1998 Dodge Dakota Headlight Wiring Diagram 9 Pin

Page 477 8W-30-14 Page 844 Alignment Specifications Recall - Ignition Switch Wiring Overheating Technical Service Bulletin # 875 Date: 000601 Recall - Ignition Switch Wiring Overheating June 2000 Safety Recall No.875 Ignition Switch Wiring Models 1994-1996 (BR) Dodge Ram Trucks NOTE: This recall applies only to the above vehicles built at the: ^ Warren Assembly Plant ("S" in the 11th VIN position) through April 4, 1996 (MDH O4O4XX); ^ St. Louis North Assembly Plant ("J" in the 11th VIN position) through March 23, 1996 (MDH 0323XX); ^ Lago Alberto Assembly Plant ("M" in the 11th VIN position) through April 14, 1996 (MDH 0414XX); or ^ Saltillo Assembly Plant ("G"in the 11th VIN position) through April 14, 1996 (MDH 0414XX). 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 ignition switch and/or steering column wiring on about 710,000 of the above vehicles may overheat when the blower motor is operated at high speed for an extended period of time. This can cause stalling, loss of blower motor or power window operation, ABS or airbag lamp illumination or a steering column/instrument panel fire. Repair A blower motor relay and overlay harness must be installed to remove the blower motor circuit from the ignition switch. In addition, the ignition switch and electrical connector must be inspected for damage and replaced if necessary. Parts Information A. Ignition Switch Wiring Package Part Number Description CBXR875O Ignition Switch Wiring Package Each package contains the components listed: Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Ignition Switch Wiring Packages to service about 10% of those vehicles. B. Ignition Switch Assembly Page 192 Locations Electronic Brake Control Module: Locations The Rear Wheel Anti-Lock (RWAL) control module is located behind the instrument panel, to the right of the steering column, and near the intermittent wiper module. Page 543 Manifold Pressure/Vacuum Sensor: Service and Repair Fig. 86 MAP Sensor L-Shaped Rubber Fitting The Manifold Absolute Pressure (MAP) sensor is located on the front of the throttle body. An L-shaped rubber fitting is used to connect the MAP sensor to throttle body. REMOVAL NOTE: The throttle body must be removed from the intake manifold for MAP sensor removal. 1. Remove air cleaner assembly. 2. Remove throttle body. 3. Remove two MAP sensor mounting bolts (screws). 4. While removing MAP sensor, slide the vacuum rubber L-shaped fitting from the throttle body 5. 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 N.m (25 in. lbs.) torque. 4. Install throttle body. 5. Install air cleaner. Page 584 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. Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Page 81 8W-30-42 Page 161 Fuel Pump Relay: Description and Operation PURPOSE The relay supplies battery voltage to fuel pump and oxygen sensor heater element when energized by Powertrain Control Module (PCM). OPERATION The PCM energizes fuel pump relay by supplying relay ground, when ignition switch is in START or RUN position and PCM is receiving a reference signal from distributor. When the PCM does not receive reference signal from ignition system, (indicating engine is not running), then the PCM interrupts relay ground circuit and no voltage is supplied to fuel pump, ignition coil, or oxygen sensor heater element. The PCM controls fuel pump relay and Auto Shutdown (ASD) relay simultaneously, through same ground circuit. CIRCUIT OPERATION Circuit A14 from fuse 8 in the Power Distribution Center (PDC) supplies battery voltage to the contact side of the fuel pump relay. Circuit F18 from fuse 9 in the fuse block supplies battery voltage 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 K51. Circuit K51 connects to cavity 51 of the PCM connector. When the PCM grounds the fuel pump relay and the contacts close, they connect circuits A14 and A61. Circuit A61 supplies power to the fuel pump motor. Page 435 Fig. 9 8. Connect the 2-way wiring connector to the mating connector on the provided overlay relay harness. Fig. 8 9. Insert the two wire terminals from the overlay harness into the headlamp switch connector. Insert the PINK wIRED TRACER wire into the "B2" cavity. Insert the BLACK w/YELLOW TRACER wire into the "R" cavity. 10. Secure the wire terminals in the headlamp switch connector with the provided 9-way wedge. C. Install the Headlamp Switch Assembly: 1. Install the headlamp switch bezel bracket on the new switch assembly. 2. Install the headlamp switch bezel on the mounting bracket. Tighten the three (3) mounting screws securely. Fig. 10 Testing and Inspection Wiper Switch: Testing and Inspection Two Speed Wiper Switch Continuity Chart Page 610 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 Page 848 Alignment: Service and Repair Caster and Camber Adjustment Camber Caster is preset by the manufacturer with no provision for adjustment. Refer to "Front Wheel Alignment Specifications" in this chapter when checking camber due to suspension damage or suspected misalignment. Caster Refer to "Front Wheel Alignment Specifications" in this chapter when checking caster. If caster is not in the acceptable range, record measurement. Caster can be adjusted by rotating cams on lower suspension arm. Page 396 Parking Brake Warning Switch: Description and Operation Park Brake Switch Input CIRCUIT OPERATION On circuit G11, the Controller Anti Lock Brake (CAB) senses when the park brake switch CLOSES. Circuit G11 from the park brake switch connects to cavity 5 of the CAB. Page 27 Compressor Clutch Relay: Description and Operation Compressor Clutch Relay The compressor clutch relay is a International Standards Organization (ISO) micro-relay The terminal designations and functions are the same as a conventional ISO relay However, the micro-relay terminal orientation (footprint) is different, the current capacity is lower and the relay case dimensions are smaller than on the conventional ISO relay. The compressor clutch relay is a electromechanical device that switches current to the compressor clutch coil when the Powertrain Control Module (PCM) grounds the coil side of the relay The PCM responds to inputs from the heater-A/C mode control switch, the low pressure cycling clutch switch, and the high pressure cut-off switch. The compressor clutch relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the PDC label for relay identification and location. Page 169 Page 439 DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 ADDITIONAL INFORMATION If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Owner Letter SAFETY RECALL TO REPLACE YOUR TRUCK'S HEADLAMP SWITCH AND INSTALL A RELAY WIRING HARNESS Dear Dodge Ram 3500 Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. DaimlerChrysler Corporation has determined that a defect, which relates to motor vehicle safety, exists in some 1994 through 1997 Dodge Ram 3500 Series trucks. The problem is... Driving your Ram truck (identified on the enclosed form) with the lights on for an extended time frame can overheat the headlamp switch and cause a fire. An overheated headlamp switch can also result in a sudden loss of headlamp and/or parklamp operation and cause an accident without warning. What DaimlerChrysler and your dealer will do... Daimlerchrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will replace the headlamp switch and do install a relay wiring harness. The work will take about 1/2 hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do to ensure your saftey... Simply contact your dealer right away to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. Bring the enclosed Owner Notification Form with you to your dealer. It identifies the required service to the dealer. If you need help... If you have trouble getting your vehicle repaired, please call the DaimlerChrysler Customer Assistance Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, DC 20590, or call the Toll Free Auto Safety Hotline at 1-800-424-9393. Washington, DC area residents may call l-202-366-0123. We're sorry for any inconvenience, but we are sincerely concerned about your safety. Thank you for your attention to this important matter. Page 489 8W-70-17 Page 295 201 Recall 00V135000: Ignition Switch Wiring Defect Ignition Switch: All Technical Service Bulletins Recall 00V135000: Ignition Switch Wiring Defect The affected vehicles were built with an ignition switch and wiring that could overheat. High electrical current loads pass through the switch when the blower motor is operated on high for an extended periods of time. This could cause the ignition switch and wiring to overheat. Dealers will install a relay and overlay harness. Owner notification began June 26, 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). 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. Page 105 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. With Pressure Test Port Fuel Pressure Release: Service and Repair With Pressure Test Port Fuel Pressure Release Procedure - Typical 1. Remove the negative battery cable, and remove the fuel tank fill cap. 2. Place sufficient shop towels under the pressure test port (schrader valve) on the fuel rail. 3. Remove the cap from the pressure test port on the fuel rail. 4. Using an appropriate fuel pressure gauge hose, place one end of hose in an approved container and screw the other end of the hose onto the test port to relieve fuel pressure. Absorb any spilled fuel with shop towels. 5. Install cap on test port. Locations Camshaft Position Sensor: Locations Camshaft Position Sensor The Camshaft Position (CMP) Sensor is mounted in the distributor housing. Page 583 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 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. Caster Correction Chart Alignment: Specifications Caster Correction Chart Caster Correction Chart Page 656 41. Verify that the blower motor operates properly. Page 836 Wiper Switch: Service and Repair Multi-Function Switch 1. Disconnect battery ground cable. 2. On models equipped with tilt wheel, remove tilt lever. 3. Remove knee blocker. 4. Remove upper and lower column covers. 5. Move upper fixed column shroud to gain access to rear of multi-function switch. 6. Remove multi-function switch tamper proof attaching screws. 7. Remove switch from column, loosen connector screw, then remove wiring connector from switch. 8. Reverse procedure to install, noting the following: a. Torque all retaining screws to 17 in-lbs. b. Torque steering column upper bracket nuts to 9-10 ft-lbs. Adjustments Valve Clearance: Adjustments These engines are equipped with hydraulic lifters with no provision for adjustment. Page 888 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. Page 742 41. Verify that the blower motor operates properly. Page 113 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 Page 737 7. Remove the key cylinder from the ignition switch (Figure 10). 8. Place the new ignition switch in the LOCK position. The switch is in the LOCK position when the column lock flag is parallel to the ignition switch terminals (Figure 11). 9. With the key cylinder in the LOCK position, insert the key cylinder into the new ignition switch until it bottoms. 10. Insert the ignition key into the key cylinder. While gently pushing the key cylinder in toward the ignition switch, rotate the ignition key clockwise to the end of travel (START position) and then back to the LOCK position. 11. If equipped, install the key cylinder retaining bracket and screw (Figure 9). Tighten the screw to 26 in-lbs (3 Nm). 12. Apply a light coating of grease to the ignition switch column lock flag and the park lock dowel pin (Figure 11). 13. Make sure that the transmission gear shift selector is in the PARK position. The park lock dowel pin must be properly indexed before installing the ignition switch (Figure 12). Page 283 63 Page 92 8W-70-19 Page 967 Coolant: Service and Repair Refer to Cooling System, Service and Repair for applicable service procedures. Page 21 Blower Motor Relay: Service and Repair Fig 39 Blower Motor Relay Removal/Installation NOTE: The blower motor relay and wire harness connector are snap-fit onto a blade-type retainer located on the stop lamp switch mounting bracket. The stop lamp switch mounting bracket is secured with two screws to the inboard side of the brake pedal support bracket, under the driver side of the instrument panel. To remove the relay: 1. Disconnect and isolate the battery negative cable. 