed message received from the Powertrain Control Module (PCM) on the Chrysler Collision Detection (CCD) data bus. The PCM uses an input from the crankshaft position sensor and internal programming to calculate what engine speed message is required. The PCM then sends the proper message to the instrument cluster on the CCD data bus. The crankshaft position sensor is a hall-effect sensor installed near the rear of the engine, where it is aimed at the trigger wheel attached to the rear flange of the crankshaft. CIRCUIT OPERATION The tachometer receives its information across the CCD Bus from the Central Timer Module (CTM). Information on engine RPM is transmitted from the Powertrain Control Module (PCM) across the CCD Bus to the CTM. The CTM calculates the position of the tachometer pointer based on the input from the PCM and adjusts the position of the gauge pointer to the necessary position. This signal is sent over the CCD Bus to the instrument cluster. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Description and Operation > Page 7625 Tachometer: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Diagnosis of the crankshaft position sensor and circuit, the Chrysler Collision Detection (CCD) data bus, and/or the Powertrain Control Module (PCM) should be performed with a DRB scan tool. For diagnosis of the tachometer and the instrument cluster circuitry, see Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Instrument Cluster. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation SYSTEM OPERATION The coolant temperature gauge gives an indication of the engine coolant temperature. The instrument cluster circuitry controls the gauge pointer position. The instrument cluster circuitry calculates the proper gauge pointer position based upon an engine coolant temperature message received from the Powertrain Control Module (PCM) on the Chrysler Collision Detection (CCD) data bus. The PCM uses an input from the engine coolant temperature sensor and internal programming to decide what engine coolant temperature message is required. The PCM then sends the proper message to the instrument cluster on the CCD data bus. If the PCM message indicates that coolant temperature is too high, the instrument cluster circuitry moves the gauge needle to the 260 °F graduation on the gauge face, turns on the Check Gauges lamp, and sends a chime tone request to the Central Timer Module (CTM). The engine coolant temperature sensor is installed in a threaded hole that penetrates a coolant passage of the engine. It is a thermistor-type sensor that changes its internal resistance with changes in engine coolant temperature. CIRCUIT OPERATION The engine coolant temperature gauge receives its information across the CCD Bus from the Central Timer Module (CTM). The engine coolant temperature sensor uses a variable resistor to send a signal to the Powertrain Control Module (PCM) indicating coolant temperature. The PCM then sends this information to the CTM across the CCD Bus. The CTM calculates the position of the engine coolant temperature gauge and based on the information received from the PCM it adjusts the position of the gauge pointer. This signal is sent over the CCD Bus to the instrument cluster. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Description and Operation > Page 7629 Temperature Gauge: Testing and Inspection (FOR ADDITONAL TESTING REFER TO BODY CONTROL MODULE) If the problem being diagnosed is related to coolant temperature gauge accuracy, be certain to confirm that the problem is with the gauge and not with cooling system performance. The actual engine coolant temperature should be checked with a test gauge or thermometer and compared to the gauge readings before you proceed with gauge diagnosis. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Diagnosis of the coolant temperature sensor and circuit, the Chrysler Collision Detection (CCD) data bus, and/or the Powertrain Control Module (PCM) should be performed with a DRB scan tool. For diagnosis of the coolant temperature gauge and the instrument cluster circuitry, see Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Instrument Cluster. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Description and Operation Temperature Warning Lamp/Indicator: Description and Operation SYSTEM OPERATION The transmission oil temperature warning lamp gives an indication when the Powertrain Control Module (PCM) has detected that the automatic transmission oil is overheated. One side of the lamp bulb receives battery voltage when the ignition switch is turned to the On position. The lamp ground is controlled by the instrument cluster circuitry based upon messages received from the PCM on the Chrysler Collision Detection (CCD) data bus. The PCM sends a lamp-on message for about two seconds when the ignition switch is turned to the On position as a bulb test. Following the bulb test, the PCM uses an input from the automatic transmission oil temperature sensor located within the transmission, along with its internal programming, to decide whether a condition exists that requires the transmission oil temperature warning lamp to be turned on. The PCM then sends the proper message to the instrument cluster on the CCD data bus to turn the lamp on or off. CIRCUIT OPERATION The transmission temperature lamp is used to alert the operator that the transmission oil temperature has exceeded a pre-determined level. Circuit T34 provides the input to the Powertrain Control Module (PCM). When the PCM determines the need for lamp illumination it sends a message over the CCD bus to the Body Control Module (BCM). The BCM processes this message and sends a message to the instrument cluster via the CCD bus for lamp illumination. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Description and Operation > Page 7633 Temperature Warning Lamp/Indicator: Testing and Inspection The diagnosis found here addresses an inoperative transmission oil temperature warning lamp condition. If the transmission oil temperature warning lamp comes on and stays on with the engine running, refer to Transmission for diagnosis of a transmission overheating condition. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. If the transmission oil temperature warning lamp fails to light during the bulb test (about two seconds after the ignition switch is turned to the On position), diagnosis of the Powertrain Control Module (PCM) and the Chrysler Collision Detection (CCD) data bus should be performed with a DRB scan tool. For diagnosis of the transmission oil temperature warning lamp and the instrument cluster circuitry, see Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Instrument Cluster. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Description and Operation Volt Meter Gauge: Description and Operation SYSTEM OPERATION The voltmeter gives an indication of the electrical system voltage. The instrument cluster circuitry controls the gauge pointer position. The instrument cluster circuitry calculates the proper gauge pointer position based upon a system voltage message received from the Powertrain Control Module (PCM) on the Chrysler Collision Detection (CCD) data bus. The PCM uses an input from the electrical system and internal programming to decide what system voltage message is required. The PCM then sends the proper message to the instrument cluster on the CCD data bus. If the PCM message indicates that the charging system has failed, the instrument cluster circuitry moves the gauge needle to the 8 Volt graduation on the gauge face, turns on the Check Gauges lamp, and sends a chime tone request to the Central Timer Module (CTM). If the PCM message indicates that system voltage is high, the instrument cluster circuitry moves the gauge needle to the 18 volt graduation on the gauge face, turns on the Check Gauges lamp, and sends a chime tone request to the CTM. CIRCUIT OPERATION The voltmeter receives its information across the CCD Bus from the Central Timer Module (CTM). The CTM calculates the position of the voltmeter gauge and based on the information received from the PCM it adjusts the position of the gauge pointer. This signal is sent over the CCD Bus to the instrument cluster. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Description and Operation > Page 7637 Volt Meter Gauge: Testing and Inspection If the problem being diagnosed is related to voltmeter gauge accuracy, be certain to confirm proper charging system operation before considering instrument cluster replacement. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Diagnosis of the system voltage input circuit, the Chrysler Collision Detection (CCD) data bus, and/or the Powertrain Control Module (PCM) should be performed with a DRB scan tool. For diagnosis of the voltmeter and the instrument cluster circuitry, see Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Instrument Cluster. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Specifications Backup Lamp Switch: Specifications Mounting .............................................................................................................................................. .................................................... 37 Nm (27 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Specifications > Page 7643 Transmission Connectors Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Light Bulb > Component Information > Service and Repair Backup Light Bulb: Service and Repair REMOVAL 1. Remove screws from tail lamp. 2. Grasp lamp, firmly pull lamp rearward to disengage retaining studs. Tail, Stop, Turn Signal And Back-Up Lamp Bulbs 3. Remove sockets from tail lamp. 4. Pull bulb from socket. 5. Separate tail lamp from cargo box. INSTALLATION 1. Install bulb in socket. 2. Install socket in tail lamp. 3. Position tail lamp in cargo box, engage retaining studs and install screws. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Service and Repair Brake Light Bulb: Service and Repair REMOVAL 1. Remove screws from tail lamp. 2. Grasp lamp, firmly pull lamp rearward to disengage retaining studs. Tail, Stop, Turn Signal And Back-Up Lamp Bulbs 3. Remove sockets from tail lamp. 4. Pull bulb from socket. 5. Separate tail lamp from cargo box. INSTALLATION 1. Install bulb in socket. 2. Install socket in tail lamp. 3. Position tail lamp in cargo box, engage retaining studs and install screws. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Component Locations Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Component Locations > Page 7655 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7656 Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7657 Brake Light Switch: Description and Operation OPERATION The brake light switch is mounted on a bracket on the brake pedal support. The switch is self adjusting. An initial adjustment is only necessary when the switch has been replaced, or removed for service access to other components. The primary function of the switch is to turn on the stop lamps during braking. The switch is also used to send signals to components that must know when the brakes are applied, such as the Powertrain Control Module (PCM), which uses the signal to cancel speed control. The Controller Anti-Lock Brake (CAB) uses the brake switch signal to monitor brake pedal application. When the switch contacts open (brakes applied), the CAB receives the brake applied signal. The CAB then monitors the Anti-Lock Brake System (ABS) to anticipate the need for an ABS stop. CIRCUIT OPERATION Circuit K29 provides an input to the Powertrain Control Module (PCM). This circuit connects to cavity C24 of the PCM connector. On circuit K29 the Controller Antilock Brakes (CAB) senses when the brake pedal has been pressed. Circuit K29 also connects to the Powertrain Control Module (PCM) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7658 Brake Light Switch: Testing and Inspection The brake light switch has a 12 volt feed circuit from the fuse block. Verity fuse is OK, then check the feed from the fuse block to the switch. If the switch is receiving a 12 volt supply, depress the brake pedal and check for voltage to the brake light circuit. If no voltage is present, the switch must be replaced. If the switch does not have 12 volts from the fuse block, check for continuity between the fuse block and switch and repair as necessary. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7659 Brake Light Switch: Adjustments 1. Push and hold brake pedal in applied position. 2. Push switch forward until fully seated against bracket. 3. Release brake pedal. 4. Lightly pull brake pedal rearward until master cylinder push rod bottoms against master cylinder internal stop. This action will set switch plunger at proper stroke length. CAUTION: Do not use excessive force to move the pedal rearward and do not overextend the pedal and push rod. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7660 Brake Light Switch: Service and Repair Stop Lamp Switch & Bracket REMOVAL 1. Disconnect switch harness. 2. Press and hold brake pedal in applied position. 3. Rotate switch counterclockwise about 30 degrees to align switch lock tab with notch in bracket. 4. Pull switch rearward out of mounting bracket and release brake pedal. INSTALLATION 1. Pull switch plunger all the way out to fully extended position. 2. Push switch plunger inward four detent positions (clicks). This is required preset position for switch installation. Plunger will extend approximately 0.55 inch out of housing at this setting. 3. Connect harness wires to switch. 4. Press and hold brake pedal down. 5. Install switch. Align tab on switch with notch in switch bracket. Then insert switch in bracket and turn it clockwise about 30 degrees to lock it in place. 6. Release brake pedal, then lightly pull pedal fully rearward. Pedal will adjust switch plunger to correct position as pedal is moved to rear. CAUTION: Do not use excessive force to move the pedal rearward for switch adjustment. Excessive force will damage the switch. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Description and Operation Cargo Lamp: Description and Operation CIRCUIT OPERATION Power for the cargo lamps is supplied on circuit M1. This is the Ignition-Off Draw (IOD) circuit and protected by a 10 Amp fuse located in the junction block. Ground for the lamp is supplied on circuit M3 through the headlamp switch to circuit Z1. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Description and Operation > Page 7664 Cargo Lamp: Service and Repair The cargo lamp and bulb is incorporated in the CHMSL assembly, refer to the CHMSL bulb removal and installation procedure for bulb replacement. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Center High Mounted Stop Lamp <--> [Center Mounted Brake Lamp] > Center Mounted Brake Lamp Bulb > Component Information > Service and Repair Center Mounted Brake Lamp Bulb: Service and Repair REMOVAL 1. Remove the CHMSL from the roof panel. 2. Rotate sockets 1/4 turn clockwise and remove from lamp. (The center bulbs light the stoplamp and the outside bulbs light the cargo lamp.) 3. Pull bulb from socket. INSTALLATION 1. Push bulb into socket. 2. Position socket in lamp an rotate socket 1/4 turn counterclockwise. 3. Install the CHMSL. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Description and Operation Ash Tray Lamp: Description and Operation CIRCUIT OPERATION Circuit E2 from fuse 5 in the junction block supplies voltage to the ash receiver lamp. Circuit E1 from the headlamp switch supplies voltage to fuse 5 in the junction block when the parking lamps or headlamps are on. Circuit Z1 provides ground for the lamp. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Description and Operation > Page 7673 Ash Tray Lamp: Testing and Inspection - Circuit E2 splices to supply voltage to illumination lamps in the instrument cluster. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Bulb > Component Information > Service and Repair Courtesy Lamp Bulb: Service and Repair REMOVAL and INSTALLATION 1. Disconnect and isolate the battery negative cable. 2. Insert a long, narrow, flat-bladed tool at the notch on the forward edge of the reading and courtesy lamp lens. 3. Gently pry the lens downward from the overhead console housing and pivot the lens down. It may be necessary to move the tool along the edge of the lens to free the lens from the console housing. 4. Remove the bulb holder by turning it counter-clockwise. 5. Remove the bulb from the bulb holder by pulling it straight out. 6. Install a new bulb by aligning its base with the socket in the bulb holder, and pushing the bulb firmly into place. 7. Pivot the lens back up into position and press upward firmly until it snaps into place. 8. Connect the battery negative cable. 9. Test the lamp by depressing the lens to check for proper lamp switching and lighting. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Description and Operation Glove Box Lamp: Description and Operation CIRCUIT OPERATION Circuit M1 from the Ignition Off Draw (IOD) fuse in cavity 12 in the junction block powers the glove box lamp. Ground for the lamp and switch is supplied on circuit Z1. When the glove box door is OPENED a ground path is completed through the lamp and switch. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp Switch > Component Information > Service and Repair Glove Box Lamp Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Open the glove box. Glove Box Lamp And Switch Remove/Install 3. Reach inside and above the glove box opening and unlatch and unplug the glove box lamp and switch wire harness connector. 4. From inside and above the glove box opening, squeeze the retaining tabs on the glove box lamp and switch housing together and push the unit out through the instrument panel mounting hole. 5. Reverse the removal procedures to install. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Description and Operation Daytime Running Lamp Control Unit: Description and Operation GENERAL INFORMATION The headlamps on vehicles sold in Canada, will go on when the ignition is turned ON. The module must also receive a signal from the engine controller. This provides a constant Lights On condition while the vehicle is rolling. The lamps illuminate at less than 50 % of normal intensity. CIRCUIT OPERATION On vehicles built for sale in Canada, the low-beam headlamps operate when the ignition switch is in the RUN position and the park brake switch OPEN. Circuit L20 from the headlamp switch connects to DRL module. Circuit L20 is HOT at all times and protected by a 15 Amp fuse located in the Power Distribution Center (PDC). The ignition RUN feed is provided on circuit L10. This circuit is protected by a 15 Amp fuse located in the junction block. Circuit L4 powers the low beams of the left and right headlamps. When the headlamp switch is OFF, the DRL module powers the low beams on circuit L4. When the headlamps are ON, the multi-function switch powers the low beams on circuit L4. Circuit L3 feeds the high beams of the headlamps and connects to DRL module. When the operator flashes the headlamps with the stalk of the multi-function switch, the DRL senses voltage on circuit L3. When it senses voltage on circuit L3, the DRL module stops supplying power to the low beams on circuit L4. The park brake switch input is provided on circuit G11. Circuit Z1 provides ground for the DRL module. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Description and Operation > Page 7687 Daytime Running Lamp Control Unit: Service and Repair REMOVAL The Daytime Running Lamp Module is located on the left inner fender. Daytime Running Lamp Module 1. Remove the bolt attaching the module to the inner fender. 2. Disconnect the electrical connector. INSTALLATION 1. Connect the electrical connector. 2. Insert the tab on the DRLM into the slot on the left inner fender. 3. Install the bolt attaching the module to the left inner fender. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Bulb > Component Information > Service and Repair Dome Lamp Bulb: Service and Repair REMOVAL 1. Using a small flat blade, pry the left side (driver's side) of the lamp lens downward. 2. Pull bulb from lamp. INSTALLATION 1. Install bulb in lamp. 2. Position lens on lamp and snap into place. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Bulb > Component Information > Service and Repair Fog/Driving Lamp Bulb: Service and Repair REMOVAL 1. Disengage fog lamp harness connector. Fog Lamp Bulb 2. Rotate bulb socket counterclockwise and pull from lamp to separate. 3. Grasp bulb and pull from socket. INSTALLATION CAUTION: Do not touch the bulb glass with fingers or other oily surfaces. Reduced bulb life will result. 1. Position bulb in socket and press into place. 2. Position bulb socket in lamp and rotate clockwise. 3. Connect fog lamp harness connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Power Distribution Center Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 7699 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Service and Repair Fog/Driving Lamp Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the cluster bezel as described. Lamp Switch Remove/Install 3. Squeeze the latch tabs on the back of the switch and remove the switch from the receptacle on the rear of the cluster bezel. 4. Reverse the removal procedures to install. Be certain that the switch latches are fully engaged in the cluster bezel receptacle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Description and Operation Hazard Warning Flasher: Description and Operation SYSTEM OPERATION Combination Flasher The combination flasher is a smart relay that functions as both the turn signal system and hazard warning system flasher. The combination flasher is designed to handle the current flow requirements of the factory-installed lighting. If supplemental lighting is added to the turn signal lamp circuits, such as when towing a trailer with lights, the combination flasher will automatically compensate. This allows the flash rate to remain the same, regardless of electrical load increases. However, if a bulb fails in the turn signal lamp circuits, the flash rate of the remaining bulbs in that circuit will increase to 120 flashes-per-minute, or higher. While the combination flasher shares the terminal orientation (footprint) of a International Standards Organization (ISO)-type relay, the internal circuitry is much different. The combination flasher contains active electronic integrated circuitry elements. Do not substitute any other relay for the combination flasher. The combination flasher cannot be repaired and, if faulty, it must be replaced. Also, because of the active electronic elements within the combination flasher, it cannot be tested with conventional automotive electrical test equipment. First, if the combination flasher is believed to be faulty, test the turn signal and hazard warning system circuits as described. Then, replace the combination flasher with a known good unit to confirm system operation. CIRCUIT OPERATION Circuit L9 from the Power Distribution Center (PDC) supplies battery voltage to the combination flasher. Circuit L19 from the flasher connects to the multi-function switch. When the operator depress the hazard flasher button, the multi-function switch connects circuit L19 to circuits L60, L61, L62, and L63. Circuit L62 powers the right rear turn signal/stop lamp. Circuit L63 powers the left rear turn signal/stop lamp. Circuit L60 powers the right indicator lamp. Circuit L61 powers the left indicator lamp. Circuit L60 also splices to feed the instrument cluster right indicator lamp. Circuit L61 splices to feed the instrument cluster left indicator lamp. Ground Circuit Circuit Z1 provides a ground for the parking lamps, turn/tail/stop lamps, and rear license plate lamps. Circuit Z1 also provides a ground for the back-up lamps and Center High Mounted Stop Lamps (CHMSL). Circuit Z1 also provide ground for the indicator lamps, and side marker lamps at the left inner fender panel. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Description and Operation > Page 7707 Hazard Warning Flasher: Testing and Inspection - Check the 20 Amp fuse located in cavity A of the PDC Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Description and Operation > Page 7708 Hazard Warning Flasher: Service and Repair REMOVAL and INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the fuse access panel by unsnapping it from the left end of the instrument panel. Combination Flasher Remove/Install 3. Unplug the combination flasher from the junction block. 4. Install the combination flasher by aligning the flasher terminals with the cavities in the junction block and pushing the flasher firmly into place. 5. Connect the battery negative cable. 6. Test the combination flasher operation. 7. Install the fuse access panel. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Description and Operation Hazard Warning Switch: Description and Operation SYSTEM OPERATION Multi-Function Switch Turn Signal Switch And Hazard Warning Switch The turn signal and hazard warning switches are integral to the multi-function switch assembly. The multi-function switch assembly is mounted to the left side of the steering column. This switch contains circuitry for the following functions: Turn signals - Hazard warning - Headlamp beam selection - Headlamp optical horn - Windshield wipers - Windshield washers. The information contained addresses only the multi-function switch functions for the turn signal and hazard warning circuits. However, the multi-function switch cannot be repaired. If any function of the switch is faulty, or if the switch is damaged, the entire switch assembly must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Description and Operation > Page 7712 Hazard Warning Switch: Testing and Inspection Perform the diagnosis of the hazard warning and/or turn signal systems as described before testing the multi-function switch. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Unplug the multi-function switch wire harness connector as described. Multi-Function Switch Continuity 2. Using an ohmmeter, perform the switch continuity checks at the switch terminals as shown in the Multi-Function Switch Continuity chart. 3. If the switch fails any of the continuity checks, replace the faulty switch. If the switch is OK, repair the lighting circuits as required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Description and Operation > Page 7713 Hazard Warning Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is so equipped, remove the tilt steering column lever. Steering Column Shrouds Remove/Install - Typical 3. Remove both the upper and lower shrouds from the steering column. 4. Remove the lower fixed column shroud. Multifunction Switch 5. Move the upper fixed column shroud to gain access to the rear of the multi-function switch. 6. Remove the multi-function switch tamper proof mounting screws (a Snap On tamper proof torx bit TTXR20B2 or equivalent is required). 7. Gently pull the switch away from the column. Loosen the wire harness connector screw. The screw will remain in the wire harness connector. 8. Unplug the wire harness connector from the multi-function switch. 9. Reverse the removal procedures to install. Tighten the fasteners as follows: - Multi-function switch wire harness connector screw - 2 N.m (17 in. lbs.) - Multi-function switch retaining screws - 2 N.m (17 in. lhs.). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair Headlamp Bulb: Service and Repair REMOVAL 1. Open hood. 2. With-in the engine compartment, remove retaining ring holding bulb to headlamp. Headlamp Bulb 3. Pull bulb socket from headlamp. 4. Grasp bulb and pull from socket. INSTALLATION CAUTION: Do not touch the bulb glass with fingers or other oily surfaces. Reduced bulb life will result. 1. Position bulb into socket and push into place. 2. Position bulb socket in headlamp. 3. Install retaining ring holding bulb to headlamp. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Description and Operation Headlamp Relay: Description and Operation SYSTEM OPERATION The headlamp relay is a International Standards Organization (ISO) micro-relay The terminal designations and functions are the same as a conventional ISO relay However, the micro-relay terminal orientation (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than on the conventional ISO relay. The headlamp relay is a electromechanical device that switches current to the headlamps when the high-line Central Timer Module (CTM) grounds the relay coil. The headlamp relay is located in the junction block, behind the fuse access panel on the left end of the instrument panel in the passenger compartment. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Description and Operation > Page 7721 Headlamp Relay: Testing and Inspection Relay Terminals The horn relay is located in the Power Distribution Center (PDC) in the engine compartment. The headlamp relay is located in the junction block in the passenger compartment. Each of these relays can be tested as described in the following procedure, however the circuits they are used in to vary. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Remove the relay from the PDC or junction block as described to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2. If not OK, replace the faulty relay. 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, test the relay circuits. If not OK, replace the faulty relay. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Description and Operation > Page 7722 Headlamp Relay: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the fuse access panel by unsnapping it from the left end of the instrument panel. Headlamp Relay Remove/Install 3. Unplug the headlamp relay from the junction block. 4. Install the headlamp relay by aligning the relay terminals with the cavities in the junction block and pushing the relay firmly into place. 5. Connect the battery negative cable. 6. Test the headlamp relay operation. 7. Install the fuse access panel. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Description and Operation Headlamp Switch: Description and Operation CIRCUIT OPERATION In Off Or Parking Lamp Position Circuit A3 from fuse 2 in the Power Distribution Center (PDC) supplies battery voltage to the headlamp switch. The headlamp switch has an internal circuit breaker. In the OFF and PARK positions, the headlamp switch feeds circuit L25 which connects to the multi-function switch. Circuit L25 powers the high-beam circuit when the operator flashes the headlamps with the turn signal stalk of the multi-function switch. The multi-function switch connects circuit L25 to circuit L3. Circuit L3 feeds the high beam of the headlamps. In On Position When the headlamp switch is in the ON position, the A3 circuit from the Power Distribution Center (PDC) connects to circuit L2. Circuit L2 connects to the multi-function switch and feeds the L4 circuit. The L4 circuit powers the low beam of the headlamps. When the operator selects high beam operation with the turn signal stalk of the multi-function switch, circuit L2 connects to the L3 circuit. Circuit L3 powers high beam operation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Description and Operation > Page 7726 Headlamp Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the cluster bezel as described. WARNING: IF THE HEADLAMP SWITCH WAS TURNED ON, WAIT FIVE MINUTES TO ALLOW THE CERAMIC DIMMER RESISTOR TO COOL. IF THE RESISTOR IS NOT ALLOWED TO COOL, IT CAN BURN YOUR FINGERS. Headlamp Switch And Bezel Remove/Install 3. Remove the three screws that secure the head- lamp switch bezel to the instrument panel. 4. Pull the headlamp switch and bezel out from the instrument panel far enough to unplug the two wire harness connectors. 5. Pull the headlamp switch control knob out to its On position stop. 6. Depress the headlamp switch knob and shaft release button on the top of the switch housing, and pull the switch knob and shaft out of the switch. 7. Remove the push nut retainer that secures the headlamp switch bezel to the switch mounting bracket. 8. Reverse the removal procedures to install. Tighten the headlamp switch mounting screws to 2.2 N.m (20 in. lbs.). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Description and Operation Hi-Beam Indicator Lamp: Description and Operation SYSTEM OPERATION The headlamp high beam indicator lamp gives an indication when the headlamp high beams are turned on. The lamp is controlled by the headlamp dimmer (multi-function) switch. One side of the high beam indicator lamp bulb is grounded at all times. The other side of the bulb receives a battery feed through the contacts of the dimmer switch when the multi-function switch stalk is actuated to turn on the headlamp high beams. CIRCUIT OPERATION Circuit L3 from the headlamps dimmer switch feeds the high beams of the headlamps and splices to circuit G34. Circuit G34 supplies power for the high beam indicator lamp. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Description and Operation > Page 7730 Hi-Beam Indicator Lamp: Testing and Inspection The diagnosis found here addresses an inoperative headlamp high beam indicator lamp condition. If the problem being diagnosed is related to inoperative headlamp high beams, refer to Lighting and Horns/Headlamp for diagnosis of the headlamp system. If no headlamp system problems are found, the following procedure will help locate an open in the high beam indicator lamp circuit. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Remove the instrument cluster bezel and the cluster as described. 2. Connect the battery negative cable. Turn the headlamps on and select the high beams with the multi-function switch stalk. Check for battery voltage at the high beam indicator driver circuit cavity of the cluster wire harness connector. If OK, replace the faulty bulb. If not OK, repair the open circuit to the headlamp dimmer (multi-function) switch as required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations Horn Relay: Locations Power Distribution Center Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 7735 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 7736 Horn Relay: Description and Operation SYSTEM OPERATION The horn relay is a International Standards Organization (ISO) micro-relay The terminal designations and functions are the same as a conventional ISO relay. However, the micro-relay terminal orientation (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than on the conventional ISO relay. The horn relay is a electromechanical device that switches current to the horn when the horn switch on the steering wheel is depressed. The horn relay is located in the Power Distribution Center (PDC), in the engine compartment. Refer to the PDC label for horn relay identification and location. If a problem is encountered with a continuously sounding horn, it can usually be quickly resolved by removing the horn relay from the PDC until further diagnosis is completed. The horn relay cannot be repaired and, if faulty, it must be replaced. The horn relay is a electromechanical device that switches current to the horn when the horn switch or the high-line Central Timer Module (CTM) grounds the relay coil. The horn relay is located in the Power Distribution Center, in the engine compartment. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 7737 Horn Relay: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Horn Relay Relay Test The horn relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the PDC label for horn relay identification and location. Remove the horn relay from the PDC as described to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2. If not OK, replace the faulty relay 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 3. If not OK, replace the faulty relay 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, see the Relay Circuit Test. If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity 30. is connected to battery voltage and should be hot at all times. If OK, go to Step 2. If not OK, repair the open circuit to the PDC 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 horn. There should be continuity between the cavity for relay terminal 87 and the horn relay output circuit cavity of the horn wire harness connector at all times. If OK, go to Step 4. If not OK, repair the open circuit to the horn as required. 4. The coil battery terminal (86) is connected to the electromagnet in the relay It is connected to battery voltage and should be hot at all times. Check for battery voltage at the cavity for relay terminal 86. If OK, go to Step 5. If not OK, repair the open circuit to the PDC fuse as required. 5. The coil ground terminal (85) is connected to the electromagnet in the relay It is grounded through the horn switch when the horn switch is depressed. It can also be grounded by the high-line Central Timer Module (CTM) in response to inputs from the Vehicle Theft Security System (VTSS) or the Remote Keyless Entry (RKE) system. Check for continuity to ground at the cavity for relay terminal 85. There should be continuity with the horn switch depressed, and no continuity with the horn switch released. If not OK, see the diagnosis for the Lighting and Horns/Horn/Horn Switch. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 7738 Horn Relay: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Power Distribution Center 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC for horn relay identification and location. 4. Unplug the horn relay from the PDC. 5. Install the horn relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 6. Install the PDC cover. 7. Connect the battery negative cable. 8. Test the relay operation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Description and Operation Horn Switch: Description and Operation SYSTEM OPERATION A center-blow, resistive membrane type horn switch is installed on the back side of the driver side airbag module trim cover in the center of the steering wheel. When the center area of the airbag trim cover is depressed, the horn switch completes a circuit to ground for the coil side of the horn relay The steering wheel and steering column must be properly grounded for the horn switch to function. The horn switch is only serviced as a part of the airbag module trim cover. If the horn switch should fail, or if the airbag is deployed, the airbag module trim cover and horn switch unit must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Description and Operation > Page 7742 Horn Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Remove the steering column opening cover and knee blocker. Check for continuity between the metal steering column jacket and a good ground. There should be continuity. If OK, go to Step 2. If not OK, refer to Steering and check for proper installation of the steering column mounting nuts. 2. Remove the driver side airbag module. Unplug the horn switch wire harness connectors. Remove the horn relay from the Power Distribution Center (PDC). Check for continuity between the steering column half of the horn switch feed wire harness connector and a good ground. There should be no continuity If OK, go to Step 3. If not OK, repair the short circuit as required. 3. Check for continuity between the steering column half of the horn switch feed wire harness connector and the horn relay control circuit cavity for the horn relay in the PDC. There should be continuity If OK, go to Step 4. If not OK, repair the open circuit as required. 4. Check for continuity between the horn switch feed wire and the horn switch ground wire on the airbag module. There should be no continuity If OK, go to Step 5. If not OK, replace the faulty horn switch. 5. Depress the center of the airbag module cover and check for continuity between the horn switch feed wire and the horn switch ground wire on the airbag module. There should be continuity If not OK, replace the faulty horn switch. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Description and Operation > Page 7743 Horn Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH A DRIVER SIDE AIRBAG, THE HORN SWITCH IS INTEGRAL TO THE AIRBAG MODULE TRIM COVER. SERVICE OF THIS COMPONENT SHOULD BE PERFORMED ONLY BY CHRYSLER-TRAINED AND AUTHORIZED DEALER SERVICE TECHNICIANS. FAILURE TO TAKE THE PROPER PRECAUTIONS OR TO FOLLOW THE PROPER PROCEDURES COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS FOR THE SERVICE PROCEDURES. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Description and Operation Key Cylinder Lamp: Description and Operation CIRCUIT OPERATION Power for the key in halo lamp is supplied on circuit M1. This is the Ignition-Off Draw (IOD) circuit and protected by a 10 Amp fuse located in the junction block. Ground for the lamp is controlled by the Central Timer Module (CTM) on circuit M50. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > License Plate Bulb > Component Information > Service and Repair License Plate Bulb: Service and Repair REMOVAL 1. From the underside of the bumper, grasp the bulb socket and rotate counter clockwise. 2. Pull bulb socket from lamp. 3. Grasp bulb and pull from socket. INSTALLATION 1. Position bulb in socket and press into place. 2. Position bulb socket in lamp and rotate clockwise to lock into place. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Map Light > Map Light Bulb > Component Information > Service and Repair > Overhead Console Reading Lamp Bulb Map Light Bulb: Service and Repair Overhead Console Reading Lamp Bulb REMOVAL 1. Insert a small flat blade between the front part of the lamp lens and overhead console. Carefully pry lens downward to release lens retaining tabs. 2. Separate lens. 3. Grasp bulb socket and remove from lamp. 4. Pull bulb from socket. INSTALLATION 1. Position bulb in socket and press into place. 2. Press bulb socket into lamp. 3. Replace lens by holding lens level and pushing rearward to seat retaining tabs. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Map Light > Map Light Bulb > Component Information > Service and Repair > Overhead Console Reading Lamp Bulb > Page 7756 Map Light Bulb: Service and Repair Reading Lamp and Courtesy Lamp Bulb REMOVAL and INSTALLATION 1. Disconnect and isolate the battery negative cable. 2. Insert a long, narrow, flat-bladed tool at the notch on the forward edge of the reading and courtesy lamp lens. 3. Gently pry the lens downward from the overhead console housing and pivot the lens down. It may be necessary to move the tool along the edge of the lens to free the lens from the console housing. 4. Remove the bulb holder by turning it counter-clockwise. 5. Remove the bulb from the bulb holder by pulling it straight out. 6. Install a new bulb by aligning its base with the socket in the bulb holder, and pushing the bulb firmly into place. 7. Pivot the lens back up into position and press upward firmly until it snaps into place. 8. Connect the battery negative cable. 9. Test the lamp by depressing the lens to check for proper lamp switching and lighting. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Marker Lamp > Marker Lamp Bulb > Component Information > Service and Repair Marker Lamp Bulb: Service and Repair REMOVAL 1. Remove park and turn signal lamp. Headlamp Bulb 2. Remove side marker lamp socket from back of lamp. 3. Pull side marker lamp bulb from socket. INSTALLATION 1. Install side marker lamp bulb in socket. 2. Install side marker lamp socket into back of lamp. 3. Install park/turn signal lamp. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Light Bulb > Component Information > Service and Repair Parking Light Bulb: Service and Repair REMOVAL 1. Remove park and turn signal lamp. Park And Turn Signal Lamp Bulb 2. Rotate bulb socket 1/4 turn counterclockwise and pull turn signal lamp socket from back of lamp. 3. Pull park and turn signal lamp bulb from socket. INSTALLATION 1. Install park and turn signal lamp bulb in socket. 2. Install park and turn signal lamp socket into back of lamp. 3. Install park/turn signal lamp. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Description and Operation Daytime Running Lamp Control Unit: Description and Operation GENERAL INFORMATION The headlamps on vehicles sold in Canada, will go on when the ignition is turned ON. The module must also receive a signal from the engine controller. This provides a constant Lights On condition while the vehicle is rolling. The lamps illuminate at less than 50 % of normal intensity. CIRCUIT OPERATION On vehicles built for sale in Canada, the low-beam headlamps operate when the ignition switch is in the RUN position and the park brake switch OPEN. Circuit L20 from the headlamp switch connects to DRL module. Circuit L20 is HOT at all times and protected by a 15 Amp fuse located in the Power Distribution Center (PDC). The ignition RUN feed is provided on circuit L10. This circuit is protected by a 15 Amp fuse located in the junction block. Circuit L4 powers the low beams of the left and right headlamps. When the headlamp switch is OFF, the DRL module powers the low beams on circuit L4. When the headlamps are ON, the multi-function switch powers the low beams on circuit L4. Circuit L3 feeds the high beams of the headlamps and connects to DRL module. When the operator flashes the headlamps with the stalk of the multi-function switch, the DRL senses voltage on circuit L3. When it senses voltage on circuit L3, the DRL module stops supplying power to the low beams on circuit L4. The park brake switch input is provided on circuit G11. Circuit Z1 provides ground for the DRL module. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Description and Operation > Page 7769 Daytime Running Lamp Control Unit: Service and Repair REMOVAL The Daytime Running Lamp Module is located on the left inner fender. Daytime Running Lamp Module 1. Remove the bolt attaching the module to the inner fender. 2. Disconnect the electrical connector. INSTALLATION 1. Connect the electrical connector. 2. Insert the tab on the DRLM into the slot on the left inner fender. 3. Install the bolt attaching the module to the left inner fender. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Power Distribution Center Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 7773 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Description and Operation Headlamp Relay: Description and Operation SYSTEM OPERATION The headlamp relay is a International Standards Organization (ISO) micro-relay The terminal designations and functions are the same as a conventional ISO relay However, the micro-relay terminal orientation (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than on the conventional ISO relay. The headlamp relay is a electromechanical device that switches current to the headlamps when the high-line Central Timer Module (CTM) grounds the relay coil. The headlamp relay is located in the junction block, behind the fuse access panel on the left end of the instrument panel in the passenger compartment. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Description and Operation > Page 7777 Headlamp Relay: Testing and Inspection Relay Terminals The horn relay is located in the Power Distribution Center (PDC) in the engine compartment. The headlamp relay is located in the junction block in the passenger compartment. Each of these relays can be tested as described in the following procedure, however the circuits they are used in to vary. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Remove the relay from the PDC or junction block as described to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2. If not OK, replace the faulty relay. 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, test the relay circuits. If not OK, replace the faulty relay. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Description and Operation > Page 7778 Headlamp Relay: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the fuse access panel by unsnapping it from the left end of the instrument panel. Headlamp Relay Remove/Install 3. Unplug the headlamp relay from the junction block. 4. Install the headlamp relay by aligning the relay terminals with the cavities in the junction block and pushing the relay firmly into place. 5. Connect the battery negative cable. 6. Test the headlamp relay operation. 7. Install the fuse access panel. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Power Distribution Center Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 7782 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 7783 Horn Relay: Description and Operation SYSTEM OPERATION The horn relay is a International Standards Organization (ISO) micro-relay The terminal designations and functions are the same as a conventional ISO relay. However, the micro-relay terminal orientation (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than on the conventional ISO relay. The horn relay is a electromechanical device that switches current to the horn when the horn switch on the steering wheel is depressed. The horn relay is located in the Power Distribution Center (PDC), in the engine compartment. Refer to the PDC label for horn relay identification and location. If a problem is encountered with a continuously sounding horn, it can usually be quickly resolved by removing the horn relay from the PDC until further diagnosis is completed. The horn relay cannot be repaired and, if faulty, it must be replaced. The horn relay is a electromechanical device that switches current to the horn when the horn switch or the high-line Central Timer Module (CTM) grounds the relay coil. The horn relay is located in the Power Distribution Center, in the engine compartment. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 7784 Horn Relay: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Horn Relay Relay Test The horn relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the PDC label for horn relay identification and location. Remove the horn relay from the PDC as described to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2. If not OK, replace the faulty relay 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 3. If not OK, replace the faulty relay 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, see the Relay Circuit Test. If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity 30. is connected to battery voltage and should be hot at all times. If OK, go to Step 2. If not OK, repair the open circuit to the PDC 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 horn. There should be continuity between the cavity for relay terminal 87 and the horn relay output circuit cavity of the horn wire harness connector at all times. If OK, go to Step 4. If not OK, repair the open circuit to the horn as required. 4. The coil battery terminal (86) is connected to the electromagnet in the relay It is connected to battery voltage and should be hot at all times. Check for battery voltage at the cavity for relay terminal 86. If OK, go to Step 5. If not OK, repair the open circuit to the PDC fuse as required. 5. The coil ground terminal (85) is connected to the electromagnet in the relay It is grounded through the horn switch when the horn switch is depressed. It can also be grounded by the high-line Central Timer Module (CTM) in response to inputs from the Vehicle Theft Security System (VTSS) or the Remote Keyless Entry (RKE) system. Check for continuity to ground at the cavity for relay terminal 85. There should be continuity with the horn switch depressed, and no continuity with the horn switch released. If not OK, see the diagnosis for the Lighting and Horns/Horn/Horn Switch. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 7785 Horn Relay: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Power Distribution Center 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC for horn relay identification and location. 4. Unplug the horn relay from the PDC. 5. Install the horn relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 6. Install the PDC cover. 7. Connect the battery negative cable. 8. Test the relay operation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations Trailer Lighting Relay: Locations Power Distribution Center Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 7789 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Specifications Backup Lamp Switch: Specifications Mounting .............................................................................................................................................. .................................................... 37 Nm (27 ft. lbs.) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Specifications > Page 7794 Transmission Connectors Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Component Locations Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Component Locations > Page 7799 Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7800 Pinout Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7801 Brake Light Switch: Description and Operation OPERATION The brake light switch is mounted on a bracket on the brake pedal support. The switch is self adjusting. An initial adjustment is only necessary when the switch has been replaced, or removed for service access to other components. The primary function of the switch is to turn on the stop lamps during braking. The switch is also used to send signals to components that must know when the brakes are applied, such as the Powertrain Control Module (PCM), which uses the signal to cancel speed control. The Controller Anti-Lock Brake (CAB) uses the brake switch signal to monitor brake pedal application. When the switch contacts open (brakes applied), the CAB receives the brake applied signal. The CAB then monitors the Anti-Lock Brake System (ABS) to anticipate the need for an ABS stop. CIRCUIT OPERATION Circuit K29 provides an input to the Powertrain Control Module (PCM). This circuit connects to cavity C24 of the PCM connector. On circuit K29 the Controller Antilock Brakes (CAB) senses when the brake pedal has been pressed. Circuit K29 also connects to the Powertrain Control Module (PCM) Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7802 Brake Light Switch: Testing and Inspection The brake light switch has a 12 volt feed circuit from the fuse block. Verity fuse is OK, then check the feed from the fuse block to the switch. If the switch is receiving a 12 volt supply, depress the brake pedal and check for voltage to the brake light circuit. If no voltage is present, the switch must be replaced. If the switch does not have 12 volts from the fuse block, check for continuity between the fuse block and switch and repair as necessary. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7803 Brake Light Switch: Adjustments 1. Push and hold brake pedal in applied position. 2. Push switch forward until fully seated against bracket. 3. Release brake pedal. 4. Lightly pull brake pedal rearward until master cylinder push rod bottoms against master cylinder internal stop. This action will set switch plunger at proper stroke length. CAUTION: Do not use excessive force to move the pedal rearward and do not overextend the pedal and push rod. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7804 Brake Light Switch: Service and Repair Stop Lamp Switch & Bracket REMOVAL 1. Disconnect switch harness. 2. Press and hold brake pedal in applied position. 3. Rotate switch counterclockwise about 30 degrees to align switch lock tab with notch in bracket. 4. Pull switch rearward out of mounting bracket and release brake pedal. INSTALLATION 1. Pull switch plunger all the way out to fully extended position. 