2. Reach under the knee blocker on the driver side of the instrument panel between the throttle and brake pedals, and unsnap the relay from the blade on the stop lamp switch bracket. 3. Lower the relay from under the instrument panel far enough to unplug the relay from the wire harness connector. 4. To install the relay, align the terminals with the cavities in the relay wire harness connector and push the relay firmly into place. 5. Reverse the remaining removal procedures to complete the installation. 6. Test the relay operation. Page 539 Manifold Pressure/Vacuum Sensor: Description and Operation 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. Page 934 Fig. 42 Serpentine Drive Belt Routing Page 686 6. Install retaining screw into bracket, then torque screw to 22-30 in-lbs. 7. Install steering column covers and torque retaining screws to 17 in-lbs 8. On models with tilt column, install tilt lever. 9. Connect battery ground cable, then ensure proper operation of ignition switch in each position. Page 68 8W-02-2 Page 897 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). Page 800 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 Page 942 Air Cleaner Housing: Service and Repair Heavy Duty Engines REMOVAL CAUTION: Do not attempt to remove the air cleaner element (filter) from the housing by removing the top cover only. To prevent damage to the air cleaner housing, the entire air cleaner housing assembly must be removed from the engine for air cleaner element replacement. Fig. 95 Air Cleaner Housing 1. Remove the air inlet tube at the side of the air cleaner housing. 2. A band-type screw clamp secures the air cleaner housing to the throttle body Loosen, but do not remove, this screw clamp. Note the clamp positioning tabs on the air cleaner housing. 3. All Engines: Disconnect the breather hose at the rear of air cleaner housing. 4. Disconnect the air pump hose at the air cleaner housing. 5. The bottom/front of the air cleaner housing is equipped with a rubber grommet. A mounting stud is attached to the intake manifold and is used to position the air cleaner housing into this grommet. Lift the assembly from the throttle body while slipping the assembly from the mounting stud. 6. Check condition of gasket at throttle body and replace as necessary. 7. The housing cover is equipped with three (3) spring clips and is hinged at the rear with plastic tabs. Unlatch the clips from the top of air cleaner housing and tilt the housing cover up and rearward for cover removal. 8. Remove the air cleaner element from air cleaner housing. INSTALLATION 1. Before installing a new air cleaner element, clean inside of air cleaner housing. 2. Position air cleaner cover to tabs on rear of air cleaner housing. Latch the three spring clips to seal cover to housing. 3. Position the air cleaner housing assembly to the throttle body while guiding the rubber grommet over the mounting stud. The lower part of the screw clamp should be below the top lip of the throttle body. 4. Push down on air cleaner housing at rubber grommet to seat housing at intake manifold. 5. Tighten throttle body-to-air cleaner housing clamp to 4 N.m (35 in. lbs.) torque. 6. Install the air inlet tube at air cleaner housing inlet. Page 73 8W-11-20 Page 418 3. Install the switch knob and shaft on the new switch assembly by depressing the release button on the bottom of the switch assembly and then inserting the shaft into the switch assembly. Fig. 10 4. Connect the 9-way wiring connector to the headlamp switch. Fig. 10 5. Connect the 2-way wiring connector to the headlamp switch (if equipped). Fig. 10 Page 119 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. 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 Page 389 Low Pressure Sensor / Switch: Testing and Inspection Fig 25 High Pressure Cut-off Switch -- Typical HIGH PRESSURE CUT-OFF SWITCH 1. Verify that the refrigerant system is properly charged. 2. Unplug the high pressure switch wire harness connector and test for continuity between the switch terminals. There should be continuity If OK, refer to the wiring diagrams and repair the circuits as required. If not OK, replace the faulty switch. Fig 28 Low Pressure Cycling Clutch Switch LOW PRESSURE CYCLING CLUTCH SWITCH Verify that the refrigerant system has the correct refrigerant charge. 1. Unplug the low pressure cycling clutch switch wire harness connector from the switch on the accumulator, and install a jumper wire between the two connector cavities. 2. Connect a manifold gauge set to the refrigerant system service ports. 3. Place the heater-A/C mode control switch knob in any A/C position and start the engine. 4. Check the continuity between the two terminals of the low pressure switch. There should be continuity with a suction pressure reading of 296 kPa (43 psi) or above, and no continuity with a suction pressure reading of 172 kPa (25 psi) or below. If OK, test and repair the compressor clutch control circuit as required. If not OK, replace the faulty switch. Page 591 Page 699 Page 697 PARTS REQUIRED: NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have~ 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available in the "Forms Folder" under "TSB/Recall" tab of MDS2 and printed on your dealership letterhead. keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. POLICY: Information Only Page 145 Powertrain Control Module: Diagnostic Trouble Code Descriptions Trouble Codes Trouble Code Descriptions For Information regarding diagnosis of all B, C, P, U and Manufacturer Codes See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions Description and Operation Fuel Level Sensor: Description and Operation CIRCUIT OPERATION The fuel level sensor is a variable resistor. Circuit G4 connects the fuel level sensor to the fuel gauge in the instrument cluster. Circuit F14 from fuse 12 in the fuse block supplies voltage to the fuel gauge. The fuel level sensor draws voltage from circuit F14 through the fuel gauge on circuit G4. Circuit Z11 provides the ground path for the fuel level sensor. As current flows through the coils in the fuel gauge, it creates a magnetic field. One of the coils in the gauge receives fixed current. The other coil is connected to the level sensor. The magnetic field controls the position of the fuel gauge pointer. The fuel level sensor contains a variable resistor. As the position of the float arm on the fuel level sensor changes, the resistor changes the current flow through the second coil in the fuel gauge. A change in current flow alters the magnetic field in the fuel gauge, which changes the pointer position. Circuit K104 from the level sensor connects to circuit K226. Circuit K226 connects to cavity C26 of the Powertrain Control Module (PCM). Circuit K226 provides the fuel level input to the PCM. Circuit K4 provides ground for the level sensor signal. Page 117 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. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. 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. Page 299 256 Page 730 Part Number Description 04326622 Ignition Switch Assembly Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive two (2) ignition switch assemblies. Additional ignition switches should be ordered only after inspection determines that replacement is required. Very few vehicles are expected to require ignition switch replacement 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: Add the cost of the recall parts package and switch assembly, if necessary, 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 "0RD875". 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: Page 721 Clutch Switch: Service and Repair The clutch start switch is an integral part of the clutch master cylinder pushrod and cannot be serviced separately. Page 255 Power Door Lock Switch: Description and Operation Unlock Left Door Switch CIRCUIT OPERATION When the switch is moved to the UNLOCK position, voltage is supplied on the P36 circuit to the right door switch, UNLOCK side. The battery voltage is passed through the switch internal bus bar to the P34 circuit. The P34 circuit then connects to the door motors on the UNLOCK side. Grounding for the UNLOCK function is provided by the P33 circuit. The P33 circuit connects back to the right door switch, LOCK side, and passes through the internal bus bar to the P35 circuit. The P35 circuit connects back to the left door switch, and passes through the switch to ground on circuit Z3. Right Door Switch CIRCUIT OPERATION When the switch is moved to the UNLOCK position voltage is supplied to the P34 circuit from the switch to the door UNLOCK side of the motors. The grounding path is through the LOCK side of the motors, circuit P33, back to the switch. The ground continues through the internal bus bar of the switch on circuit P35 to the left door switch. At the left door switch, the ground passes through that switches internal bus bar to ground on circuit Z3. Page 118 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. 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. Page 646 a. Turn the ignition switch to the ON position. b. Turn the blower motor on LOW and verify that the blower is operating. c. Disconnect the relay. ^ If the blower motor stops, this relay is for the blower motor. ^ If the blower motor does not stop, this relay is NOT for the blower motor. d. Turn the ignition switch OFF and connect the relay. 4. ^ If a blower motor relay is NOT present, continue with Section "B - Inspect Ignition Switch and Wiring." ^ If a blower motor relay is present, no further action is necessary. Return the vehicle to the customer. B. Inspect Ignition Switch and Wiring 1. Disconnect the negative battery cable(s). NOTE: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Remove the five (5) screws that secure the knee blocker to the lower instrument panel and then remove the knee blocker (Figure 3). 3. Remove the steering column tilt lever by turning it counter-clockwise. Page 529 Page 87 8W-30-49 Page 277 45 Page 471 8W-11-20 Page 347 8W-80-36 Page 762 12. Install the PINK with BLACK tracer blower relay harness wire (with a blade terminal) into cavity 43 of the 84-way connector (Figure 14 and Figure 16). 13. Install the BLUE wedge into the 84-way connector. 14. Install the cover onto the rear of the 84-way connector. 15. Connect the 84-way bulkhead connector. 16. Disconnect the WHITE electrical connector on the blower relay harness. Install the PINK with BLACK tracer wire that was removed from the 84-way connector into the WHITE connector opening (Figure 16). Reconnect the WHITE connector. Secure the connector near the bulkhead connector with a tie strap. 17. Install the BLACK with ORANGE tracer blower relay harness wire into cavity 5 of the 7-way ignition switch connector (Figure 16). 18. Disconnect the BLACK 2-way electrical connector on the blower relay harness (Figure 16). Remove the BLUE wedge and then install the BLACK with ORANGE tracer wire that was removed from the ignition switch connector into cavity 2 of the BLACK connector. Install the wedge and reconnect the BLACK 2-way connector. Secure the connector and any excess wiring near the base of the steering column with a tie strap. 19. Cut off the terminal and then strip about 1" of wire insulation from the end of the DARK GREEN wire that was removed from the fuseblock earlier. 20. Strip about 1" of wire insulation from the end of the DARK GREEN with WHITE blower relay harness wire (Figure 16). 21. Slide a piece of heat shrink tubing onto the wire. 22. Connect the DARK GREEN and DARK GREEN with WHITE tracer wires by twisting the wire ends together. 23. Solder the twisted wire ends using rosin core solder. CAUTION: Wire splice must be soldered. Do NOT use a solderless connector. 24. Center the piece of heat shrink tubing over the splice. Heat the tubing with a heat source until sealant comes out each end of the tubing. 25. Install the DARK GREEN blower relay harness wire into cavity 12 of the fuseblock (Figure 16). 26. Install the PINK with BLACK tracer blower relay harness wire into cavity 11 of the fuseblock (Figure 16). 27. Install the TAN fuseblock wedge (Figure 13). 28. Reinstall the 30-amp fuse in the fuseblock F2 Blower Motor location (Figure 13). Component Testing Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Component Testing Fig. 66 Engine Coolant Temperature Sensor 1. Disconnect wire harness connector from coolant temperature sensor. 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. Sensor Resistance (OHMS) - Coolant Temperature Sensor/Intake Air Temperature Sensor 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 less than 1340 ohms with the engine warm. Refer to 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. 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. Page 522 INSTALLATION 1. Position crankshaft position sensor to engine and install mounting bolts. Tighten bolts to 8 N.m (70 in. lbs.) torque. 2. Connect main harness electrical connector to sensor. 3. Clean the EGR tube and exhaust manifold (at EGR tube mounting point) of any old gasket material. 4. Install a new gasket to exhaust manifold end of EGR tube and install EGR tube to both manifolds. Tighten mounting nut at intake manifold. Tighten 2 mounting bolts at exhaust manifold to 23 N.m (204 in. lbs.) torque. 5. Coat the threads of the oil pressure sending unit with thread sealant. Do not allow any of the thread sealant to get into the sending unit opening, or the opening at the engine. Install sending unit to engine and tighten to 14 N.m (130 in. lbs.) torque. Install electrical connector to sending unit. 6. Clean the intake manifold and EGR valve of any old gasket material. 7. Install a new EGR valve gasket at intake manifold. 8. Install EGR valve to intake manifold. Tighten 2 bolts to 23 N.m (200 in. lbs.) torque. 9. Position EGR valve control and install its electrical connector. Connect hoses between EGR valve and EGR valve control. Connect hose between main vacuum harness and control valve. 10. Install spark plug cable loom and spark plug cables to valve cover mounting stud. 11. Install the air cleaner housing and plastic air intake tube. Brake Warning Lamp Switch Parking Brake Warning Switch: Description and Operation Brake Warning Lamp Switch CIRCUIT OPERATION Circuit G9 provides an input to the Controller Anti Lock Brake (CAB). The CAB receives the input when either the ignition switch is in the START position, or the park brake warning lamp switch in the hydraulic combination valve CLOSES. Page 470 8W-10-6 Page 229 Recall 00V135000: Ignition Switch Wiring Defect Ignition Switch: Recalls Recall 00V135000: Ignition Switch Wiring Defect The affected vehicles were built with an ignition switch and wiring that could overheat. High electrical current loads pass through the switch when the blower motor is operated on high for an extended periods of time. This could cause the ignition switch and wiring to overheat. Dealers will install a relay and overlay harness. Owner notification began June 26, 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). Page 560 Page 331 8W-30-48 Page 97 8W-80-6 Page 350 Page 306 2. Disconnect wire from rear sensor on axle housing. 3. Remove sensor and bracket mounting bolt and remove sensor and bracket. INSTALLATION 1. Secure sensor wire to rear brake hose with clips provided. 2. Install sensor and mounting bracket in axle housing. Install mounting bolt and tighten to 24 Nm (18 ft. lbs.). 3. Connect wire to sensor and secure wire to mounting bracket. 4. Remove support and lower vehicle. Page 503 Page 330 8W-30-47 Page 79 8W-30-14 Page 936 Drive Belt: Service and Repair Removal 1. Attach a suitable wrench to the pulley mounting bolt of the automatic tensioner. 2. Rotate tensioner assembly clockwise until tension has been relieved. 3. Remove belt from vehicle. Installation 1. Position drive belt over all pulleys except idler pulley. 2. Attach a suitable wrench to the pulley mounting bolt of the automatic tensioner. 3. Rotate wrench clockwise, place belt over idler pulley then allow tensioner to rotate back into place. Ensure belt is properly seated on all pulleys. 4. Check belt indexing marks as outlined under "Belt Tensioner Replacement." 1993-96 5.9L/V8-360HD & 8.0L/V10-488 ENGINES Removal 1. Attach a wrench to pulley mounting bolt of automatic tensioner. The threads on this bolt are left-hand. 2. Release tension from belt by rotating tensioner counterclockwise. When all belt tension has been released remove belt from tensioner first, then other pulleys. Installation 1. Position drive belt on all pulleys except tensioner pulley. 2. Attach a wrench to pulley bolt of tensioner, then rotate wrench counterclockwise. 3. Place belt over tensioner pulley, let tension rotate back into place, then ensure belt is properly seated on all pulleys. Page 294 195 Page 437 6. Connect the single wire connector from the overlay harness to the ground terminal on the headlamp switch assembly. Fig. 4 7. Tuck the relay pack into the instrument panel pocket on the left side between the demister duct and the HVAC duct and then install the headlamp switch into the instrument panel. Tighten the three attaching screws securely. 8. Connect the lighter wiring connector. 9. Connect the auxiliary power outlet wiring connector to the power outlet on the cluster bezel. Fig. 3 10. Install the cluster bezel and engage the cluster bezel snap-clip retainers to the instrument panel. Fig. 2 11. Install the ash receiver bracket. Tighten the bracket screws securely. 12. Install the ash receiver. Page 467 8W-02-3 Page 217 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 Page 256 Power Door Lock Switch: Testing and Inspection - Check the 50 Amp fuse in cavity 1 of the PDC - Check the 20 Amp fuse in cavity 19 of the fuse block - Check the grounding point for the door lock switch Page 577 - 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. Symbols Page 196 Air Bag Control Module: Vehicle Damage Warnings CAUTION: Before disconnecting any control module connector, make sure the ignition is "OFF" and the battery is disconnected. Failure to do so could damage the module. Page 302 Wheel Speed Sensor: Description and Operation Rear Wheel Antilock Brakes 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 it transmits to the Controller Anti Lock Brake (CAB). Circuits B113 and B114, a pair of twisted wires, connect to the sensor to provide signals to the CAB. The B113 circuit also connects to the universal data link connector. Circuit B113 connects to cavity 14 of the CAB. Circuit B114 connects to cavity 13 of the CAB. Page 377 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. 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 Page 701 Locations Power Distribution (Part 1 Of 3) Page 760 14. Place the ignition switch against the lock housing opening on the steering column. Ensure that the ignition switch park lock dowel pin enters the slot in the park lock slider linkage in the steering column. 15. Install the ignition switch screws (Figure 8). Tighten the screws to 26 in-lbs (3 Nm). 16. Connect the key-in/halo light electrical connector to the new ignition switch (Figure 7). NOTE: DO NOT connect the 7-way ignition switch connector. D. Install Blower Motor Relay and Overlay Harness 1. Remove the 30-amp fuse from the fuseblock F2 -- Blower Motor location (Figure 13). 2. Remove the TAN wedge from the fuseblock (Figure 13). 3. Remove the BLACK with ORANGE tracer (A22) wire from cavity 11 of the fuseblock (Figure 13); then cut the terminal off and tape the wire back to the harness. 4. Remove the DARK GREEN (C1) wire from cavity 12 of the fuseblock (Figure 13). 5. Disconnect the 84-way bulkhead connector. 6. Remove the cover from the rear of the 84-way connector. 7. Remove the BLUE wedge from the 84-way connector. Page 125 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Page 645 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 For Blower Motor Relay NOTE: Very few vehicles are expected to already be equipped with a blower motor relay. 1. Inspect the brake pedal support bracket for the presence of a blower motor relay attached to the brake lamp switch bracket (Figure 1) or locate a blower motor relay that is secured near the brake pedal bracket with a tie strap. NOTE: 1995 model year vehicles that were built with original equipment foglamps will have two (2) foglamp relays mounted on this bracket. 2. If a blower motor relay is NOT found, inspect the area near the 84-way bulkhead connector for a WHITE single wire connector with BLACK ends that connects two PINK with BLACK tracer wires (Figure 2). If the connector and wires are present, follow the wiring harness to locate the blower motor relay that is secured under the instrument panel. 3. If a relay was located in either Step 1 or Step 2, verify that this is a blower motor relay as follows: Page 734 8. Inspect the ignition switch assembly for heat damage near the 4th and 5th terminals (Figure 6). ^ Check the ignition switch terminals for discoloration. ^ Inspect the ignition switch connector and body for indications of melting or deformation. 9. If the wiring connector and switch assembly are NOT damaged, continue with Section "E Install Blower Motor Relay and Overlay Harness." ^ If the 7-way switch wiring connector has indications of heat damage, the ignition switch wiring harness pigtail must be replaced. Continue with Section "C - Replace Ignition Switch Wiring Pigtail." ^ If the ignition switch assembly has indications of heat damage, the ignition switch assembly and the wiring harness pigtail must be replaced. Continue with Section "C - Replace Ignition Switch Wiring Pigtail." C. Replace Ignition Switch Wiring Pigtail IMPORTANT: Only those vehicles that had wiring and/or ignition switch damage as determined by the inspection in Section "B" require ignition switch wiring pigtail replacement. Very few vehicles are expected to require this repair. 1. Disconnect the ignition switch key-in/halo light electrical connector (Figure 7). 2. Disconnect the clockspring electrical connector from the clockspring (Figure 7). 3. Disconnect the multi-function switch electrical connector (Figure 7). 4. Remove the plastic steering column wiring trough from the steering column. The trough is attached to the column with three push clips. Page 924 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 Page 109 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 Page 606 Page 487 8W-33-3 Revisions to the Splice Information. Page 315 8W-30-10 Page 634 Crankshaft Position Sensor: Service and Repair Heavy Duty Engines Fig. 51 Crankshaft Position Sensor The sensor is bolted to the top of the cylinder block near the rear of right cylinder head. 1. Remove the air cleaner assembly and its plastic air intake tube. 2. Remove the spark plug cable loom and spark plug cables from valve cover mounting stud at rear of right valve cover. Position spark plug cables to top of valve cover. 3. Disconnect 2 hoses at Exhaust Gas Recirculation (EGR) valve. Note position of hoses at EGR valve before removal. 4. Disconnect electrical connector and hoses at electric EGR valve control. Note position of hoses before removal. 5. Remove 2 EGR valve mounting bolts and remove EGR valve. Discard old EGR gasket. 6. Disconnect electrical connector at engine oil pressure sending unit. Fig. 52 Oil Pressure Sending Unit - Removal/Installation 7. To prevent damage to oil pressure sending unit, a special tool, such as number C-4597 must be used. Remove sending unit from engine. 8. Loosen EGR tube mounting nut at intake manifold. 9. Remove 2 EGR tube mounting bolts at exhaust manifold and remove EGR tube. Discard old gasket at exhaust manifold. 10. Disconnect crankshaft position sensor pigtail harness from main wiring harness. 11. Remove 2 sensor (recessed hex head) mounting bolts and remove sensor. Recall - Headlamp Switch Technical Service Bulletin # 819 Date: 990601 Recall - Headlamp Switch June 1999 Dealer Service Instructions for: Safety Recall No. 819 - Headlamp Switch MODELS 1994-1997 (BR) Dodge Ram 3500 Series Trucks NOTE: This recall applies only to 3500 series trucks built through October 21, 1996 (MDH 1021XX). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service as determined by using the DIAL VIP System. SUBJECT Extended operation of the lights on about 79,000 of the above vehicles can overheat the headlamp switch and cause a fire. An overheated headlamp switch can also result in a sudden loss of headlamp and/or parklamp operation and cause an accident without warning. REPAIR The headlamp switch must be replaced and a parklamp circuit relay wiring harness must be installed. In addition, the headlamp switch electrical connector must be inspected and any damaged wires must be replaced. PARTS INFORMATION Part Number Description CAJM8190 Headlamp Switch Package Each package contains the following components: Quantity Description 1 Headlamp Switch 1 Overlay Relay Harness 1 2-Way Female Connector 1 2-Way Wedge 1 Headlamp Switch Connector 1 Headlamp Switch Connector Wedge 1 Wire Kit (Contains 9 individual wires with terminals at one end) 9 Heat Shrink Tubing Each dealer, to whom vehicles in the recall were invoiced (or the current dealer at the same street address), will receive enough Headlamp Switch Packages to service about 25% of those vehicles. SERVICE PROCEDURE A. Remove the Headlamp Switch Assembly: 1. Disconnect the negative battery cable(s). Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. Fig. 1 2. Open the cup holder and remove the two (2) screws that secure the cup holder assembly to the instrument panel. Page 469 8W-80-2 Revision to the plant diagnostic connector circuit. Component Test Throttle Position Sensor: Testing and Inspection Component Test Fig. 40 Sensor And IAC Location - Typical The Throttle Position Sensor (TPS) can be tested with a digital voltmeter. The center 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 must be greater than 200 millivolts. At wide open throttle, TPS output voltage must be less than 4.8 volts. The output voltage should increase gradually as the throttle plate is slowly opened from idle to WOT. NOTE: For additional testing information and circuit diagnosis see Testing and Inspection/Test TC-26A or TC-27A 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. Page 341 8W-70-26 Revisions to the Connector Pin-outs. Page 651 7. Remove the key cylinder from the ignition switch (Figure 10). 8. Place the new ignition switch in the LOCK position. The switch is in the LOCK position when the column lock flag is parallel to the ignition switch terminals (Figure 11). 9. With the key cylinder in the LOCK position, insert the key cylinder into the new ignition switch until it bottoms. 10. Insert the ignition key into the key cylinder. While gently pushing the key cylinder in toward the ignition switch, rotate the ignition key clockwise to the end of travel (START position) and then back to the LOCK position. 11. If equipped, install the key cylinder retaining bracket and screw (Figure 9). Tighten the screw to 26 in-lbs (3 Nm). 12. Apply a light coating of grease to the ignition switch column lock flag and the park lock dowel pin (Figure 11). 13. Make sure that the transmission gear shift selector is in the PARK position. The park lock dowel pin must be properly indexed before installing the ignition switch (Figure 12). Page 335 8W-70-13 Page 703 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. All Wheel Antilock Brakes Brake Light Switch: Description and Operation All Wheel Antilock Brakes CIRCUIT OPERATION On circuit V40, the Controller Anti Lock Brake (CAB) senses when the brake pedal has been pressed. Circuit V40 connects to cavity 9 of the CAB and splices to the stop lamp switch and the Power-train Control Module (PCM). Page 948 Fuel Pressure Release: Service and Repair W/O Pressure Test Port 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 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 injection 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. 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. Connector Views Oxygen Sensor: Connector Views Page 248 This Repair Procedure clamps three RFl filters around the intermittent wiper module's wiring. 1. Record the radio station presets. 2. Disconnect and isolate the battery negative cable. 3. Remove the five screws that secure the knee bolster to the dash pane! and remove the knee bolster. 4. Locate the intermittent wiper module located under the instrument panel and above the accelerator pedal. Slide the module off its mounting bracket. 5. Separate the nine wires entering the connector on back of the module into three groups. Install a snap-together filter on each of the three groups of wires. The filter should be placed as close to the module as possible. 6. Apply foam tape (P/N 4318028) around the RFI filters. 7. Slide the module back onto its mounting bracket. 8. Install the knee bolster. 9. Connect the negative cable and reset the clock and reprogram the radio to the station presets identified in step one. Page 590 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. Page 495 8W-80-6 Page 451 Page 556 Oxygen Sensor: Service and Repair Heavy Duty Engines Fig. 10 Left/Right Heated Oxygen Sensors - HDC Engines NOTE: The left and right Oxygen (02S) sensors are located on the left and right exhaust downpipes. 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 N.m (22 ft. lbs.) torque. 2. Connect the 02S sensor wire connector. 3. Lower the vehicle. Page 902 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. Testing and Inspection Brake Switch (Cruise Control): Testing and Inspection 1. Remove stop lamp switch from mounting bracket, then disconnect switch from wiring harness. 2. Using a suitable ohmmeter, ensure switch continuity is as follows: a. With switch plunger released, continuity should exist between pins 5 and 6. b. With switch plunger depressed, continuity should exist between pins 1 and 2 and between pins 3 and 4. 3. If switch continuity is as specified, switch is satisfactory; if not, replace switch. Locations Fuse Block (Part 1 Of 2) Page 415 Fig. 7 ^ Carefully inspect the connector and terminals B1, B2, R and H for signs of damage from overheating (melted connector and/or discolored terminal). If any one of these terminals shows signs of damage, ALL FOUR of these terminals MUST be replaced. Continue with Step 3. ^ Carefully inspect the connector and all other terminals. If any terminals in addition to B1, B2, R and H are damaged, terminals B1, B2, R, H and any other damaged terminals MUST be replaced. Continue with Step 3. ^ If there is no indication of heat damage, continue with Step 6. 3. For vehicles with headlamp switch wire terminal and connector heat damage: Remove any damaged wire terminals from the headlamp switch connector using a small screwdriver, Miller Special Tool #8197 or equivalent. If the connector is also damaged and cannot be reused, remove all wires and discard the connector. 4. Replace any damaged wires as determined in Step 2 as follows: a. Cut the electrical tape and remove the affected wire(s) from the bundle. b. Cut off the damaged wire approximately 10 inches from the terminal. NOTE: Stagger the wire splice locations by about 1/2 inch. c. Remove about 1 inch of insulation from the end of the wire. d. Remove about l inch of insulation from the end of the matching color and gauge wire and terminal provided in the parts package. e. Slip one piece of the provided heat shrink tubing over the new wire end. f. Twist the exposed wire ends of the harness wire and the replacement wire end together. g. Solder the twisted wire ends together using rosin core solder. CAUTION: All wiring splices must be soldered or future circuit failure may occur. h. Slide the heat shrink tubing over the wire splice and heat the tubing until the tubing shrinks tightly around the wire and sealant comes out both ends of the tubing. i. Repeat Steps A - H for all other damaged wires as necessary. Page 80 8W-30-18 Locations Left Impact Sensor Page 86 8W-30-48 Page 317 8W-10-6 Page 676 12. Install the PINK with BLACK tracer blower relay harness wire (with a blade terminal) into cavity 43 of the 84-way connector (Figure 14 and Figure 16). 13. Install the BLUE wedge into the 84-way connector. 14. Install the cover onto the rear of the 84-way connector. 15. Connect the 84-way bulkhead connector. 16. Disconnect the WHITE electrical connector on the blower relay harness. Install the PINK with BLACK tracer wire that was removed from the 84-way connector into the WHITE connector opening (Figure 16). Reconnect the WHITE connector. Secure the connector near the bulkhead connector with a tie strap. 17. Install the BLACK with ORANGE tracer blower relay harness wire into cavity 5 of the 7-way ignition switch connector (Figure 16). 18. Disconnect the BLACK 2-way electrical connector on the blower relay harness (Figure 16). Remove the BLUE wedge and then install the BLACK with ORANGE tracer wire that was removed from the ignition switch connector into cavity 2 of the BLACK connector. Install the wedge and reconnect the BLACK 2-way connector. Secure the connector and any excess wiring near the base of the steering column with a tie strap. 19. Cut off the terminal and then strip about 1" of wire insulation from the end of the DARK GREEN wire that was removed from the fuseblock earlier. 20. Strip about 1" of wire insulation from the end of the DARK GREEN with WHITE blower relay harness wire (Figure 16). 21. Slide a piece of heat shrink tubing onto the wire. 22. Connect the DARK GREEN and DARK GREEN with WHITE tracer wires by twisting the wire ends together. 23. Solder the twisted wire ends using rosin core solder. CAUTION: Wire splice must be soldered. Do NOT use a solderless connector. 24. Center the piece of heat shrink tubing over the splice. Heat the tubing with a heat source until sealant comes out each end of the tubing. 25. Install the DARK GREEN blower relay harness wire into cavity 12 of the fuseblock (Figure 16). 26. Install the PINK with BLACK tracer blower relay harness wire into cavity 11 of the fuseblock (Figure 16). 27. Install the TAN fuseblock wedge (Figure 13). 28. Reinstall the 30-amp fuse in the fuseblock F2 Blower Motor location (Figure 13). Page 34 Audible Warning Device Control Module: Testing and Inspection - Check the 15 Amp fuse in cavity 17 of the fuse block - Check the 50 Amp fuse located in cavity 1 of the PDC - Check the door jamb switches for a good ground - Check the lamp filaments - For the day/night mirror, check the backup lamp switch, the 10 Amp fuse in cavity 15 of the fuse block, and the 40 Amp fuse in cavity 2 of the PDC 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. ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions Wheel Speed Sensor: Technical Service Bulletins ABS - Kelsey Hayes EBC-5H, EBC 310 Test Revisions NUMBER: 26-10-99I GROUP: Miscellaneous DATE: October, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1993-1997 Kelsey Hayes EBC-5H, EBC 310 ABS Diagnostic Manual - Publication Number 81-699-96026 DESCRIPTION OF CHANGES Revisions to the ABS test procedures for wheel speed sensors Page 741 29. Disconnect the ground eyelet near the airbag squib connector (Figure 17). 30. Double stack the ground eyelet on the BLACK blower relay harness wire onto the ground screw. Install the ground screw and tighten securely. 31. Attach the blower relay onto one of the horizontal relay mounting tabs on the bracket located on the brake pedal support just above the brake lamp switch and pedal (Figure 18). NOTE: For early 1994 model year vehicles that do not have a relay bracket or if two relays are already attached to the bracket, secure the relay to the wiring harness with a tie strap. 32. Re-tape all of the portions of the ignition switch wiring harness from which tape was removed. 33. Position the ignition switch wires back inside of the wiring trough. 34. Snap the steering column wiring trough back on to the steering column using the supplied clips as necessary. 35. Connect the 7-way ignition switch electrical connector. 36. Install the lower steering column shroud (Figure 4). 37. Install the upper and lower steering column covers (Figure 4). 38. Install the steering column tilt lever (Figure 4). 39. Install the knee blocker and tighten the screws securely (Figure 3). 40. Connect the negative battery cable(s). Page 649 5. Remove the ignition switch wires from the wiring trough. Remove any tape from the ignition switch wires. 6. Stagger cut all of the ignition switch wires (7) on the vehicle harness side about 1/2" apart. Make sure that all wires are cut so that the wire splices will be located inside the wiring trough and towards the bottom of the steering column. NOTE: Splices that are located towards the top of the steering column are more susceptible to damage. 7. Strip about 1" of wire insulation from each wire on the vehicle wire harness. 