2. Push switch plunger inward four detent positions (clicks). This is required preset position for switch installation. Plunger will extend approximately 0.55 inch out of housing at this setting. 3. Connect harness wires to switch. 4. Press and hold brake pedal down. 5. Install switch. Align tab on switch with notch in switch bracket. Then insert switch in bracket and turn it clockwise about 30 degrees to lock it in place. 6. Release brake pedal, then lightly pull pedal fully rearward. Pedal will adjust switch plunger to correct position as pedal is moved to rear. CAUTION: Do not use excessive force to move the pedal rearward for switch adjustment. Excessive force will damage the switch. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Service and Repair Combination Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is so equipped, remove the tilt steering column lever. Steering Column Shrouds Remove/Install - Typical 3. Remove both the upper and lower shrouds from the steering column. 4. Remove the lower fixed column shroud. Multifunction Switch 5. Move the upper fixed column shroud to gain access to the rear of the multi-function switch. 6. Remove the multi-function switch tamper proof mounting screws (a Snap On tamper proof torx bit TTXR20B2 or equivalent is required). 7. Gently pull the switch away from the column. Loosen the wire harness connector screw. The screw will remain in the wire harness connector. 8. Unplug the wire harness connector from the multi-function switch. 9. Reverse the removal procedures to install. Tighten the fasteners as follows: - Multi-function switch wire harness connector screw - 2 N.m (17 in. lbs.) - Multi-function switch retaining screws - 2 N.m (17 in. lhs.). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Service and Repair Fog/Driving Lamp Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the cluster bezel as described. Lamp Switch Remove/Install 3. Squeeze the latch tabs on the back of the switch and remove the switch from the receptacle on the rear of the cluster bezel. 4. Reverse the removal procedures to install. Be certain that the switch latches are fully engaged in the cluster bezel receptacle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Service and Repair Glove Box Lamp Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Open the glove box. Glove Box Lamp And Switch Remove/Install 3. Reach inside and above the glove box opening and unlatch and unplug the glove box lamp and switch wire harness connector. 4. From inside and above the glove box opening, squeeze the retaining tabs on the glove box lamp and switch housing together and push the unit out through the instrument panel mounting hole. 5. Reverse the removal procedures to install. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Description and Operation Hazard Warning Switch: Description and Operation SYSTEM OPERATION Multi-Function Switch Turn Signal Switch And Hazard Warning Switch The turn signal and hazard warning switches are integral to the multi-function switch assembly. The multi-function switch assembly is mounted to the left side of the steering column. This switch contains circuitry for the following functions: Turn signals - Hazard warning - Headlamp beam selection - Headlamp optical horn - Windshield wipers - Windshield washers. The information contained addresses only the multi-function switch functions for the turn signal and hazard warning circuits. However, the multi-function switch cannot be repaired. If any function of the switch is faulty, or if the switch is damaged, the entire switch assembly must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Description and Operation > Page 7817 Hazard Warning Switch: Testing and Inspection Perform the diagnosis of the hazard warning and/or turn signal systems as described before testing the multi-function switch. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Unplug the multi-function switch wire harness connector as described. Multi-Function Switch Continuity 2. Using an ohmmeter, perform the switch continuity checks at the switch terminals as shown in the Multi-Function Switch Continuity chart. 3. If the switch fails any of the continuity checks, replace the faulty switch. If the switch is OK, repair the lighting circuits as required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Description and Operation > Page 7818 Hazard Warning Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is so equipped, remove the tilt steering column lever. Steering Column Shrouds Remove/Install - Typical 3. Remove both the upper and lower shrouds from the steering column. 4. Remove the lower fixed column shroud. Multifunction Switch 5. Move the upper fixed column shroud to gain access to the rear of the multi-function switch. 6. Remove the multi-function switch tamper proof mounting screws (a Snap On tamper proof torx bit TTXR20B2 or equivalent is required). 7. Gently pull the switch away from the column. Loosen the wire harness connector screw. The screw will remain in the wire harness connector. 8. Unplug the wire harness connector from the multi-function switch. 9. Reverse the removal procedures to install. Tighten the fasteners as follows: - Multi-function switch wire harness connector screw - 2 N.m (17 in. lbs.) - Multi-function switch retaining screws - 2 N.m (17 in. lhs.). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation Headlamp Switch: Description and Operation CIRCUIT OPERATION In Off Or Parking Lamp Position Circuit A3 from fuse 2 in the Power Distribution Center (PDC) supplies battery voltage to the headlamp switch. The headlamp switch has an internal circuit breaker. In the OFF and PARK positions, the headlamp switch feeds circuit L25 which connects to the multi-function switch. Circuit L25 powers the high-beam circuit when the operator flashes the headlamps with the turn signal stalk of the multi-function switch. The multi-function switch connects circuit L25 to circuit L3. Circuit L3 feeds the high beam of the headlamps. In On Position When the headlamp switch is in the ON position, the A3 circuit from the Power Distribution Center (PDC) connects to circuit L2. Circuit L2 connects to the multi-function switch and feeds the L4 circuit. The L4 circuit powers the low beam of the headlamps. When the operator selects high beam operation with the turn signal stalk of the multi-function switch, circuit L2 connects to the L3 circuit. Circuit L3 powers high beam operation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Page 7822 Headlamp Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the cluster bezel as described. WARNING: IF THE HEADLAMP SWITCH WAS TURNED ON, WAIT FIVE MINUTES TO ALLOW THE CERAMIC DIMMER RESISTOR TO COOL. IF THE RESISTOR IS NOT ALLOWED TO COOL, IT CAN BURN YOUR FINGERS. Headlamp Switch And Bezel Remove/Install 3. Remove the three screws that secure the head- lamp switch bezel to the instrument panel. 4. Pull the headlamp switch and bezel out from the instrument panel far enough to unplug the two wire harness connectors. 5. Pull the headlamp switch control knob out to its On position stop. 6. Depress the headlamp switch knob and shaft release button on the top of the switch housing, and pull the switch knob and shaft out of the switch. 7. Remove the push nut retainer that secures the headlamp switch bezel to the switch mounting bracket. 8. Reverse the removal procedures to install. Tighten the headlamp switch mounting screws to 2.2 N.m (20 in. lbs.). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Description and Operation Horn Switch: Description and Operation SYSTEM OPERATION A center-blow, resistive membrane type horn switch is installed on the back side of the driver side airbag module trim cover in the center of the steering wheel. When the center area of the airbag trim cover is depressed, the horn switch completes a circuit to ground for the coil side of the horn relay The steering wheel and steering column must be properly grounded for the horn switch to function. The horn switch is only serviced as a part of the airbag module trim cover. If the horn switch should fail, or if the airbag is deployed, the airbag module trim cover and horn switch unit must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Description and Operation > Page 7826 Horn Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Remove the steering column opening cover and knee blocker. Check for continuity between the metal steering column jacket and a good ground. There should be continuity. If OK, go to Step 2. If not OK, refer to Steering and check for proper installation of the steering column mounting nuts. 2. Remove the driver side airbag module. Unplug the horn switch wire harness connectors. Remove the horn relay from the Power Distribution Center (PDC). Check for continuity between the steering column half of the horn switch feed wire harness connector and a good ground. There should be no continuity If OK, go to Step 3. If not OK, repair the short circuit as required. 3. Check for continuity between the steering column half of the horn switch feed wire harness connector and the horn relay control circuit cavity for the horn relay in the PDC. There should be continuity If OK, go to Step 4. If not OK, repair the open circuit as required. 4. Check for continuity between the horn switch feed wire and the horn switch ground wire on the airbag module. There should be no continuity If OK, go to Step 5. If not OK, replace the faulty horn switch. 5. Depress the center of the airbag module cover and check for continuity between the horn switch feed wire and the horn switch ground wire on the airbag module. There should be continuity If not OK, replace the faulty horn switch. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Description and Operation > Page 7827 Horn Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH A DRIVER SIDE AIRBAG, THE HORN SWITCH IS INTEGRAL TO THE AIRBAG MODULE TRIM COVER. SERVICE OF THIS COMPONENT SHOULD BE PERFORMED ONLY BY CHRYSLER-TRAINED AND AUTHORIZED DEALER SERVICE TECHNICIANS. FAILURE TO TAKE THE PROPER PRECAUTIONS OR TO FOLLOW THE PROPER PROCEDURES COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS FOR THE SERVICE PROCEDURES. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Description and Operation Turn Signal Switch: Description and Operation SYSTEM OPERATION Multi-Function Switch Turn Signal Switch And Hazard Warning Switch The turn signal and hazard warning switches are integral to the multi-function switch assembly. The multi-function switch assembly is mounted to the left side of the steering column. This switch contains circuitry for the following functions: Turn signals - Hazard warning - Headlamp beam selection - Headlamp optical horn - Windshield wipers - Windshield washers. The information contained addresses only the multi-function switch functions for the turn signal and hazard warning circuits. However, the multi-function switch cannot be repaired. If any function of the switch is faulty, or if the switch is damaged, the entire switch assembly must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Description and Operation > Page 7831 Turn Signal Switch: Testing and Inspection Perform the diagnosis of the hazard warning and/or turn signal systems as described before testing the multi-function switch. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Unplug the multi-function switch wire harness connector as described. Multi-Function Switch Continuity 2. Using an ohmmeter, perform the switch continuity checks at the switch terminals as shown in the Multi-Function Switch Continuity chart. 3. If the switch fails any of the continuity checks, replace the faulty switch. If the switch is OK, repair the lighting circuits as required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Tail Light Bulb > Component Information > Service and Repair Tail Light Bulb: Service and Repair REMOVAL 1. Remove screws from tail lamp. 2. Grasp lamp, firmly pull lamp rearward to disengage retaining studs. Tail, Stop, Turn Signal And Back-Up Lamp Bulbs 3. Remove sockets from tail lamp. 4. Pull bulb from socket. 5. Separate tail lamp from cargo box. INSTALLATION 1. Install bulb in socket. 2. Install socket in tail lamp. 3. Position tail lamp in cargo box, engage retaining studs and install screws. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations Trailer Lighting Relay: Locations Power Distribution Center Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 7839 Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Service and Repair Combination Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is so equipped, remove the tilt steering column lever. Steering Column Shrouds Remove/Install - Typical 3. Remove both the upper and lower shrouds from the steering column. 4. Remove the lower fixed column shroud. Multifunction Switch 5. Move the upper fixed column shroud to gain access to the rear of the multi-function switch. 6. Remove the multi-function switch tamper proof mounting screws (a Snap On tamper proof torx bit TTXR20B2 or equivalent is required). 7. Gently pull the switch away from the column. Loosen the wire harness connector screw. The screw will remain in the wire harness connector. 8. Unplug the wire harness connector from the multi-function switch. 9. Reverse the removal procedures to install. Tighten the fasteners as follows: - Multi-function switch wire harness connector screw - 2 N.m (17 in. lbs.) - Multi-function switch retaining screws - 2 N.m (17 in. lhs.). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Description and Operation Turn Signal Flasher: Description and Operation SYSTEM OPERATION Combination Flasher The combination flasher is a smart relay that functions as both the turn signal system and hazard warning system flasher. The combination flasher is designed to handle the current flow requirements of the factory-installed lighting. If supplemental lighting is added to the turn signal lamp circuits, such as when towing a trailer with lights, the combination flasher will automatically compensate. This allows the flash rate to remain the same, regardless of electrical load increases. However, if a bulb fails in the turn signal lamp circuits, the flash rate of the remaining bulbs in that circuit will increase to 120 flashes-per-minute, or higher. While the combination flasher shares the terminal orientation (footprint) of a International Standards Organization (ISO)-type relay, the internal circuitry is much different. The combination flasher contains active electronic integrated circuitry elements. Do not substitute any other relay for the combination flasher. The combination flasher cannot be repaired and, if faulty, it must be replaced. Also, because of the active electronic elements within the combination flasher, it cannot be tested with conventional automotive electrical test equipment. First, if the combination flasher is believed to be faulty, test the turn signal and hazard warning system circuits as described. Then, replace the combination flasher with a known good unit to confirm system operation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Description and Operation > Page 7847 Turn Signal Flasher: Service and Repair Combination Flasher Replacement REMOVAL and INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the fuse access panel by unsnapping it from the left end of the instrument panel. Combination Flasher Remove/Install 3. Unplug the combination flasher from the junction block. 4. Install the combination flasher by aligning the flasher terminals with the cavities in the junction block and pushing the flasher firmly into place. 5. Connect the battery negative cable. 6. Test the combination flasher operation. 7. Install the fuse access panel. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Indicator > Component Information > Description and Operation Turn Signal Indicator: Description and Operation SYSTEM OPERATION The left and right turn signal indicator lamps give an indication when the turn signal circuits are activated. The lamps are completely controlled by a hard-wired input to the instrument cluster from the turn signal and hazard warning (multi-function) switches. The lamps are grounded at all times and receive battery feed through the contacts of the multi-function switch when the turn signal lever (multi-function switch stalk) or hazard warning button are actuated to the On position. The instrument cluster circuitry does not perform a bulb test of these lamps. Turn Signal Indicator Lamp The turn signal indicator lamps are located in the instrument cluster. They flash with the exterior turn signal lamps to give the driver a visual indication that a turn signal or the hazard warning system is operating. For diagnosis and service of these lamps, refer to Lighting and Horns/Turn Signals CIRCUIT OPERATION Circuits L61 and L6O power the turn signal indicator lamps. Circuit L61 powers the left indicator lamp. Circuit L6O powers the right indicator lamp. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Indicator > Component Information > Description and Operation > Page 7851 Turn Signal Indicator: Testing and Inspection The diagnosis found here addresses an inoperative turn signal indicator lamp condition. For any other turn signal problem, refer to Lighting and Horns /Turn Signal and Lighting and Horns/Hazard Warning Systems for diagnosis. If no turn signal or hazard warning system problem is found, the following procedure will help locate a short or open in the indicator lamp circuit. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Remove the instrument cluster bezel and the cluster as described. 2. Connect the battery negative cable. Activate the hazard warning system by moving the hazard warning switch button to the On position. Check for battery voltage at the inoperative (right or left) turn signal circuit cavity of the cluster wire harness connector. There should be a switching (on and off) battery voltage signal. If OK, replace the faulty (right or left) indicator lamp bulb. If not OK, repair the open circuit to the turn signal/hazard warning (multi-function) switch as required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair > Park and Turn Signal Lamp Bulb Turn Signal Bulb: Service and Repair Park and Turn Signal Lamp Bulb REMOVAL 1. Remove park and turn signal lamp. Park And Turn Signal Lamp Bulb 2. Rotate bulb socket 1/4 turn counterclockwise and pull turn signal lamp socket from back of lamp. 3. Pull park and turn signal lamp bulb from socket. INSTALLATION 1. Install park and turn signal lamp bulb in socket. 