8. Stagger cut the matching wires on the supplied ignition switch pigtail to match up with the harness side. Allow sufficient length for the soldered connections. Make sure that the overall length of the wiring is the same as the original harness. NOTE: Be sure to cut the supplied ignition switch pigtail wires so that they match the wire color of the vehicle wire harness. On some vehicles, the YELLOW harness wire matches with the BLUE/YELLOW* vehicle wire and the BLACK harness wire matches with the GRAY/BLACK* vehicle wire. 9. Strip about 1" of wire insulation from each wire on the ignition switch pigtail. 10. Slide a piece of heat shrink tubing onto each wire of the new pigtail. 11. Connect the supplied switch pigtail harness to the vehicle harness by twisting all wire ends together. Be sure to match all wire colors. 12. Solder the twisted wire ends using rosin core solder. CAUTION: Wire splices must be soldered. Do NOT use solderless connectors. 13. Center the pieces of heat shrink tubing over each of the splices. Heat the tubing with a heat source until sealant comes out each end of the tubing. 14. Connect the multi-function switch electrical connector (Figure 7). 15. Connect the clockspring electrical connector (Figure 7). 16. ^ If the ignition switch was damaged and must be replaced, as determined by the inspection in Section "B," continue with Section "D -- Replace Ignition Switch Assembly." ^ If the ignition switch was NOT damaged, as determined by the inspection in Section "B," continue with Section "E - Install Blower Motor Relay and Overlay Harness." D. Replace Ignition Switch Assembly IMPORTANT: Only those vehicles that had ignition switch damage as determined by the inspection in Section "B," require ignition switch replacement. Very few vehicles are expected to require this repair. 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. Page 115 - 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. Symbols Page 475 8W-30-8 Description and Operation 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. Page 683 Ignition Switch: Description and Operation CIRCUIT OPERATION When the ignition switch is in the RUN position, it connects circuit A2 from fuse 2 in the Power Distribution Center (PDC) to circuit A22. Circuit A22 connects to the fuse block. Through the fuse block, circuit A22 feeds circuits A20, L10, F23, C1 and F21. Circuits A20, L10, F23, and C1 are protected by separate fuses. A circuit breaker protects circuit F21. When the ignition switch is in the START or RUN position, it connects circuit A1 from fuse 3 in the PDC to circuit A21. Circuit A21 powers circuits F18, F12, and F14 through the fuse block. Separate fuses protect each circuit. In the START position, the ignition switch connects circuit A1 from fuse 3 in the PDC to circuit A41. Circuit A41 connects to either the clutch pedal position sensor or the clutch pedal position switch bypass jumper. Also in the START position, the ignition switch connects circuit G9 to ground. In the ACCESSORY or RUN position, the ignition switch connects circuit A1 to circuit A31. Circuit A31 connects to the fuse block and feeds circuits F30, L5, Xl2, and V6. Separate fuses protect each circuit. Page 647 4. Remove the upper and lower steering column covers (Figure 4). 5 Remove the lower steering column shroud (Figure 4). 6. Disconnect the 7-way ignition switch electrical connector (Figure 5). 7. Inspect the 7-way ignition switch connector for heat damage near the 4th and 5th terminals (BLACK with ORANGE tracer and PINK with BLACK tracer wires) (Figure 5). ^ Look for brown or black discoloration of the wire insulation or melting of the wire insulation near the connector. ^ Check the wiring terminals for discoloration. ^ Inspect the connector for indications of melting or deformation. Page 432 13. Pull the headlamp switch control knob out to the ON position stop. 14. Depress the switch knob and shaft release button on the bottom of the switch assembly and then pull the switch knob and shaft out of the switch. Fig. 5 15. Remove the three screws that secure the headlamp switch bezel to the switch mounting bracket and then remove the bezel. Unscrew the plastic mounting bracket (shaft bushing) nut and remove the bezel mounting bracket from the switch assembly. Discard the switch assembly. B. Install the Parklamp Circuit Overlap Harness: 1. Remove the wedge from the 9-way headlamp switch wiring connector. Fig. 6 2. Inspect the 9-way headlamp switch connector and all nine (9) terminals for indications of heat damage. Locations Page 189 Air Bag Control Module And Control Module Connector Page 501 Coolant Temperature Sensor/Switch (For Computer): Specifications Switch Torque Switch Torque Cooling Fan Switch 8-18 ft.lb Page 611 Throttle Position Sensor: Service and Repair REMOVAL 1. Remove air intake tube at throttle body 2. Disconnect Throttle Position Sensor (TPS) electrical connector. Fig. 80 TPS Mounting Bolts 3. Remove two TPS mounting bolts. 4. Remove TPS from throttle body INSTALLATION Fig. 81 Installation The throttle shaft end of the throttle body slides into a socket in the TPS. The TPS must be installed so that it can be rotated a few degrees. If the sensor will not rotate, install the sensor with the throttle shaft on the other side of the socket tangs. The TPS will be under slight tension when rotated. 1. Install the TPS and two retaining bolts. 2. Tighten bolts to 7 N.m (60 in. lbs.) torque. 3. Manually operate the throttle control lever by hand to check for any binding of the TPS. 4. Connect TPS electrical connector to TPS. 5. Install air intake tube. Page 77 8W-30-8 Locations Fig. 15 MAP And Throttle Position Sensor Location - Typical Locations Page 694 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. Page 903 Ignition Cable: Specifications Minimum ..................................................................................................................................................... 250 ohms per inch (3,000 ohms per foot) Maximum ............................................................................................................................................... 1,000 ohms per inch (12,000 ohms per foot) Page 280 55 Light Duty Engines Air Cleaner Housing: Service and Repair Light Duty Engines REMOVAL CAUTION: Do not attempt to remove the air cleaner element (filter) from the housing by removing the top cover only. To prevent damage to the air cleaner housing, the entire air cleaner housing assembly must be removed from the engine for air cleaner element replacement. Fig. 95 Air Cleaner Housing 1. Remove the air inlet tube at the side of the air cleaner housing. 2. A band-type screw clamp secures the air cleaner housing to the throttle body Loosen, but do not remove, this screw clamp. Note the clamp positioning tabs on the air cleaner housing. 3. All Engines: Disconnect the breather hose at the rear of air cleaner housing. 4. The bottom/front of the air cleaner housing is equipped with a rubber grommet. A mounting stud is attached to the intake manifold and is used to position the air cleaner housing into this grommet. Lift the assembly from the throttle body while slipping the assembly from the mounting stud. 5. Check condition of gasket at throttle body and replace as necessary. 6. The housing cover is equipped with three (3) spring clips and is hinged at the rear with plastic tabs. Unlatch the clips from the top of air cleaner housing and tilt the housing cover up and rearward for cover removal. 7. Remove the air cleaner element from air cleaner housing. INSTALLATION 1. Before installing a new air cleaner element, clean inside of air cleaner housing. 2. Position air cleaner cover to tabs on rear of air cleaner housing. Latch the three spring clips to seal cover to housing. 3. Position the air cleaner housing assembly to the throttle body while guiding the rubber grommet over the mounting stud. The lower part of the screw clamp should be below the top lip of the throttle body. 4. Push down on air cleaner housing at rubber grommet to seat housing at intake manifold. 5. Tighten throttle body-to-air cleaner housing clamp to 4 N.m (35 in. lbs.) torque. 6. Install the air inlet tube at air cleaner housing inlet. Page 95 8W-70-25 Component Locations Power Distribution (Part 1 Of 3) Page 521 Crankshaft Position Sensor: Service and Repair Heavy Duty Engines Fig. 51 Crankshaft Position Sensor The sensor is bolted to the top of the cylinder block near the rear of right cylinder head. 1. Remove the air cleaner assembly and its plastic air intake tube. 2. Remove the spark plug cable loom and spark plug cables from valve cover mounting stud at rear of right valve cover. Position spark plug cables to top of valve cover. 3. Disconnect 2 hoses at Exhaust Gas Recirculation (EGR) valve. Note position of hoses at EGR valve before removal. 4. Disconnect electrical connector and hoses at electric EGR valve control. Note position of hoses before removal. 5. Remove 2 EGR valve mounting bolts and remove EGR valve. Discard old EGR gasket. 6. Disconnect electrical connector at engine oil pressure sending unit. Fig. 52 Oil Pressure Sending Unit - Removal/Installation 7. To prevent damage to oil pressure sending unit, a special tool, such as number C-4597 must be used. Remove sending unit from engine. 8. Loosen EGR tube mounting nut at intake manifold. 9. Remove 2 EGR tube mounting bolts at exhaust manifold and remove EGR tube. Discard old gasket at exhaust manifold. 10. Disconnect crankshaft position sensor pigtail harness from main wiring harness. 11. Remove 2 sensor (recessed hex head) mounting bolts and remove sensor. Page 434 Fig. 8 5. Insert all of the wire terminals into their proper locations in the supplied connector EXCEPT TERMINALS "B2" and "R". Retape the wiring bundle as necessary. Fig. 8 6. For vehicles WITHOUT headlamp switch connector or terminal heat damage: Remove the PINK w/RED TRACER wire from location "B2" and the BLACK w/YELLOW TRACER wire from location "R" of the headlamp switch connector using a small screwdriver, Miller Special Tool # 8197 or equivalent. Fig. 9 7. Insert the wire terminals that were originally in locations "B2" and "R" of the headlamp wiring connector into the supplied 2-way wiring connector. Insert the PINK wired TRACER wire into the (+) cavity. Insert the BLACK w/YELLOW TRACER wire into the (-) cavity. Secure the terminals with the provided 2-way wedge. Page 549 JTEC O2 Sensor Configuration Page 445 Headlamp Switch: Service and Repair 1. Disconnect battery ground cable, then remove cup holder and ash tray assemblies. 2. Pry instrument cluster bezel carefully away from instrument panel to disengage clips, then unplug connectors from cigar lighter and auxiliary power outlet. 3. Remove mounting screws from headlamp switch bezel, then remove headlamp switch and bezel. 4. Disconnect harness connectors from switch, then pull headlamp switch knob out to its full stop. 5. Depress release button on bottom of switch housing and knob and stem from switch. 6. Remove mounting screws, then switch from switch bezel. 