2. Install park and turn signal lamp socket into back of lamp. 3. Install park/turn signal lamp. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair > Park and Turn Signal Lamp Bulb > Page 7857 Turn Signal Bulb: Service and Repair Tail, Stop, Turn Signal and Back-Up Lamp Bulb REMOVAL 1. Remove screws from tail lamp. 2. Grasp lamp, firmly pull lamp rearward to disengage retaining studs. Tail, Stop, Turn Signal And Back-Up Lamp Bulbs 3. Remove sockets from tail lamp. 4. Pull bulb from socket. 5. Separate tail lamp from cargo box. INSTALLATION 1. Install bulb in socket. 2. Install socket in tail lamp. 3. Position tail lamp in cargo box, engage retaining studs and install screws. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Description and Operation Turn Signal Switch: Description and Operation SYSTEM OPERATION Multi-Function Switch Turn Signal Switch And Hazard Warning Switch The turn signal and hazard warning switches are integral to the multi-function switch assembly. The multi-function switch assembly is mounted to the left side of the steering column. This switch contains circuitry for the following functions: Turn signals - Hazard warning - Headlamp beam selection - Headlamp optical horn - Windshield wipers - Windshield washers. The information contained addresses only the multi-function switch functions for the turn signal and hazard warning circuits. However, the multi-function switch cannot be repaired. If any function of the switch is faulty, or if the switch is damaged, the entire switch assembly must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Description and Operation > Page 7861 Turn Signal Switch: Testing and Inspection Perform the diagnosis of the hazard warning and/or turn signal systems as described before testing the multi-function switch. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Unplug the multi-function switch wire harness connector as described. Multi-Function Switch Continuity 2. Using an ohmmeter, perform the switch continuity checks at the switch terminals as shown in the Multi-Function Switch Continuity chart. 3. If the switch fails any of the continuity checks, replace the faulty switch. If the switch is OK, repair the lighting circuits as required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Lighting and Horns > Underhood Lamp > Underhood Light Bulb > Component Information > Service and Repair Underhood Light Bulb: Service and Repair REMOVAL 1. Disconnect the wire harness connector from the underhood lamp. 2. Rotate the bulb counter-clockwise and remove it from the lamp base socket. INSTALLATION 1. Insert a replacement bulb in the lamp base socket and rotate it clockwise. 2. Connect the wire harness connector to the lamp. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Description and Operation Power Window Switch: Description and Operation SYSTEM OPERATION The power windows are controlled by two-way momentary switches mounted in a bezel on the trim panel of each front door. A second power window switch on the left side allows the driver to control the passenger side window. The power windows will only operate when the ignition switch is in the On position. Both front door windows can be raised or lowered electrically by operating the power window switches. The switches control the battery and ground feeds to the power window motors. The power window switches cannot be repaired and, if faulty or damaged, they must be replaced. CIRCUIT OPERATION Driver Side Switch Circuit F21 supplies voltage to the right power window switch for raising and lowering the windows. When the drivers side switch is put in the DOWN position, the switch supplies voltage to circuit Q26. Circuit Q26 connects to the down side of the passenger side switch. Voltage passes through the passenger side switch to the window motor on circuit Q22. The ground path from the motor is on circuit Q12 back through the passenger side switch to circuit Q16, through the drivers side switch to ground on circuit Z1. When the drivers side switch is put in the UP position, the switch supplies voltage to circuit Q16. Circuit Q16 connects to the UP side of the passenger side switch. Voltage passes through the passenger's side switch to the window motor on circuit Q12. The ground path from the motor is on circuit Q22 back through the passenger's side switch to circuit Q26, through the drivers side switch to ground on circuit Z1. Passenger Side Switch Circuit F21 splices to supply voltage to the right window switch on the passenger side of the vehicle. When the passenger side switch is put in the DOWN position, the switch supplies voltage to the motor on circuit Q22. The ground path from the motor is on circuit Q12 back through the passenger side switch to circuit Q16, through the drivers side switch to ground on circuit Z1. In the UP position, the passenger side switch supplies voltage to the window motor on circuit Q12. The ground path from the motor is on circuit Q22 back through the passenger side switch to circuit Q26, through the drivers side switch to ground on circuit Z1. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Helpful Information Power Window Switch: Testing and Inspection Helpful Information - Check fuse E in the PDC. - Check the circuit breaker in cavity 20 of the junction block. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Helpful Information > Page 7873 Power Window Switch: Testing and Inspection Power Window Switch Test Before you proceed with this diagnosis, confirm proper circuit breaker operation. See the diagnosis for the Circuit Breaker. 1. Remove the switch from the trim panel as described. Carefully separate the wire harness connector from the switch body. Left Side Switch Continuity Right Side Switch Continuity 2. Check the switch continuity in each position, as shown in the charts. If OK, see the Power Window Motor diagnosis. If not OK, replace the faulty switch. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Page 7874 Power Window Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Power Window And Lock Switches Remove/Install 2. Using a wide flat-bladed tool such as a trim stick, gently pry the upper edge of the power lock and power window switch bezel to release the snap clip retainer that secures the bezel to the door trim panel. 3. Pull the switch bezel away from the door trim panel far enough to access the wire harness connectors. 4. Gently pry the locking tabs of the wire harness connectors away from the switches and carefully unplug the switches. 5. Using a wide flat-bladed tool such as a trim stick, gently pry the sides of the switch cavity on the back of the switch bezel to release the power window switch from the bezel. 6. Reverse the removal procedures to install. When installing the switch bezel to the door trim panel, insert the rear of the bezel into the trim panel opening, then push down on the front of the bezel until the retaining tab snaps into place. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Circuit Breaker > Component Information > Description and Operation Power Window Circuit Breaker: Description and Operation SYSTEM OPERATION An automatic resetting circuit breaker in the fuseblock module is used to protect the power window system circuit. The circuit breaker can protect the system from a short circuit, or from an overload condition caused by an obstructed or stuck window glass or regulator. The circuit breaker cannot be repaired and, if faulty, it must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Circuit Breaker > Component Information > Description and Operation > Page 7879 Power Window Circuit Breaker: Testing and Inspection 1. Locate the correct circuit breaker in the fuse- block module. Pull out the circuit breaker slightly, but be sure that the terminals still contact the terminals in the fuseblock module cavities. 2. Connect the negative lead of a 12-volt DC voltmeter to a good ground. 3. With the voltmeter positive lead, check both terminals of the circuit breaker for battery voltage. If only one terminal has battery voltage, the circuit breaker is faulty and must be replaced. If neither terminal has battery voltage, repair the open circuit from the Power Distribution Center (PDC) as required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Service and Repair Front Door Window Motor: Service and Repair REMOVAL 1. Raise the door window to its full up position. 2. Disconnect and isolate the battery negative cable. 3. Remove the power window switch as described. Inside Door Latch Release Handle Pocket Screw Remove/Install 4. Pull the inside door latch release handle to the open position and remove the screw in the release handle pocket that secures the door trim panel to the inside door handle bracket. Door Trim Panel Remove/Install 5. Remove the four screws that secure the door trim panel to the inner door. 6. To disengage the stepped retainers that secure the door trim panel to the inner door, gently pull the lower edge of the trim panel away from the door while lifting the panel upwards. 7. Pull the door trim panel away from the inner door far enough to access the inside door latch release linkage rod at the back of the inside door handle. 8. Unsnap the plastic retainer clip from the inside door handle end of the latch release linkage rod, and remove the rod end from the inside door handle. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Service and Repair > Page 7884 Door Trim Panel Wire Harness Connectors 9. On the driver side only, if the vehicle is so equipped, unplug the power mirror switch wire harness connector. 10. If the vehicle is so equipped, unplug the Infinity upper door speaker wire harness connector. 11. Remove the door trim panel and set it aside. 12. Pull the door watershield away from the inner door panel. 13. Lower the door glass far enough to access the glass lift channel nuts. Door Glass 14. Remove the nuts that secure the glass lift channel to the regulator arms. 15. Separate the glass and lift channel from the regulator arms. 16. Lift the glass to its fully-raised position and apply tape to secure the glass to the upper door frame. Power Window Regulator Remove/Install 17. Unplug the power window motor wire harness connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Service and Repair > Page 7885 Fig. 39 Power Regulator Bolts 18. Loosen the three bolts that secure the regulator to the keyed holes of the inner door panel. 19. Remove the three remaining bolts that secure the regulator to the inner door panel. 20. Remove the power window regulator and motor as a unit from the door through the lower access hole in the inner door panel. 21. Reverse the removal procedures to install. Tighten the regulator mounting bolts and the glass lift channel nuts to 9 N.m (80 in. lbs.). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Description and Operation Power Window Switch: Description and Operation SYSTEM OPERATION The power windows are controlled by two-way momentary switches mounted in a bezel on the trim panel of each front door. A second power window switch on the left side allows the driver to control the passenger side window. The power windows will only operate when the ignition switch is in the On position. Both front door windows can be raised or lowered electrically by operating the power window switches. The switches control the battery and ground feeds to the power window motors. The power window switches cannot be repaired and, if faulty or damaged, they must be replaced. CIRCUIT OPERATION Driver Side Switch Circuit F21 supplies voltage to the right power window switch for raising and lowering the windows. When the drivers side switch is put in the DOWN position, the switch supplies voltage to circuit Q26. Circuit Q26 connects to the down side of the passenger side switch. Voltage passes through the passenger side switch to the window motor on circuit Q22. The ground path from the motor is on circuit Q12 back through the passenger side switch to circuit Q16, through the drivers side switch to ground on circuit Z1. When the drivers side switch is put in the UP position, the switch supplies voltage to circuit Q16. Circuit Q16 connects to the UP side of the passenger side switch. Voltage passes through the passenger's side switch to the window motor on circuit Q12. The ground path from the motor is on circuit Q22 back through the passenger's side switch to circuit Q26, through the drivers side switch to ground on circuit Z1. Passenger Side Switch Circuit F21 splices to supply voltage to the right window switch on the passenger side of the vehicle. When the passenger side switch is put in the DOWN position, the switch supplies voltage to the motor on circuit Q22. The ground path from the motor is on circuit Q12 back through the passenger side switch to circuit Q16, through the drivers side switch to ground on circuit Z1. In the UP position, the passenger side switch supplies voltage to the window motor on circuit Q12. The ground path from the motor is on circuit Q22 back through the passenger side switch to circuit Q26, through the drivers side switch to ground on circuit Z1. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Helpful Information Power Window Switch: Testing and Inspection Helpful Information - Check fuse E in the PDC. - Check the circuit breaker in cavity 20 of the junction block. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Helpful Information > Page 7891 Power Window Switch: Testing and Inspection Power Window Switch Test Before you proceed with this diagnosis, confirm proper circuit breaker operation. See the diagnosis for the Circuit Breaker. 1. Remove the switch from the trim panel as described. Carefully separate the wire harness connector from the switch body. Left Side Switch Continuity Right Side Switch Continuity 2. Check the switch continuity in each position, as shown in the charts. If OK, see the Power Window Motor diagnosis. If not OK, replace the faulty switch. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Page 7892 Power Window Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Power Window And Lock Switches Remove/Install 2. Using a wide flat-bladed tool such as a trim stick, gently pry the upper edge of the power lock and power window switch bezel to release the snap clip retainer that secures the bezel to the door trim panel. 3. Pull the switch bezel away from the door trim panel far enough to access the wire harness connectors. 4. Gently pry the locking tabs of the wire harness connectors away from the switches and carefully unplug the switches. 5. Using a wide flat-bladed tool such as a trim stick, gently pry the sides of the switch cavity on the back of the switch bezel to release the power window switch from the bezel. 6. Reverse the removal procedures to install. When installing the switch bezel to the door trim panel, insert the rear of the bezel into the trim panel opening, then push down on the front of the bezel until the retaining tab snaps into place. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7898 Wiper Relay: Description and Operation SYSTEM OPERATION The intermittent wipe relay is a International Standards Organization (ISO) micro-relay The terminal designations and functions are the same as a conventional ISO relay. However, the micro-relay terminal orientation (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than on the conventional ISO relay The intermittent wipe relay is a electromechanical device that switches current to the windshield wiper motor or wiper motor park switch when the relay is energized or de-energized by the Central Timer Module (CTM) in response to the proper inputs from the windshield wiper (multi-function) switch. The intermittent wipe relay is located in the Power Distribution Center (PDC), in the engine compartment. Refer to the PDC label for relay identification and location. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7899 Wiper Relay: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Intermittent Wiper Relay Relay Test The intermittent wipe relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the PDC label for intermittent wipe relay identification and location. Remove the intermittent wipe relay from the PDC as described to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2. If not OK, replace the faulty relay. 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 3. If not OK, replace the faulty relay 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, see the Relay Circuit Test. If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to the wiper (multi-function) switch. There should be continuity between the cavity for relay terminal 30 and the two fused ignition switch output circuit cavities of the multi-function switch wire harness connector at all times. If OK, go to Step 2. If not OK, repair the open circuit(s) to the multi-function switch as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position. There should be continuity between the cavity for relay terminal 87A and the wiper park switch sense circuit cavities of the wiper motor wire harness connector and the 14-way Central Timer Module (CTM) wire harness connector at all times. If OK, go to Step 3. If not OK, repair the open circuit(s) to the wiper motor and CTM as required. 3. The relay normally open terminal (87) is connected to the common feed terminal (30) in the energized position. There should be battery voltage at the cavity for relay terminal 87 with the ignition switch in the On or Accessory positions. If OK, go to Step 4. If not OK, repair the open circuit to the ignition switch as required. 4. The coil battery terminal (86) is connected to the electromagnet in the relay. There should be battery voltage at the cavity for relay terminal 86 with the ignition switch in the On or Accessory positions. If OK, go to Step 5. If not OK, repair the open circuit to the ignition switch as required. 5. The coil ground terminal (85) is connected to the electromagnet in the relay. It is grounded by the CTM to energize the relay and cycle the wiper motor. Check for continuity between the cavity for relay terminal 85 and the intermittent wiper relay control circuit cavity of the 14-way CTM wire harness connector. There should be continuity. If OK, replace the faulty base version CTM; or, use a DRB scan tool and the proper Diagnostic Procedures for diagnosis of the high-line version CTM. If not OK, repair the open circuit to the CTM as required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7900 Wiper Relay: Service and Repair REMOVAL and INSTALLATION 1. Disconnect and isolate the battery negative cable. Power Distribution Center 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC cover for intermittent wipe relay identification and location. 