7. Reverse procedure to install Locations Camshaft Position Sensor: Locations Camshaft Position Sensor The Camshaft Position (CMP) Sensor is mounted in the distributor housing. Page 39 Key Reminder Relay: Description and Operation CIRCUIT OPERATION The time delay relay is used to allow a time-ON function for the ignition switch lamp. Power for the relay is provided on the M1 circuit from the IOD fuse (fuse 17) in the fuse block. Circuit M2 provides ground for the time delay relay through the right and left door jamb switches and the headlamp switch. When a door is OPENED, or the headlamp switch is moved to the dome/cargo lamp ON position, a ground path is provided for the relay on circuit M2. This energizes the relay, causing the contacts to CLOSE. When the relay contacts CLOSE, power is provided through the relay to circuit M50. The M50 circuit supplies current to the key-in-switch halo lamp. Circuit Z3 provides ground for the lamp. Page 585 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 Page 76 8W-11-22 Revision to the Coolant Temperature Sensor and EGR solenoid descriptions. Page 617 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 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. Page 85 8W-30-47 Page 890 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 Page 120 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. Terminal Removal Page 494 8W-70-26 Revisions to the Connector Pin-outs. Page 926 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. Page 502 Page 293 193 Description and Operation Power Mirror Switch: Description and Operation CIRCUIT OPERATION The power mirror switch has a right and a left position. Moving the switch to either of these positions changes the voltage path internal to the switch (changes polarity at the motors). When the switch is moved to the LEFT position and mirror movement UP is selected, voltage is supplied through the P75 circuit and the ground path is through circuit P73. When the DOWN movement is selected, the power and ground are reversed. If a LEFT door mirror movement LEFT is selected, voltage is supplied through the P71 circuit and the ground is passed through circuit P73. When the left door mirror RIGHT movement is selected, the power and ground are reversed. When the switch is moved to the RIGHT position and mirror movement UP is selected, voltage is supplied through the P72 circuit and the ground path is through circuit P70. When the DOWN movement is selected, the power and ground are reversed. If a RIGHT door mirror movement LEFT is selected, voltage is supplied through the P74 circuit and the ground is passed through circuit P70. When the left door mirror RIGHT movement is selected, the power and ground are reversed. Locations Key Reminder Relay: Locations Fuse Block (Part 1 Of 2) Page 480 8W-30-44 Page 966 Coolant: Specifications System Capacity System Capacity Coolant capacity 20 qt (US) Page 859 5. Connect vehicle fuel line into adapter tool 6923. 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". 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 pressure is at 0 psi, connect DRB scan tool and refer to Powertrain Control Module/Testing and Inspection. 10. If operating pressure is above 54.2 psi, fuel pump is OK but fuel pressure regulator is defective. Fuel pressure regulator is not serviced separately. Replace fuel pump module assembly. 11. After performing pressure test, install fuel line into fuel rail. Install latch clip into fuel rail. Page 504 Coolant Temperature Sensor/Switch (For Computer): Description and Operation CIRCUIT OPERATION The engine coolant temperature 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 engine 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. Component Test Crankshaft Position Sensor: Testing and Inspection Component Test 1. Near the rear of the intake manifold, disconnect sensor pigtail harness connector from main wiring harness. Fig. 26 Sensor Connector 2. Place an ohmmeter across terminals B and C. Ohmmeter should be set to 1K-to-1OK scale for this test. The meter reading should be open (infinite resistance). Replace sensor if a low resistance is indicated. Description and Operation Ambient Temperature Sensor / Switch HVAC: Description and Operation CIRCUIT OPERATION The ambient temperature sensor is a variable resistor. Circuit G31 supplies voltage from the overhead console to the sensor. Circuit G32 is the signal return from the sensor to the overhead console. Page 269 Parking Brake Warning Switch: Description and Operation Park Brake Switch Input CIRCUIT OPERATION On circuit G11, the Controller Anti Lock Brake (CAB) senses when the park brake switch CLOSES. Circuit G11 from the park brake switch connects to cavity 5 of the CAB. Page 886 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). Description and Operation Fuel Pump Control Unit: Description and Operation CIRCUIT OPERATION The in-tank fuel pump module contains the fuel pump motor and the fuel level sensor. Page 692 1996 - 1997 (SR) Viper **2001 - 2002 (ST) Sebring Coupe/Stratus Coupe** 1997 - 2001** (TJ) Wrangler 1999 - **2001** (WJ) Grand Cherokee 1997 - **2001** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. NOTE: **SOME 2001 MODEL YEAR PACKAGES (AN/AN84/DN/JR/LH/PL/PT/RS/TJ) REQUIRE OCCUPANT RESTRAINT CONTROLLER (ORC) CONFIGURATION USING THE DRB III(R) AS DETAILED IN EACH VEHICLE SPECIFIC PACKAGE.** DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. NOTE: FOR SOME 2000 MODEL YEAR APPLICATIONS (AB/AN/AN84/DN/JA/NS) **AND SOME 2001 CARRYOVER APPLICATIONS (AB/BR/WJ/XJ)**, A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05013528AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT IS ORANGE, AND MUST BE PRESENTED TO THE CUSTOMER IN PLACE OF THE YELLOW ONE, P/N 05013517AA, THAT WILL COME IN THE AIRBAG KIT. **FOR SOME 2001 MODEL YEAR APPLICATIONS (WITH J1850 BUS, AN/AN84/DN/JR/LH/PL(PT/RS/TJ) A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05016025AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT MUST BE PRESENTED TO THE CUSTOMER AFTER INSTALLATION.** Page 150 Page 923 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). Page 414 13. Pull the headlamp switch control knob out to the ON position stop. 14. Depress the switch knob and shaft release button on the bottom of the switch assembly and then pull the switch knob and shaft out of the switch. Fig. 5 15. Remove the three screws that secure the headlamp switch bezel to the switch mounting bracket and then remove the bezel. Unscrew the plastic mounting bracket (shaft bushing) nut and remove the bezel mounting bracket from the switch assembly. Discard the switch assembly. B. Install the Parklamp Circuit Overlap Harness: 1. Remove the wedge from the 9-way headlamp switch wiring connector. Fig. 6 2. Inspect the 9-way headlamp switch connector and all nine (9) terminals for indications of heat damage. Page 11 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) Page 925 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. Page 456 Camshaft Position Sensor: Diagrams Testing and Inspection Brake Fluid: Testing and Inspection NOTE: Swollen rubber parts indicate the presence of petroleum in the brake fluid. To confirm that contamination exists, make the following test: Place a small amount of the drained brake fluid into a small clear glass bottle. Separation of the fluid into distinct layers will indicate mineral oil content. If there is any question of mineral oil content, drain system, flush thoroughly and replace all rubber parts. Page 146 Powertrain Control Module: Service and Repair Fig. 34 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 4 N.m (35 in. lbs.). 3. Check pin connectors in the PCM and the three 32-way connectors for corrosion or damage. Repair as necessary 4. Install three 32-way connectors. 5. Install battery cable. Page 870 Fuel Pressure Release: Service and Repair W/O Pressure Test Port 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 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 injection 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. 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. Page 298 209 Page 297 207 Page 82 8W-30-44 Page 159 Except CNG Page 515 Crankshaft Position Sensor: Description and Operation Circuit Operation 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. Page 769 Ignition Switch: Description and Operation CIRCUIT OPERATION When the ignition switch is in the RUN position, it connects circuit A2 from fuse 2 in the Power Distribution Center (PDC) to circuit A22. Circuit A22 connects to the fuse block. Through the fuse block, circuit A22 feeds circuits A20, L10, F23, C1 and F21. Circuits A20, L10, F23, and C1 are protected by separate fuses. A circuit breaker protects circuit F21. When the ignition switch is in the START or RUN position, it connects circuit A1 from fuse 3 in the PDC to circuit A21. Circuit A21 powers circuits F18, F12, and F14 through the fuse block. Separate fuses protect each circuit. In the START position, the ignition switch connects circuit A1 from fuse 3 in the PDC to circuit A41. Circuit A41 connects to either the clutch pedal position sensor or the clutch pedal position switch bypass jumper. Also in the START position, the ignition switch connects circuit G9 to ground. In the ACCESSORY or RUN position, the ignition switch connects circuit A1 to circuit A31. Circuit A31 connects to the fuse block and feeds circuits F30, L5, Xl2, and V6. Separate fuses protect each circuit. Light Duty Engines Air Cleaner Housing: Service and Repair Light Duty Engines REMOVAL CAUTION: Do not attempt to remove the air cleaner element (filter) from the housing by removing the top cover only. To prevent damage to the air cleaner housing, the entire air cleaner housing assembly must be removed from the engine for air cleaner element replacement. Fig. 95 Air Cleaner Housing 1. Remove the air inlet tube at the side of the air cleaner housing. 2. A band-type screw clamp secures the air cleaner housing to the throttle body Loosen, but do not remove, this screw clamp. Note the clamp positioning tabs on the air cleaner housing. 3. All Engines: Disconnect the breather hose at the rear of air cleaner housing. 4. The bottom/front of the air cleaner housing is equipped with a rubber grommet. A mounting stud is attached to the intake manifold and is used to position the air cleaner housing into this grommet. Lift the assembly from the throttle body while slipping the assembly from the mounting stud. 5. Check condition of gasket at throttle body and replace as necessary. 6. The housing cover is equipped with three (3) spring clips and is hinged at the rear with plastic tabs. Unlatch the clips from the top of air cleaner housing and tilt the housing cover up and rearward for cover removal. 7. Remove the air cleaner element from air cleaner housing. INSTALLATION 1. Before installing a new air cleaner element, clean inside of air cleaner housing. 2. Position air cleaner cover to tabs on rear of air cleaner housing. Latch the three spring clips to seal cover to housing. 3. Position the air cleaner housing assembly to the throttle body while guiding the rubber grommet over the mounting stud. The lower part of the screw clamp should be below the top lip of the throttle body. 4. Push down on air cleaner housing at rubber grommet to seat housing at intake manifold. 5. Tighten throttle body-to-air cleaner housing clamp to 4 N.m (35 in. lbs.) torque. 6. Install the air inlet tube at air cleaner housing inlet. Page 736 1. Remove the ignition switch mounting screws (Figure 8). Use a tamper-proof torx bit (Snap-on PN TTXR2OA2 or equivalent) to remove the screws. 2. Remove the ignition switch from the steering column. 3. Insert the ignition key into the key cylinder and turn the key to the LOCK position. 4 Depress the key cylinder retaining pin or, if equipped, use the tamper-proof torx bit to remove the key cylinder retaining screw and bracket (Figure 9). 5. Turn the ignition key to the OFF position. The key cylinder will then unseat from the ignition switch. When the key cylinder is unseated, it will be approximately 1/8" away from the ignition switch halo light ring. Do NOT attempt to remove the key cylinder at this time. 6. With the key cylinder unseated, turn the ignition key to the LOCK position and then remove the key. Page 770 Ignition Switch: Service and Repair REMOVAL 1. Disconnect battery ground cable. 2. On models with tilt column, remove tilt lever. 3. Remove upper and lower covers, then the ignition switch mounting screws using a suitable Torx tool. 4. Remove switch from column, then the seven terminal connector from switch. 5. Remove key-in-switch/halo light four terminal connector from ignition switch. 6. Remove key cylinder from switch as follows: a. Insert key and ensure switch is in lock position. Fig. 5 Key Cylinder Retaining Pin Depression b. Using a torx tool remove key cylinder retaining screw and bracket. Sensor Operation Crankshaft Position Sensor: Description and Operation Sensor Operation DESCRIPTION Engine speed and crankshaft position are provided through the crankshaft position sensor. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. Fig. 5 Sensor Operation The flywheel/drive plate has 8 single notches, spaced every 45 degrees, at its outer edge. NOTE: The engine will not operate if the PCM does not receive a crankshaft position sensor input. OPERATION The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. For each engine revolution, there are 8 pulses generated on V-8 engines. The 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. Page 142 cylinder engine running in excess of 6,500 RPM. Spark Control SPARK CONTROL The K4 microcomputer controls the generation and timing of spark pulses. The spark advance and dwell characteristics are determined by: engine speed, throttle position, MAP, coolant temperature, barometric air pressure, air temperature, and vehicle speed. Transmission Control TRANSMISSION CONTROL The PCM operation includes control of 3 and 4 speed automatic transmissions utilizing electronic governor pressure control, eliminating the need for a separate transmission controller. Transmission control is achieved through regulation of governor pressure using a variable force solenoid valve. (Valve position is controlled by pulse width modulation. Torque convertor lock-up and overdrive solenoids are also controlled by the PCM, as are the transmission protection relay and dashboard overdrive lamp. PCM inputs affecting transmission operation include the throttle position sensor, output shaft speed sensor, vehicle speed sensor, engine speed sensor, brake switch, cruise control switches, ignition, overdrive on/off switch and sump fluid temperature thermistor. Electronic Governor Pressure Control Regulation of governor pressure enables control of WOT shift points to within +/- 50 RPM resulting in improved shift quality (as opposed to control to within +/- 300 RPM in transmission utilizing mechanical governors). The elimination of the mechanical governor resulted in a physically smaller and lighter package. Torque calculation can be used to determine when upshifting is advantageous. Anti-Hunt Shift Strategy This strategy was added in order to maintain fuel economy over a variety of load conditions. This technique allows for relatively early upshift in mid-range throttle settings under light load conditions, resulting in improved fuel economy. Under heavier loading, shifts are delayed to prevent upshifting into a condition where insufficient torque is available to maintain vehicle speed, resulting in downshift/upshift cycling. Sump Pump Temperature Sensing A thermistor is attached to the lock-up solenoid and submerged in the sump fluid. The sump fluid temperature is a factor in the calculation of WOT shift strategy, low temperature shift compensation, sump temperature limiting strategy, overdrive strategy, torque converter clutch strategy, and governor pressure transducer calibration. Page 561 Throttle Position Sensor: Description and Operation 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. Page 241 This Repair Procedure clamps three RFl filters around the intermittent wiper module's wiring. 1. Record the radio station presets. 2. Disconnect and isolate the battery negative cable. 3. Remove the five screws that secure the knee bolster to the dash pane! and remove the knee bolster. 4. Locate the intermittent wiper module located under the instrument panel and above the accelerator pedal. Slide the module off its mounting bracket. 5. Separate the nine wires entering the connector on back of the module into three groups. Install a snap-together filter on each of the three groups of wires. The filter should be placed as close to the module as possible. 6. Apply foam tape (P/N 4318028) around the RFI filters. 7. Slide the module back onto its mounting bracket. 8. Install the knee bolster. 9. Connect the negative cable and reset the clock and reprogram the radio to the station presets identified in step one. Page 809 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. Page 564 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 Fuel Pressure Test - With Test Port Fuel Pressure: Testing and Inspection Fuel Pressure Test - With Test Port Fig. 5 Fuel Injectors - Typical (V10 Shown) NOTE: The fuel pressure test port is located on the end of the fuel rail near the engine thermostat housing. A sealing cap is screwed onto the test port. FUEL PRESSURE REGULATOR 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. With engine at idle speed, system fuel pressure should be 339 kPa +/- 34 kPa (49.2 psi +/- 5 psi). WARNING: Do not allow fuel to spill onto the engine intake or exhaust manifolds. Place shop towels under and around the pressure port to absorb fuel. WARNING: Wear proper eye protection when testing fuel system pressure. 1. Remove the protective cap at the fuel rail test port. Connect the 0-414 kPa (0-60 psi) fuel pressure gauge (from gauge set 5069) to the test port pressure fitting on the fuel rail. 2. Start the engine and note pressure gauge reading. Fuel pressure should be 339 kPa +/- 34 kPa (49.2 psi +/- 5 psi) at idle. 3. If pressure is at 0 psi, connect DRB scan tool and refer to Powertrain Control Module. 4. If operating pressure is above 54.2 psi, fuel pump is OK but fuel pressure regulator is defective. Fuel pressure regulator is not serviced separately. Replace fuel pump module assembly. Page 889 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. Recall - Ignition Switch Wiring Overheating Technical Service Bulletin # 875 Date: 000601 Recall - Ignition Switch Wiring Overheating June 2000 Safety Recall No.875 Ignition Switch Wiring Models 1994-1996 (BR) Dodge Ram Trucks NOTE: This recall applies only to the above vehicles built at the: ^ Warren Assembly Plant ("S" in the 11th VIN position) through April 4, 1996 (MDH O4O4XX); ^ St. Louis North Assembly Plant ("J" in the 11th VIN position) through March 23, 1996 (MDH 0323XX); ^ Lago Alberto Assembly Plant ("M" in the 11th VIN position) through April 14, 1996 (MDH 0414XX); or ^ Saltillo Assembly Plant ("G"in the 11th VIN position) through April 14, 1996 (MDH 0414XX). 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 ignition switch and/or steering column wiring on about 710,000 of the above vehicles may overheat when the blower motor is operated at high speed for an extended period of time. This can cause stalling, loss of blower motor or power window operation, ABS or airbag lamp illumination or a steering column/instrument panel fire. Repair A blower motor relay and overlay harness must be installed to remove the blower motor circuit from the ignition switch. In addition, the ignition switch and electrical connector must be inspected for damage and replaced if necessary. Parts Information A. Ignition Switch Wiring Package Part Number Description CBXR875O Ignition Switch Wiring Package Each package contains the components listed: Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Ignition Switch Wiring Packages to service about 10% of those vehicles. B. Ignition Switch Assembly Sensor Test Intake Air Temperature Sensor: Testing and Inspection Sensor Test Fig. 69 Intake Manifold Air Temperature Sensor 1. Disconnect the wire harness connector from the intake manifold air temperature sensor. Sensor Resistance (OHMS) - Coolant Temperature Sensor/Intake Air Temperature Sensor 2. Test the resistance of the sensor with an input impedance (digital) volt-ohmmeter. The resistance (as measured across the sensor terminals) should be less than 1340 ohms with the engine warm. Refer to the 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. 3. Test the resistance of the wire harness. Do this between the Powertrain Control Module (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. NOTE: for additional testing information, see Testing and Inspection/Test TC-57A or Test TC-58A. Page 421 DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 ADDITIONAL INFORMATION If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Owner Letter SAFETY RECALL TO REPLACE YOUR TRUCK'S HEADLAMP SWITCH AND INSTALL A RELAY WIRING HARNESS Dear Dodge Ram 3500 Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. DaimlerChrysler Corporation has determined that a defect, which relates to motor vehicle safety, exists in some 1994 through 1997 Dodge Ram 3500 Series trucks. The problem is... Driving your Ram truck (identified on the enclosed form) with the lights on for an extended time frame can overheat the headlamp switch and cause a fire. An overheated headlamp switch can also result in a sudden loss of headlamp and/or parklamp operation and cause an accident without warning. What DaimlerChrysler and your dealer will do... Daimlerchrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will replace the headlamp switch and do install a relay wiring harness. The work will take about 1/2 hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do to ensure your saftey... Simply contact your dealer right away to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. Bring the enclosed Owner Notification Form with you to your dealer. It identifies the required service to the dealer. If you need help... If you have trouble getting your vehicle repaired, please call the DaimlerChrysler Customer Assistance Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, DC 20590, or call the Toll Free Auto Safety Hotline at 1-800-424-9393. Washington, DC area residents may call l-202-366-0123. We're sorry for any inconvenience, but we are sincerely concerned about your safety. Thank you for your attention to this important matter. Page 216 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. Page 704 POLICY: Information Only Page 123 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 Page 28 Compressor Clutch Relay: Testing and Inspection Compressor Clutch Relay RELAY TEST The compressor clutch relay is located in the Power Distribution Center (PDC). Refer to the PDC label for relay identification and location. Remove the relay from the PDC to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2. If not OK, replace the faulty relay. 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 +/-5 ohms. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, SEE the Relay Circuit Test. If not OK, replace the faulty relay. RELAY CIRCUIT TEST 1. The relay common feed terminal cavity (30) is connected to fused battery feed. There should be battery voltage at the cavity for relay terminal 30 at all times. If OK, go to Step 2. If not OK, repair the open circuit to the PDC fuse as required. 2. The relay normally closed terminal (87A) is not used in this application. Go to Step 3. 3. The relay normally open terminal cavity (87) is connected to the compressor clutch coil. There should be continuity between this cavity and the A/C compressor clutch relay output circuit cavity of the compressor clutch coil wire harness connector. If OK, go to Step 4. If not OK, repair the open circuit as required. 4. The relay coil battery terminal (86) is connected to the fused ignition switch output (run/start) circuit. There should be battery voltage at the cavity for relay terminal 86 with the ignition switch in the On position. If OK, go to Step 5. If not OK, repair the open circuit to the fuse block module as required. 5. The coil ground terminal cavity (85) is switched to ground through the Powertrain Control Module (PCM). There should be continuity between this cavity and the A/C compressor clutch relay control circuit cavity of the PCM wire harness connector C (gray) at all times. If not OK, repair the open circuit as required. 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. Page 855 Fuel Pressure: Specifications Fuel Pressure Engine at curb idle ............................................................................................................................... ........................................ 339 ± 34 kPa (49.2 ± 5 psi) Fuel Pressure Drop (Fuel pump not engaged) ..................................................................................................................................... Up to 138 kPa (20 psi) Fuel Pressure Leakdown ................................................................................................................................................. 30 psi (minimum for five minutes) Page 83 8W-30-45 Light Duty Engines Crankshaft Position Sensor: Service and Repair Light Duty Engines REMOVAL The sensor is bolted to the top of the cylinder block near the rear of right cylinder head. Fig. 25 Crankshaft Position Sensor - Typical 1. Remove the air cleaner intake tube. 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 N.m (70 in. lbs.) torque. 3. Connect main harness electrical connector to sensor. 4. Install air cleaner tube. Page 133 Powertrain Control Module: Description and Operation Circuit Operation Battery Feed CIRCUIT OPERATION Circuit A14 from fuse 8 in the Power Distribution Center (PDC) supplies battery voltage to cavity A22 of the Powertrain Control Module (PCM). Ground CIRCUIT OPERATION 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. Page 579 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. How to Read Wiring Diagrams Wire Color Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire and color. 