4. Unplug the intermittent wipe relay from the PDC. 5. Install the intermittent wipe relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 6. Install the PDC cover. 7. Connect the battery negative cable. 8. Test the relay operation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Service and Repair Washer Fluid Level Switch: Service and Repair REMOVAL 1. Remove the washer reservoir as described. NOTE: The pivoting float of the washer fluid sensor must be in a horizontal position within the reservoir in order to be removed. With the reservoir empty and held in an upright position, the pivoting float will orient itself to the horizontal position when the sensor connector is pointed straight downwards. 2. Gently pry the washer fluid level sensor out of the rubber grommet seal. Care must be taken not to damage the reservoir. 3. Remove the rubber grommet seal from the reservoir and discard. 4. Reverse the removal procedures to install. Always use a new rubber grommet seal on the reservoir. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation Windshield Washer Switch: Description and Operation SYSTEM OPERATION Multi-Function Switch Wiper Switch And Washer Switch The windshield wiper and washer switches are contained in the multi-function switch assembly. The multi-function switch assembly is secured to the left side of the steering column. The multi-function switch contains circuitry for the following functions: Turn signals - Hazard warning - Headlamp beam selection - Headlamp optical horn - Windshield wipers - Windshield washers. The information contained addresses only the switch functions for the wiper and washer systems. However, the multi-function switch cannot be repaired. If any function of the multi-function switch is faulty, or if the switch is damaged, the entire switch assembly must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation > Page 7908 Windshield Washer Switch: Testing and Inspection Perform the diagnosis for the wiper system and/or washer system as described before testing the multi-function switch. WARNING: ON VEHICLES EQUIPPED WITH AN AIRBAG, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Unplug the multi-function switch wire harness connector as described. Multi-Function Switch Continuity 2. Using an ohmmeter, perform the switch continuity checks at the switch terminals as shown in the Multi-Function Switch Continuity chart. 3. If the switch fails any of the continuity checks, replace the faulty switch. If the switch is OK, repair the wiper system and/or washer system wire harness circuits as required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation > Page 7909 Windshield Washer Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is so equipped, remove the tilt steering column lever. Steering Column Shrouds Remove/Install - Typical 3. Remove both the upper and lower shrouds from the steering column. 4. Remove the lower fixed column shroud. Multi-Function Switch Connector - Typical 5. Move the upper fixed column shroud to gain access to the rear of the multi-function switch. 6. Remove the multi-function switch tamper proof mounting screws (a Snap On tamper proof torx bit TTXR20B2 or equivalent is required). 7. Gently pull the switch away from the column. Loosen the wire harness connector screw. The screw will remain in the wire harness connector. 8. Unplug the wire harness connector from the multi-function switch. 9. Reverse the removal procedures to install. Tighten the fasteners as follows: - Multi-function switch wire harness connector screw - 2 N.m (17 in. lbs.) - Multi-function switch retaining screws - 2 N.m (17 in. lbs.). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation Wiper Switch: Description and Operation SYSTEM OPERATION Multi-Function Switch Wiper Switch And Washer Switch The windshield wiper and washer switches are contained in the multi-function switch assembly. The multi-function switch assembly is secured to the left side of the steering column. The multi-function switch contains circuitry for the following functions: Turn signals - Hazard warning - Headlamp beam selection - Headlamp optical horn - Windshield wipers - Windshield washers. The information contained addresses only the switch functions for the wiper and washer systems. However, the multi-function switch cannot be repaired. If any function of the multi-function switch is faulty, or if the switch is damaged, the entire switch assembly must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 7913 Wiper Switch: Testing and Inspection Perform the diagnosis for the wiper system and/or washer system as described before testing the multi-function switch. WARNING: ON VEHICLES EQUIPPED WITH AN AIRBAG, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Unplug the multi-function switch wire harness connector as described. Multi-Function Switch Continuity 2. Using an ohmmeter, perform the switch continuity checks at the switch terminals as shown in the Multi-Function Switch Continuity chart. 3. If the switch fails any of the continuity checks, replace the faulty switch. If the switch is OK, repair the wiper system and/or washer system wire harness circuits as required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 7914 Wiper Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is so equipped, remove the tilt steering column lever. Steering Column Shrouds Remove/Install - Typical 3. Remove both the upper and lower shrouds from the steering column. 4. Remove the lower fixed column shroud. Multi-Function Switch Connector - Typical 5. Move the upper fixed column shroud to gain access to the rear of the multi-function switch. 6. Remove the multi-function switch tamper proof mounting screws (a Snap On tamper proof torx bit TTXR20B2 or equivalent is required). 7. Gently pull the switch away from the column. Loosen the wire harness connector screw. The screw will remain in the wire harness connector. 8. Unplug the wire harness connector from the multi-function switch. 9. Reverse the removal procedures to install. Tighten the fasteners as follows: - Multi-function switch wire harness connector screw - 2 N.m (17 in. lbs.) - Multi-function switch retaining screws - 2 N.m (17 in. lbs.). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Indicator > Component Information > Description and Operation Washer Fluid Level Indicator: Description and Operation SYSTEM OPERATION The low washer fluid warning lamp gives an indication when the fluid level in the washer fluid reservoir is too low. The instrument cluster circuitry lights the lamp for about two seconds when the ignition switch is turned to the On position as a bulb test. After the bulb test, the instrument cluster circuitry controls the lamp based upon a hard-wired input from the washer fluid level seasor The washer fluid level sensor uses a float in the reservoir to monitor the fluid level. The up and down action of the float opens or closes the switch within the washer fluid level sensor that provides a ground signal to the instrument cluster circuitry If the instrument cluster circuitry senses a ground input from the washer fluid level sensor for more than sixty seconds, it turns on the low fuel warning lamp and sends a chime tone request to the Central Timer Module (CTM). This helps to reduce the effects of fluid sloshing within the reservoir. This lamp also latches. Once the lamp has been turned on, it will remain on until washer fluid is added to the reservoir and the ignition switch is cycled. The standard washer fluid level sensor is mounted on the inboard side and near the front of the washer reservoir. A barbed nipple on the sensor is press-fit into a rubber grommet seal installed in a hole in the side of the reservoir. When the fluid level in the reservoir falls below the pivoting float on the sensor, the float changes position and closes the internal switch contacts of the sensor. Refer to Wiper and Washer Systems for diagnosis of the low washer fluid warning lamp and circuit, including the sensor. The washer fluid level sensor cannot be repaired. If faulty or damaged, the sensor unit must be replaced. CIRCUIT OPERATION Circuit G29 connects the low washer fluid switch to the warning lamp in the instrument cluster. When the low washer fluid switch closes, it connects circuits G29 and Z1. Circuit Z1 provides a ground path, illuminating the warning lamp. Circuit Z1 also provides ground for the windshield washer pump motor. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Indicator > Component Information > Description and Operation > Page 7918 Washer Fluid Level Indicator: Testing and Inspection The diagnosis found here addresses an inoperative low washer fluid warning lamp condition. If the problem being diagnosed is related to lamp accuracy, be certain to confirm that the problem is with the lamp or washer fluid level sensor and not with a damaged or empty washer fluid reservoir. Inspect the reservoir for proper fluid level and signs of damage or distortion that could affect sensor performance before you proceed with lamp diagnosis. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check the fuse in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Turn the ignition switch to the On position. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the ignition switch as required. 3. Turn the ignition switch to the Off position. Unplug the wire harness connector from the washer fluid level sensor. Install a jumper wire between the two cavities of the sensor wire harness connector. Turn the ignition switch to the On position. The low washer fluid warning lamp should light. Remove the jumper wire and the lamp should go off. If OK, replace the faulty washer fluid level sensor. If not OK, go to Step 4. 4. Turn the ignition switch to the Off position. Check for continuity between the ground circuit cavity of the washer fluid level sensor wire harness connector and a good ground. There should be continuity If OK, go to Step 5. If not OK, repair the open circuit as required. 5. Disconnect and isolate the battery negative cable. Remove the instrument cluster bezel and the cluster as described. The washer fluid level sensor wire harness connector is still unplugged. Check for continuity between the washer fluid level sense circuit cavity of the cluster wire harness connector and a good ground. There should be no continuity. If OK, go to Step 6. If not OK, repair the short circuit as required. 6. Check for continuity between the washer fluid level sense circuit cavities of the cluster wire harness connector and the washer fluid level sensor wire harness connector. There should be continuity. If OK, replace the faulty bulb. If not OK, repair the open circuit as required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Service and Repair Washer Fluid Level Switch: Service and Repair REMOVAL 1. Remove the washer reservoir as described. NOTE: The pivoting float of the washer fluid sensor must be in a horizontal position within the reservoir in order to be removed. With the reservoir empty and held in an upright position, the pivoting float will orient itself to the horizontal position when the sensor connector is pointed straight downwards. 2. Gently pry the washer fluid level sensor out of the rubber grommet seal. Care must be taken not to damage the reservoir. 3. Remove the rubber grommet seal from the reservoir and discard. 4. Reverse the removal procedures to install. Always use a new rubber grommet seal on the reservoir. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Technical Service Bulletins > Customer Interest for Windshield Washer Hose: > 08-05-97 > Feb > 97 > Windshield Wipers - Squeak During Operation Windshield Washer Hose: Customer Interest Windshield Wipers - Squeak During Operation NO: 08-05-97 GROUP: Electrical DATE: Feb. 14, 1997 SUBJECT: Squeak During Windshield Wiper Operation MODELS: 1997 (AN) Dakota NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT BEFORE NOV. 7, 1996 (MDH 1107XX). SYMPTOM/CONDITION: Squeak is heard during windshield wiper operation when the wiper blades near the top of their travel (blade near the A pillar). NOTE: THE SQUEAK IS MORE PREVALENT WHEN THE WINDSHIELD AND COWL AREAS ARE DRY. DIAGNOSIS: Open the hood, then with the ignition key to the RUN position. Turn the windshield wipers ON "low" speed. Observe the left windshield washer hose that feeds the left washer nozzle. The hose is visible through the cowl grille. If a squeak is heard when the wiper blade reaches or comes near the end of its travel (blade near the A pillar) and the windshield washer hose for the left washer nozzle appears to be contacting the wiper linkage, perform the following Repair Procedure. For a windshield wiper system squeaking condition other than described above such as a squeaking wiper linkage and pivot, refer to the 1997 Dakota Service Manual (Publication No. 81-370-7110), Group 8K for component service. REPAIR PROCEDURE: This bulletin involves securing the left washer hose to the cowl grille with a tie strap. 1. Remove the cowl to hood weatherstrip (Figure 1). 2. Gently pry the cowl plenum screen/grille up enough to be able to slide your fingers between the cowl and grille. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Technical Service Bulletins > Customer Interest for Windshield Washer Hose: > 08-05-97 > Feb > 97 > Windshield Wipers - Squeak During Operation > Page 7930 NOTE: IT MAY BE NECESSARY TO REMOVE THE LEFT COWL PLENUM SCREEN/GRILLE RETAINING PIN (PLASTIC RIVET) TO GAIN ACCESS TO THE WINDSHIELD WASHER HOSE (FIGURE 2). 3. To keep the windshield washer hose from contacting the wiper linkage, the hose must be secured to the third rib of the cowl plenum screen/grille (Figure 3) by a tie strap. 4. Insert a 6 to 8 in. BLACK tie strap through the screen/grille as shown in Figure 4. 5. Using your fingers, loop the tie strap around the washer hose and the third rib of the cowl plenum screen/grille (Figure 4). Insert the end of the tie strap into the strap retainer. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Technical Service Bulletins > Customer Interest for Windshield Washer Hose: > 08-05-97 > Feb > 97 > Windshield Wipers - Squeak During Operation > Page 7931 6. Gut the excess material from the tie strap (Figure 5). 7. Rotate the tie strap so that the end of the strap is facing down into the cowl. 8. Install the cowl to hood seal. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-43-10-94 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield Washer Hose: > 08-05-97 > Feb > 97 > Windshield Wipers - Squeak During Operation Windshield Washer Hose: All Technical Service Bulletins Windshield Wipers - Squeak During Operation NO: 08-05-97 GROUP: Electrical DATE: Feb. 14, 1997 SUBJECT: Squeak During Windshield Wiper Operation MODELS: 1997 (AN) Dakota NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT BEFORE NOV. 7, 1996 (MDH 1107XX). SYMPTOM/CONDITION: Squeak is heard during windshield wiper operation when the wiper blades near the top of their travel (blade near the A pillar). NOTE: THE SQUEAK IS MORE PREVALENT WHEN THE WINDSHIELD AND COWL AREAS ARE DRY. DIAGNOSIS: Open the hood, then with the ignition key to the RUN position. Turn the windshield wipers ON "low" speed. Observe the left windshield washer hose that feeds the left washer nozzle. The hose is visible through the cowl grille. If a squeak is heard when the wiper blade reaches or comes near the end of its travel (blade near the A pillar) and the windshield washer hose for the left washer nozzle appears to be contacting the wiper linkage, perform the following Repair Procedure. For a windshield wiper system squeaking condition other than described above such as a squeaking wiper linkage and pivot, refer to the 1997 Dakota Service Manual (Publication No. 81-370-7110), Group 8K for component service. REPAIR PROCEDURE: This bulletin involves securing the left washer hose to the cowl grille with a tie strap. 1. Remove the cowl to hood weatherstrip (Figure 1). 2. Gently pry the cowl plenum screen/grille up enough to be able to slide your fingers between the cowl and grille. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield Washer Hose: > 08-05-97 > Feb > 97 > Windshield Wipers - Squeak During Operation > Page 7937 NOTE: IT MAY BE NECESSARY TO REMOVE THE LEFT COWL PLENUM SCREEN/GRILLE RETAINING PIN (PLASTIC RIVET) TO GAIN ACCESS TO THE WINDSHIELD WASHER HOSE (FIGURE 2). 3. To keep the windshield washer hose from contacting the wiper linkage, the hose must be secured to the third rib of the cowl plenum screen/grille (Figure 3) by a tie strap. 4. Insert a 6 to 8 in. BLACK tie strap through the screen/grille as shown in Figure 4. 5. Using your fingers, loop the tie strap around the washer hose and the third rib of the cowl plenum screen/grille (Figure 4). Insert the end of the tie strap into the strap retainer. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield Washer Hose: > 08-05-97 > Feb > 97 > Windshield Wipers - Squeak During Operation > Page 7938 6. Gut the excess material from the tie strap (Figure 5). 7. Rotate the tie strap so that the end of the strap is facing down into the cowl. 8. Install the cowl to hood seal. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-43-10-94 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Description and Operation Windshield Washer Pump: Description and Operation SYSTEM OPERATION The washer pump and motor are mounted near the bottom of the washer reservoir. A barbed nipple on the pump housing is press-fit into a rubber grommet seal installed in a hole near the bottom of the reservoir. A permanently lubricated and sealed motor is coupled to a rotor-type pump. Washer fluid is gravity-fed from the reservoir to the pump. When the motor is energized, the pump pressurizes the washer fluid and forces it through the plumbing to the nozzles. The washer pump and motor unit cannot be repaired. If faulty, the entire washer pump and motor unit must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Description and Operation > Page 7942 Windshield Washer Pump: Service and Repair REMOVAL 1. Remove the washer reservoir as described. 2. Gently pry the washer pump out of the rubber grommet seal. Care must be taken not to damage the reservoir. 3. Remove the rubber grommet seal from the reservoir and discard. 4. Reverse the removal procedures to install. Always use a new rubber grommet seal on the reservoir. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Description and Operation Windshield Washer Reservoir: Description and Operation SYSTEM OPERATION The washer fluid reservoir is secured to the right side of the dash panel and the right inner fender shield in the engine compartment. The washer pump and motor unit has a barbed nipple, which is press-fit into a rubber grommet seal inserted in a hole near the bottom of the reservoir. The washer reservoir has a snap-fit filler cap with a rubber gasket. The cap hinges on and is secured to a molded-in hook formation on the reservoir behind the filler neck. The reservoir also has a provision for a washer fluid level sensor. The reservoir and filler cap are each available for service. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Description and Operation > Page 7946 Windshield Washer Reservoir: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the engine air filter housing. Washer System 3. Remove the screw that secures the reservoir to the inner fender shield. 4. Remove the two screws that secure the reservoir to the cowl plenum panel. 5. Move the reservoir far enough to access the washer pump. 6. Unplug the wire harness connectors from the washer pump and the washer fluid level sensor. 7. Remove the washer hose from the washer pump and drain the washer fluid from the reservoir into a clean container for reuse. 8. Remove the reservoir from the vehicle. 9. Reverse the removal procedures to install. Tighten the reservoir mounting screws to 2.7 N.m (24 in. lbs.). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Description and Operation Windshield Washer Spray Nozzle: Description and Operation SYSTEM OPERATION Washer Nozzle And Plumbing Pressurized washer fluid is fed through a single hose, attached to a barbed nipple on the washer pump. The hose is routed through a grommet inserted in a hole in the cowl plenum panel to an in-line fitting located in the cowl plenum area, beneath the cowl plenum cover/grille panel. A hose from the in-line fitting in the cowl plenum is routed through clips molded into the underside of the cowl plenum cover/grille panel to a Y fitting near the passenger side washer nozzle. Hoses from the Y fitting are routed to the two washer nozzles, which are snap-fit into openings in the cowl plenum cover/grille panel. The two fluidic washer nozzles are not adjustable. The nozzles and hose fittings cannot be repaired and, if faulty or damaged, they must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Description and Operation > Page 7950 Windshield Washer Spray Nozzle: Service and Repair REMOVAL 1. Remove the cowl plenum cover/grille panel. See Wiper and Washer Systems/Wiper Motor for the procedures. 2. From the underside of the cowl plenum cover/ grille panel, disconnect the washer hose from the nozzle fitting. 3. From the underside of the cowl plenum coven grille panel, compress the retaining tabs of the washer nozzle and push the nozzle out through the top of the panel. 4. Reverse the removal procedures to install Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation Windshield Washer Switch: Description and Operation SYSTEM OPERATION Multi-Function Switch Wiper Switch And Washer Switch The windshield wiper and washer switches are contained in the multi-function switch assembly. The multi-function switch assembly is secured to the left side of the steering column. The multi-function switch contains circuitry for the following functions: Turn signals - Hazard warning - Headlamp beam selection - Headlamp optical horn - Windshield wipers - Windshield washers. The information contained addresses only the switch functions for the wiper and washer systems. However, the multi-function switch cannot be repaired. If any function of the multi-function switch is faulty, or if the switch is damaged, the entire switch assembly must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation > Page 7954 Windshield Washer Switch: Testing and Inspection Perform the diagnosis for the wiper system and/or washer system as described before testing the multi-function switch. WARNING: ON VEHICLES EQUIPPED WITH AN AIRBAG, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Unplug the multi-function switch wire harness connector as described. Multi-Function Switch Continuity 2. Using an ohmmeter, perform the switch continuity checks at the switch terminals as shown in the Multi-Function Switch Continuity chart. 3. If the switch fails any of the continuity checks, replace the faulty switch. If the switch is OK, repair the wiper system and/or washer system wire harness circuits as required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation > Page 7955 Windshield Washer Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is so equipped, remove the tilt steering column lever. Steering Column Shrouds Remove/Install - Typical 3. Remove both the upper and lower shrouds from the steering column. 4. Remove the lower fixed column shroud. Multi-Function Switch Connector - Typical 5. Move the upper fixed column shroud to gain access to the rear of the multi-function switch. 6. Remove the multi-function switch tamper proof mounting screws (a Snap On tamper proof torx bit TTXR20B2 or equivalent is required). 7. Gently pull the switch away from the column. Loosen the wire harness connector screw. The screw will remain in the wire harness connector. 8. Unplug the wire harness connector from the multi-function switch. 9. Reverse the removal procedures to install. Tighten the fasteners as follows: - Multi-function switch wire harness connector screw - 2 N.m (17 in. lbs.) - Multi-function switch retaining screws - 2 N.m (17 in. lbs.). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Description and Operation Wiper Arm: Description and Operation SYSTEM OPERATION All Dakota truck models have two 50.8-centimeter (20-inch) windshield wiper blades with replaceable rubber elements (squeegees). These wiper blades include an anti-lift feature. The wiper blades and squeegees must be oriented correctly When installed on the wiper arms for the anti-lift feature to be effective. See the Wiper and Washer Systems/Wiper Blade and Element Removal and Installation procedures for more information. Caution should be exercised to protect the rubber squeegees from any petroleum-based cleaners or contaminants, which will rapidly deteriorate the rubber. If the squeegees are damaged, worn or contaminated, they must be replaced. Wiper squeegees exposed to the elements for a long time tend to lose their wiping effectiveness. Periodic cleaning of the squeegees is suggested to remove deposits of salt and road film. The wiper blades arms, and windshield should be cleaned with a sponge or cloth and windshield washer solvent, a mild detergent, or a non-abrasive cleaner. If the squeegees continue to streak or smear, they should be replaced. The blades are mounted to two spring-loaded wiper arms. The spring tension of the wiper arms controls the pressure applied to the blades on the glass. The wiper arms are secured by a nut to each of the two wiper pivots on the cowl plenum cover/grille panel at the base of the windshield. The wiper arms and blades cannot be adjusted or repaired. If faulty or damaged, they must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Description and Operation > Page 7959 Wiper Arm: Service and Repair REMOVAL and INSTALLATION 1. Open the hood. Wiper Arm Remove/Install 2. Unsnap the wiper arm pivot cover by lifting it at the pivot end of the arm. 3. Remove the pivot cover by pulling it straight out from where it snaps into the wiper arm hinge. 4. Remove the nut that secures the wiper arm to the wiper pivot. Wiper Arm Puller 5. Use a battery terminal puller to remove the wiper arm from the wiper pivot. Wiper Arm Installation Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Description and Operation > Page 7960 6. Install the arm and blade with the wiper motor in the Park position. Mount the arms on the pivot shafts so that the front and rear edges of the wiper blade are aligned with the wiper alignment lines concealed in the upper margin of the lower windshield blackout area, ± 15 mm (± 0.59 in.). See the Wiper and Washer Systems/Wiper Arm Installation illustration. 7. Install the wiper arm pivot nuts and tighten to 24 N.m (212 in. lbs.). 8. Operate the wipers with the windshield glass wet, then turn the wiper switch to the Off position. Check for the correct wiper arm positioning and readjust if required. 9. Snap the pivot covers back onto the wiper arms. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Customer Interest: > 23-014-06 > Mar > 06 > Wipers/Washers - Wipers Smear or Streak Windshield Wiper Blade: Customer Interest Wipers/Washers - Wipers Smear or Streak Windshield NUMBER: 23-014-06 GROUP: Body DATE: March 8, 2006 SUBJECT: Windshield Wiper Blade/Element Maintenance MODELS: All All All Chrysler Group Vehicles DISCUSSION: Windshield wiper blades/elements are frequently replaced unnecessarily. Because of the environmental conditions vehicles can be operated in, a film can build up on both the windshield and the windshield wiper elements that will cause poor cleaning/streaking of the windshield, and in some instances, a chattering condition as the wipers blades travel across the windshield. Replacement of the wiper blades/elements is normally NOT required to correct streaking issues. A simple NORMAL MAINTENANCE cleaning of the wiper blades/elements and windshield is all that is required. If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper blades/elements is obvious, the following steps should be performed: 1. Use a soft cloth or sponge & squeegee and MOPAR Windshield Washer Solvent (p/n 04318067AB, 16 Oz. bottle or p/n 04318068AB, 32 Oz. bottle), MOPAR Glass Cleaner (p/n 04897623AB, 16 Oz. bottle) or a solution of 50/50 alcohol and water, to wash the windshield. 2. Raise the wiper blades off the glass and clean the wiper blade elements (rubber insert) with MOPAR Windshield Washer Solvent or a solution of 50/50 alcohol and water and a soft cloth, paper towel or sponge. 3. Return the wiper blades to their normal operating position and function the washer system. If the wiper blades/elements are not streaking the windshield or chattering, replacing the blade assembly(ies) is not necessary. If the wipe pattern is still objectionable, repeat step 2 several times. If the wipe pattern is still objectionable, replace the wiper blades/elements. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 23-014-06 > Mar > 06 > Wipers/Washers - Wipers Smear or Streak Windshield Wiper Blade: All Technical Service Bulletins Wipers/Washers - Wipers Smear or Streak Windshield NUMBER: 23-014-06 GROUP: Body DATE: March 8, 2006 SUBJECT: Windshield Wiper Blade/Element Maintenance MODELS: All All All Chrysler Group Vehicles DISCUSSION: Windshield wiper blades/elements are frequently replaced unnecessarily. Because of the environmental conditions vehicles can be operated in, a film can build up on both the windshield and the windshield wiper elements that will cause poor cleaning/streaking of the windshield, and in some instances, a chattering condition as the wipers blades travel across the windshield. Replacement of the wiper blades/elements is normally NOT required to correct streaking issues. A simple NORMAL MAINTENANCE cleaning of the wiper blades/elements and windshield is all that is required. If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper blades/elements is obvious, the following steps should be performed: 1. Use a soft cloth or sponge & squeegee and MOPAR Windshield Washer Solvent (p/n 04318067AB, 16 Oz. bottle or p/n 04318068AB, 32 Oz. bottle), MOPAR Glass Cleaner (p/n 04897623AB, 16 Oz. bottle) or a solution of 50/50 alcohol and water, to wash the windshield. 2. Raise the wiper blades off the glass and clean the wiper blade elements (rubber insert) with MOPAR Windshield Washer Solvent or a solution of 50/50 alcohol and water and a soft cloth, paper towel or sponge. 3. Return the wiper blades to their normal operating position and function the washer system. If the wiper blades/elements are not streaking the windshield or chattering, replacing the blade assembly(ies) is not necessary. If the wipe pattern is still objectionable, repeat step 2 several times. If the wipe pattern is still objectionable, replace the wiper blades/elements. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiper Blade: > 08-05-97 > Feb > 97 > Windshield Wipers - Squeak During Operation Wiper Motor Linkage: All Technical Service Bulletins Windshield Wipers - Squeak During Operation NO: 08-05-97 GROUP: Electrical DATE: Feb. 14, 1997 SUBJECT: Squeak During Windshield Wiper Operation MODELS: 1997 (AN) Dakota NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT BEFORE NOV. 7, 1996 (MDH 1107XX). SYMPTOM/CONDITION: Squeak is heard during windshield wiper operation when the wiper blades near the top of their travel (blade near the A pillar). NOTE: THE SQUEAK IS MORE PREVALENT WHEN THE WINDSHIELD AND COWL AREAS ARE DRY. DIAGNOSIS: Open the hood, then with the ignition key to the RUN position. Turn the windshield wipers ON "low" speed. Observe the left windshield washer hose that feeds the left washer nozzle. The hose is visible through the cowl grille. If a squeak is heard when the wiper blade reaches or comes near the end of its travel (blade near the A pillar) and the windshield washer hose for the left washer nozzle appears to be contacting the wiper linkage, perform the following Repair Procedure. For a windshield wiper system squeaking condition other than described above such as a squeaking wiper linkage and pivot, refer to the 1997 Dakota Service Manual (Publication No. 81-370-7110), Group 8K for component service. REPAIR PROCEDURE: This bulletin involves securing the left washer hose to the cowl grille with a tie strap. 1. Remove the cowl to hood weatherstrip (Figure 1). 2. Gently pry the cowl plenum screen/grille up enough to be able to slide your fingers between the cowl and grille. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiper Blade: > 08-05-97 > Feb > 97 > Windshield Wipers - Squeak During Operation > Page 7979 NOTE: IT MAY BE NECESSARY TO REMOVE THE LEFT COWL PLENUM SCREEN/GRILLE RETAINING PIN (PLASTIC RIVET) TO GAIN ACCESS TO THE WINDSHIELD WASHER HOSE (FIGURE 2). 3. To keep the windshield washer hose from contacting the wiper linkage, the hose must be secured to the third rib of the cowl plenum screen/grille (Figure 3) by a tie strap. 4. Insert a 6 to 8 in. BLACK tie strap through the screen/grille as shown in Figure 4. 5. Using your fingers, loop the tie strap around the washer hose and the third rib of the cowl plenum screen/grille (Figure 4). Insert the end of the tie strap into the strap retainer. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiper Blade: > 08-05-97 > Feb > 97 > Windshield Wipers - Squeak During Operation > Page 7980 6. Gut the excess material from the tie strap (Figure 5). 7. Rotate the tie strap so that the end of the strap is facing down into the cowl. 8. Install the cowl to hood seal. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-43-10-94 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiper Blade: > 08-05-97 > Feb > 97 > Windshield Wipers - Squeak During Operation > Page 7986 NOTE: IT MAY BE NECESSARY TO REMOVE THE LEFT COWL PLENUM SCREEN/GRILLE RETAINING PIN (PLASTIC RIVET) TO GAIN ACCESS TO THE WINDSHIELD WASHER HOSE (FIGURE 2). 3. To keep the windshield washer hose from contacting the wiper linkage, the hose must be secured to the third rib of the cowl plenum screen/grille (Figure 3) by a tie strap. 4. Insert a 6 to 8 in. BLACK tie strap through the screen/grille as shown in Figure 4. 5. Using your fingers, loop the tie strap around the washer hose and the third rib of the cowl plenum screen/grille (Figure 4). Insert the end of the tie strap into the strap retainer. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiper Blade: > 08-05-97 > Feb > 97 > Windshield Wipers - Squeak During Operation > Page 7987 6. Gut the excess material from the tie strap (Figure 5). 7. Rotate the tie strap so that the end of the strap is facing down into the cowl. 8. Install the cowl to hood seal. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-43-10-94 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Page 7988 Wiper Blade: Description and Operation SYSTEM OPERATION All Dakota truck models have two 50.8-centimeter (20-inch) windshield wiper blades with replaceable rubber elements (squeegees). These wiper blades include an anti-lift feature. The wiper blades and squeegees must be oriented correctly When installed on the wiper arms for the anti-lift feature to be effective. See the Wiper and Washer Systems/Wiper Blade and Element Removal and Installation procedures for more information. Caution should be exercised to protect the rubber squeegees from any petroleum-based cleaners or contaminants, which will rapidly deteriorate the rubber. If the squeegees are damaged, worn or contaminated, they must be replaced. Wiper squeegees exposed to the elements for a long time tend to lose their wiping effectiveness. Periodic cleaning of the squeegees is suggested to remove deposits of salt and road film. The wiper blades arms, and windshield should be cleaned with a sponge or cloth and windshield washer solvent, a mild detergent, or a non-abrasive cleaner. If the squeegees continue to streak or smear, they should be replaced. The blades are mounted to two spring-loaded wiper arms. The spring tension of the wiper arms controls the pressure applied to the blades on the glass. The wiper arms are secured by a nut to each of the two wiper pivots on the cowl plenum cover/grille panel at the base of the windshield. The wiper arms and blades cannot be adjusted or repaired. If faulty or damaged, they must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Page 7989 Wiper Blade: Service and Repair REMOVAL and INSTALLATION The wiper blade and element are an anti-lift design, so as to resist the effects of air lifting the blade and element off the windshield glass in high winds or at highway speeds. However, in order for this feature to be effective, the wiper blades and elements must be properly oriented on the windshield. NOTE: The notched retainer end of the wiper element should always be oriented towards the end of the wiper blade that is nearest to the wiper pivot. To remove the wiper blade and/or element, proceed as follows: 1. Turn the wiper/washer switch to the On position. By turning the ignition switch to the On and Off positions, cycle the wiper blades to a convenient working location on the windshield. 2. Lift the wiper arm to raise the wiper blade and element off of the windshield glass. 3. Remove the wiper blade from the wiper arm, or the wiper element from the wiper blade as follows: Wiper Blade Remove/Install - Typical a. To remove the wiper blade from the wiper arm, push the release tab under the arm tip and slide the blade away from the tip towards the pivot end of the arm. b. To remove the wiper element from the wiper blade, pinch the notched retainer (pivot) end of the wiper element tightly between the thumb and fore-finger. Then, pull the element firmly towards the wiper pivot until the notched retainer of the wiper element clears the wiper blade claw. Once the notched retainer is released from the claw, the element will slide easily out of the remaining claws. 4. Install the wiper blade on the wiper arm, or the wiper element in the wiper blade as follows: a. To install the wiper blade on the wiper arm, slide the blade retainer into the U-shaped formation on the tip of the wiper arm until the release tab snaps into its locked position. Be certain that the notched retainer for the wiper element is oriented towards the end of the wiper blade that is nearest to the wiper pivot. b. To install the wiper element in the wiper blade, start at the wiper pivot end of the blade and slide the element through each pair of wiper blade claws. The element is fully installed when the notched retainer on the wiper element is engaged with the claws on the wiper pivot end of the wiper blade. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Description and Operation Wiper Motor: Description and Operation SYSTEM OPERATION The two-speed permanent magnet wiper motor has an integral transmission and park switch. The motor is secured to the wiper linkage and pivot module bracket with three screws. The wiper motor output shaft passes through a hole in the module bracket, where a nut secures the wiper motor crank arm to the output shaft. Wiper speed is controlled by current flow to the appropriate set of brushes. The wiper motor completes its wipe cycle when the wiper/washer (multi-function) switch is turned to the Off position, and parks the blades in the lowest portion of the wipe pattern. The wiper linkage, pivots, bushings, mounting bracket, and motor are only serviced as a complete unit. If any part of this assembly is faulty or damaged, the entire wiper module must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Description and Operation > Page 7993 Wiper Motor: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the wiper arms as described. Cowl Plenum Cover/Grille Panel Weatherstrip 3. Remove the weatherstrip along the front edge of cowl plenum cover/grille panel and the cowl plenum panel. Cowl Plenum Cover/Grille Panel Remove/Install 4. Remove the four plastic nuts that secure the cowl plenum cover/grille panel to the studs on the cowl top panel near the base of the windshield. 5. Remove the two plastic rivets that secure each side of the cowl plenum cover/grille panel to the cowl plenum panel and the cowl top panel. 6. Lift the cowl plenum cover/grille panel from the vehicle far enough to access the windshield washer and vacuum plumbing near the right end of the cowl plenum. 7. Disconnect the windshield washer supply hose at the in-line connector. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Description and Operation > Page 7994 Vacuum Reservoir 8. Disconnect the vacuum supply hose from the vacuum reservoir, which is secured under the right end of the cowl plenum cover/grille panel. 9. Remove the cowl plenum cover/grille panel from the vehicle and set it aside. Wiper Module Remove/Install 10. Remove the four screws that secure the wiper module to the cowl plenum panel. 11. Move the wiper module as required to access the wiper motor wire harness connector. 12. Unplug the wiper motor wire harness connector. 13. Remove the wiper module from the cowl plenum. 14. Reverse the removal procedures to install. Tighten the wiper module mounting screws to 8 N.m (72 in. lbs.). Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Technical Service Bulletins > Customer Interest for Wiper Motor Linkage: > 08-05-97 > Feb > 97 > Windshield Wipers - Squeak During Operation Wiper Motor Linkage: Customer Interest Windshield Wipers - Squeak During Operation NO: 08-05-97 GROUP: Electrical DATE: Feb. 14, 1997 SUBJECT: Squeak During Windshield Wiper Operation MODELS: 1997 (AN) Dakota NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT BEFORE NOV. 7, 1996 (MDH 1107XX). SYMPTOM/CONDITION: Squeak is heard during windshield wiper operation when the wiper blades near the top of their travel (blade near the A pillar). NOTE: THE SQUEAK IS MORE PREVALENT WHEN THE WINDSHIELD AND COWL AREAS ARE DRY. DIAGNOSIS: Open the hood, then with the ignition key to the RUN position. Turn the windshield wipers ON "low" speed. Observe the left windshield washer hose that feeds the left washer nozzle. The hose is visible through the cowl grille. If a squeak is heard when the wiper blade reaches or comes near the end of its travel (blade near the A pillar) and the windshield washer hose for the left washer nozzle appears to be contacting the wiper linkage, perform the following Repair Procedure. For a windshield wiper system squeaking condition other than described above such as a squeaking wiper linkage and pivot, refer to the 1997 Dakota Service Manual (Publication No. 81-370-7110), Group 8K for component service. REPAIR PROCEDURE: This bulletin involves securing the left washer hose to the cowl grille with a tie strap. 1. Remove the cowl to hood weatherstrip (Figure 1). 2. Gently pry the cowl plenum screen/grille up enough to be able to slide your fingers between the cowl and grille. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Technical Service Bulletins > Customer Interest for Wiper Motor Linkage: > 08-05-97 > Feb > 97 > Windshield Wipers - Squeak During Operation > Page 8003 NOTE: IT MAY BE NECESSARY TO REMOVE THE LEFT COWL PLENUM SCREEN/GRILLE RETAINING PIN (PLASTIC RIVET) TO GAIN ACCESS TO THE WINDSHIELD WASHER HOSE (FIGURE 2). 3. To keep the windshield washer hose from contacting the wiper linkage, the hose must be secured to the third rib of the cowl plenum screen/grille (Figure 3) by a tie strap. 4. Insert a 6 to 8 in. BLACK tie strap through the screen/grille as shown in Figure 4. 5. Using your fingers, loop the tie strap around the washer hose and the third rib of the cowl plenum screen/grille (Figure 4). Insert the end of the tie strap into the strap retainer. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Technical Service Bulletins > Customer Interest for Wiper Motor Linkage: > 08-05-97 > Feb > 97 > Windshield Wipers - Squeak During Operation > Page 8004 6. Gut the excess material from the tie strap (Figure 5). 7. Rotate the tie strap so that the end of the strap is facing down into the cowl. 8. Install the cowl to hood seal. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-43-10-94 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor Linkage: > 08-05-97 > Feb > 97 > Windshield Wipers Squeak During Operation Wiper Motor Linkage: All Technical Service Bulletins Windshield Wipers - Squeak During Operation NO: 08-05-97 GROUP: Electrical DATE: Feb. 14, 1997 SUBJECT: Squeak During Windshield Wiper Operation MODELS: 1997 (AN) Dakota NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT BEFORE NOV. 7, 1996 (MDH 1107XX). SYMPTOM/CONDITION: Squeak is heard during windshield wiper operation when the wiper blades near the top of their travel (blade near the A pillar). NOTE: THE SQUEAK IS MORE PREVALENT WHEN THE WINDSHIELD AND COWL AREAS ARE DRY. DIAGNOSIS: Open the hood, then with the ignition key to the RUN position. Turn the windshield wipers ON "low" speed. Observe the left windshield washer hose that feeds the left washer nozzle. The hose is visible through the cowl grille. If a squeak is heard when the wiper blade reaches or comes near the end of its travel (blade near the A pillar) and the windshield washer hose for the left washer nozzle appears to be contacting the wiper linkage, perform the following Repair Procedure. For a windshield wiper system squeaking condition other than described above such as a squeaking wiper linkage and pivot, refer to the 1997 Dakota Service Manual (Publication No. 81-370-7110), Group 8K for component service. REPAIR PROCEDURE: This bulletin involves securing the left washer hose to the cowl grille with a tie strap. 1. Remove the cowl to hood weatherstrip (Figure 1). 2. Gently pry the cowl plenum screen/grille up enough to be able to slide your fingers between the cowl and grille. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor Linkage: > 08-05-97 > Feb > 97 > Windshield Wipers Squeak During Operation > Page 8010 NOTE: IT MAY BE NECESSARY TO REMOVE THE LEFT COWL PLENUM SCREEN/GRILLE RETAINING PIN (PLASTIC RIVET) TO GAIN ACCESS TO THE WINDSHIELD WASHER HOSE (FIGURE 2). 3. To keep the windshield washer hose from contacting the wiper linkage, the hose must be secured to the third rib of the cowl plenum screen/grille (Figure 3) by a tie strap. 4. Insert a 6 to 8 in. BLACK tie strap through the screen/grille as shown in Figure 4. 5. Using your fingers, loop the tie strap around the washer hose and the third rib of the cowl plenum screen/grille (Figure 4). Insert the end of the tie strap into the strap retainer. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor Linkage: > 08-05-97 > Feb > 97 > Windshield Wipers Squeak During Operation > Page 8011 6. Gut the excess material from the tie strap (Figure 5). 7. Rotate the tie strap so that the end of the strap is facing down into the cowl. 8. Install the cowl to hood seal. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-43-10-94 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Technical Service Bulletins > Page 8012 Wiper Motor Linkage: Description and Operation SYSTEM OPERATION The wiper linkage and pivot module is secured with screws to the cowl plenum panel beneath the cowl plenum cover/grille panel. The wiper motor is secured with screws to the center of the linkage and pivot module bracket. The wiper pivots are secured to the ends of the module bracket. The two wiper pivot crank arms and the wiper motor crank arm each have ball studs on their ends. The motor crank arm ball stud is the longer of the three. Two drive links connect the motor crank arm to the pivot crank arms. The passenger side drive link has a plastic socket-type bushing on each end. The driver side drive link has a plastic socket-type bushing on one end, and a plastic sleeve-type bushing on the other end. The socket-type bushing on one end of each drive link is fit over the ball stud on the crank arm of its respective pivot. The driver side drive link sleeve-type bushing end is then fit over the motor crank arm ball stud, and the other socket-type bushing of the passenger side drive link is snap-fit over the exposed end of the motor crank arm ball stud. The wiper linkage, pivots, bushings, mounting bracket, and motor are only serviced as a complete unit. If any part of this assembly is faulty or damaged, the entire wiper module must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Technical Service Bulletins > Page 8013 Wiper Motor Linkage: Service and Repair The wiper linkage and pivots can only be removed or installed as a unit with the wiper motor. See Wiper and Washer Systems/Wiper Motor for the service procedures. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Description and Operation Wiper Pivot: Description and Operation SYSTEM OPERATION The wiper linkage and pivot module is secured with screws to the cowl plenum panel beneath the cowl plenum cover/grille panel. The wiper motor is secured with screws to the center of the linkage and pivot module bracket. The wiper pivots are secured to the ends of the module bracket. The two wiper pivot crank arms and the wiper motor crank arm each have ball studs on their ends. The motor crank arm ball stud is the longer of the three. Two drive links connect the motor crank arm to the pivot crank arms. The passenger side drive link has a plastic socket-type bushing on each end. The driver side drive link has a plastic socket-type bushing on one end, and a plastic sleeve-type bushing on the other end. The socket-type bushing on one end of each drive link is fit over the ball stud on the crank arm of its respective pivot. The driver side drive link sleeve-type bushing end is then fit over the motor crank arm ball stud, and the other socket-type bushing of the passenger side drive link is snap-fit over the exposed end of the motor crank arm ball stud. The wiper linkage, pivots, bushings, mounting bracket, and motor are only serviced as a complete unit. If any part of this assembly is faulty or damaged, the entire wiper module must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations Power Distribution Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 8020 Wiper Relay: Description and Operation SYSTEM OPERATION The intermittent wipe relay is a International Standards Organization (ISO) micro-relay The terminal designations and functions are the same as a conventional ISO relay. However, the micro-relay terminal orientation (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than on the conventional ISO relay The intermittent wipe relay is a electromechanical device that switches current to the windshield wiper motor or wiper motor park switch when the relay is energized or de-energized by the Central Timer Module (CTM) in response to the proper inputs from the windshield wiper (multi-function) switch. The intermittent wipe relay is located in the Power Distribution Center (PDC), in the engine compartment. Refer to the PDC label for relay identification and location. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 8021 Wiper Relay: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Intermittent Wiper Relay Relay Test The intermittent wipe relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the PDC label for intermittent wipe relay identification and location. Remove the intermittent wipe relay from the PDC as described to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2. If not OK, replace the faulty relay. 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 3. If not OK, replace the faulty relay 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, see the Relay Circuit Test. If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to the wiper (multi-function) switch. There should be continuity between the cavity for relay terminal 30 and the two fused ignition switch output circuit cavities of the multi-function switch wire harness connector at all times. If OK, go to Step 2. If not OK, repair the open circuit(s) to the multi-function switch as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position. There should be continuity between the cavity for relay terminal 87A and the wiper park switch sense circuit cavities of the wiper motor wire harness connector and the 14-way Central Timer Module (CTM) wire harness connector at all times. If OK, go to Step 3. If not OK, repair the open circuit(s) to the wiper motor and CTM as required. 3. The relay normally open terminal (87) is connected to the common feed terminal (30) in the energized position. There should be battery voltage at the cavity for relay terminal 87 with the ignition switch in the On or Accessory positions. If OK, go to Step 4. If not OK, repair the open circuit to the ignition switch as required. 4. The coil battery terminal (86) is connected to the electromagnet in the relay. There should be battery voltage at the cavity for relay terminal 86 with the ignition switch in the On or Accessory positions. If OK, go to Step 5. If not OK, repair the open circuit to the ignition switch as required. 5. The coil ground terminal (85) is connected to the electromagnet in the relay. It is grounded by the CTM to energize the relay and cycle the wiper motor. Check for continuity between the cavity for relay terminal 85 and the intermittent wiper relay control circuit cavity of the 14-way CTM wire harness connector. There should be continuity. If OK, replace the faulty base version CTM; or, use a DRB scan tool and the proper Diagnostic Procedures for diagnosis of the high-line version CTM. If not OK, repair the open circuit to the CTM as required. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 8022 Wiper Relay: Service and Repair REMOVAL and INSTALLATION 1. Disconnect and isolate the battery negative cable. Power Distribution Center 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC cover for intermittent wipe relay identification and location. 4. Unplug the intermittent wipe relay from the PDC. 5. Install the intermittent wipe relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 6. Install the PDC cover. 7. Connect the battery negative cable. 8. Test the relay operation. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation Wiper Switch: Description and Operation SYSTEM OPERATION Multi-Function Switch Wiper Switch And Washer Switch The windshield wiper and washer switches are contained in the multi-function switch assembly. The multi-function switch assembly is secured to the left side of the steering column. The multi-function switch contains circuitry for the following functions: Turn signals - Hazard warning - Headlamp beam selection - Headlamp optical horn - Windshield wipers - Windshield washers. The information contained addresses only the switch functions for the wiper and washer systems. However, the multi-function switch cannot be repaired. If any function of the multi-function switch is faulty, or if the switch is damaged, the entire switch assembly must be replaced. Dodge Dakota 2wd Workshop Manual (V6-3.9L VIN X (1997)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 8026 Wiper Switch: Testing and Inspection Perform the diagnosis for the wiper system and/or washer system as described before testing the multi-function switch. WARNING: ON VEHICLES EQUIPPED WITH AN AIRBAG, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Unplug the multi-function switch wire harness connector as described. Multi-Function Switch Continuity 2. Using an ohmmeter, perform the switch continuity checks at the switch terminals as shown in the Multi-Function Switch Continuity chart. 3. If the switch fails any of the continuity checks, replace the faulty switch. If the switch is OK, repair the wiper system and/or washer system wire harness circuits as required.