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. Page 553 Oxygen Sensor: Testing and Inspection Sensor Heating Element Test Light Duty Engines Fig. 9 Upstream/Downstream Oxygen Sensors - LDC Engines The upstream O2S sensor is located on the inlet end of the catalytic converter. The downstream O2S sensor is located on the outlet end of the catalytic converter (Fig. 62). Each O2S heating element can be tested with an ohmmeter as follows: Disconnect the O2S sensor connector. Connect the ohmmeter test leads across the white wire terminals of the sensor connector. Resistance should be between 5 and 7 ohms. Replace the sensor if the ohmmeter displays an infinity (open) reading. Heavy Duty Engines Fig. 63 Left/Right Oxygen Sensor Location The left and right 025 sensors are located on the left and right exhaust downpipes. Each O2S heating element can be tested with an ohmmeter as follows: Disconnect the O2S sensor connector. Connect the ohmmeter test leads across the white wire terminals of the sensor connector. Resistance should be between 5 and 7 ohms. Replace the sensor if the ohmmeter displays an infinity (open) reading. Page 468 8W-30-10 Page 103 Powertrain Control Module: Technical Service Bulletins PCM - Cruise Control System Check NO: 08-01-96 GROUP: Electrical DATE: Jan. 19, 1996 SUBJECT: Speed Control Light Flickers and/or Servo Clicks MODELS: 1996 (BR) Ram Truck 1996 (AN) Dakota 1996 (AB) Ram Van/wagon 1996 (XJ) Cherokee SYMPTOM/CONDITION: The speed control indicator light, located on the speed control switch module, may flicker and/or a click may be heard from the speed control servo when the ignition key is turned to the RUN/START position and/or when the key is turned from RUN/START to OFF. DISCUSSION: The speed control indicator light is operated by the Powertrain Control Module (PCM). When the PCM is first powered-up by positioning the ignition key to the RUN/START position, the PCM performs a systems check. During the system check, the PCM momentarily provides power for the speed control indicator light, causing the light to illuminate. Also, the speed control servo is supplied with battery voltage at the same time. When the servo receives power, a click may also be noticed. This is due to the dump solenoid being energized momentarily. The PCM performs an additional systems check when the ignition switch is turned from RUN to OFF. The flickering of the light or the sound of the dump solenoid clicking will not have any adverse effects on the electrical system within the vehicle. Please inform your customers that the flickering of the light and the click from the dump solenoid is due to a PCM systems check and is a normal operation of the system. NOTE: Do not replace the clockspring or any other components directly or indirectly related to the speed control system for this condition. POLICY: Information Only Page 732 a. Turn the ignition switch to the ON position. b. Turn the blower motor on LOW and verify that the blower is operating. c. Disconnect the relay. ^ If the blower motor stops, this relay is for the blower motor. ^ If the blower motor does not stop, this relay is NOT for the blower motor. d. Turn the ignition switch OFF and connect the relay. 4. ^ If a blower motor relay is NOT present, continue with Section "B - Inspect Ignition Switch and Wiring." ^ If a blower motor relay is present, no further action is necessary. Return the vehicle to the customer. B. Inspect Ignition Switch and Wiring 1. Disconnect the negative battery cable(s). NOTE: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Remove the five (5) screws that secure the knee blocker to the lower instrument panel and then remove the knee blocker (Figure 3). 3. Remove the steering column tilt lever by turning it counter-clockwise. Page 891 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. Page 314 8W-02-3 Page 363 Page 102 8W-80-36 Page 542 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 Page 816 Transmission Temperature Sensor/Switch: Description and Operation CIRCUIT OPERATION 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. The Powertrain Control Module (PCM) supplies 5 Volts to the sensor on circuit K7. Circuit T54 from the sensor connects to cavity B1 of the PCM and provides the transmission temperature input. The PCM provides ground for the sensor on cavity K4. The PCM grounds the transmission temperature warning lamp on circuit G14. Circuit G14 connects to cavity C7 of the PCM. The transmission temperature warning lamp is located in the message center. Page 685 c. Rotate key clockwise to Off position to unseat cylinder from ignition switch. d. With cylinder in unseated position rotate key counterclockwise to lock position, then remove key and cylinder. INSTALLATION 1. Install electrical connector to switch, then mount switch to column. 2. Ensure shifter is in park position. Park lock dowel pin in switch must engage with column park lock slider linkage. Fig. 7 Ignition Switch Park Lock Dowel Pin 4. With key cylinder and ignition in lock position, insert cylinder into ignition switch assembly until it bottoms. 5. Insert key and push inward on key cylinder, then rotate key clockwise to end of travel. Locations Initial Inspection and Diagnostic Overview Powertrain Control Module: Initial Inspection and Diagnostic Overview - If the system loses ground for the Z12 circuits the vehicle will not operate. Page 533 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 Page 678 41. Verify that the blower motor operates properly. Page 339 8W-70-24 Page 752 Part Number Description 04326622 Ignition Switch Assembly Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive two (2) ignition switch assemblies. Additional ignition switches should be ordered only after inspection determines that replacement is required. Very few vehicles are expected to require ignition switch replacement 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: Add the cost of the recall parts package and switch assembly, if necessary, 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 "0RD875". 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: Page 323 Revisions to the Powertrain Control Module wiring. Page 327 8W-30-44 Page 497 8W-80-22 Page 620 Camshaft Position Sensor: Testing and Inspection Helpful Information - Circuit K6 splices to supply 5 Volts to the crank-shaft 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 Page 436 3. Install the switch knob and shaft on the new switch assembly by depressing the release button on the bottom of the switch assembly and then inserting the shaft into the switch assembly. Fig. 10 4. Connect the 9-way wiring connector to the headlamp switch. Fig. 10 5. Connect the 2-way wiring connector to the headlamp switch (if equipped). Fig. 10 Page 130 B21 T60 BR Solenoid Control 3-4 Shift B22 K221 TN/PK Fuel Temp Sensor Signal B25 T13 DB/BK Output Shaft Speed Sensor Ground B27 G7 WT/OR Vehicle Speed Sensor Signal B28 T14 LG/BK Output Shaft Speed Sensor Signal B29 T25 LG/WT Governor Pressure Signal B30 K30 PK Transmission Relay Control B31 K7 OR 5-Volt Supply B32 K35 GY/YL EGR Solenoid Control C1 C13 DB/OR A/C Comp. Clutch Relay Control C3 K51 DB/YL Auto Shutdown Relay Control C4 V36 TN/RD S/C Vacuum Solenoid Control C5 V35 LG/RD S/C Vent Solenoid Control C6 T18 LG/OR Overdrive Off Lamp Driver C7 G14 PK/BK Trans Temp. Lamp Driver C11 V32 YL/RD 12 Volt Supply C12 A142 DG/OR Auto Shutdown Relay Output C13 T6 OR/WT Overdrive Off Switch Sense C15 K118 PK/YL Battery Temp. Sensor Signal C16 G12 TN/YL Generator Lamp Driver C17 G3 BK/PK MIL (Check Engine) Lamp Driver C18 G24 GY/PK Service Reminder Indicator Driver C19 K31 BR/WT Fuel Pump Relay Control C20 K52 PK Evaporative Emission Solenoid Control C22 C20 BR A/C Request Signal C23 C90 LG A/C Select Signal C24 V40 WT/PK Brake Switch Sense C26 K226 DB/WT Low Fuel Sense C27 D21 PK/DB SCI Transmit C29 D20 OG SCI Receive C31 G21 GY/LB Tachometer Signal C32 V37 RD/LG Speed Control Switch Signal Locations Vehicle Speed Sensor: Locations Helpful Information Oxygen Sensor: Testing and Inspection Helpful Information - Along with supplying voltage to the ASD relay contacts, circuit A14 connects to cavity A22 of the PCM. - Circuit A142 splices to supply voltage to the fuel injectors and ignition coil(s). - 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 Locations Fuel Pump Relay: Locations Power Distribution (Part 1 Of 3) Page 431 3. Remove the cup holder assembly from the instrument panel. 4. Remove the ash receiver from the ash receiver bracket. Fig. 2 5. Remove the two (2) screws that secure the ash receiver bracket to the instrument panel. 6. Remove the ash receiver bracket from the instrument panel. Fig. 3 7. Carefully pry the cluster bezel away from the instrument panel to disengage the eight (8) snap-clip retainers. 8. Unplug the wiring harness connector from the lighter. 9. Unplug the wiring harness connector from the auxiliary power outlet. 10. Set the cluster bezel aside. Fig. 4 11. Remove the three (3) screws that secure the headlamp switch bezel to the instrument panel. 12. Pull the headlamp switch and bezel out from the instrument panel and then unplug the wiring harness connector(s). Architecture Powertrain Control Module: Description and Operation Architecture Hardware HARDWARE ARCHITECTURE The design of the Powertrain Control Module (PCM) can be broken up into about eight major sections. The main microcontroller, a Motorola MC68HC16Z2, is attached to a 256k byte memory device (flash memory) which is programmed after manufacture of the module. (This memory can be reprogrammed at the factory or at a dealership. The MC68HC11D3 and MC68HC11K4 microcomputers have memories which are permanently programmed during their manufacture, and therefore cannot be reprogrammed.) The microcomputers communicate over a bus which allows for rapid transmission of high priority messages. The Z2 executes the primary powertrain control strategy; transmits fuel and spark requirements to the D3 and K4; communicates with outside devices; and processes 14 analog inputs and about half of the one bit inputs and outputs. The D3 microcomputer controls fuel injector timing pulses and a small number of one bit inputs and outputs. The K4 controls spark timing pulses, processes 8 analog inputs and a number of one bit inputs and outputs. Other major sections of the PCM design include the power supply, input conditioning circuits, output driver circuits, serial communication interface circuits, and a device which controls ignition coil currents. Software SOFTWARE ARCHITECTURE The 68HC16Z2 microcontroller is the main computing unit of the Powertrain Control Module (PCM). The 68HC11D3 and K4 microcontrollers control fuel and spark respectively. They handle the critical timing requirements of their tasks, communicating with the Z2 using high level commands. The Z2 operating system is the heart of the software and was written expressly for this PCM. Every 500 microseconds the Z2 interrupts what it is doing to perform periodic tasks such as updating sensor inputs values and checking for the occurrence of a crank position pulse. If this pulse is observed, a program known as the decision maker is executed and performs high priority tasks such as fuel and spark calculations, and RPM processing. Low priority tasks (i.e. OBDII processing, SCI and CCD communications) are executed during the time between crank pulses. The Z2 software is divided into a main operating strategy and three separate calibration areas. The main strategy contains information specific to the various engines and transmissions supported by this PCM. Once installed, the information contained in this area is fixed for a given engine and transmission. Changes to this data, if required, can be performed only by computer programming personnel. The calibration areas (engine, transmission and OBDII) contain information relating to emissions, fuel economy and driveability and can be altered directly by calibration personnel. Page 124 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 Page 282 59 Page 322 8W-30-8 Page 482 8W-30-46 Page 479 8W-30-42 Page 693 With Four Wheel Antilock System Electronic Brake Control Module: Service and Repair With Four Wheel Antilock System 1. Disconnect battery cables and remove battery from vehicle, then disconnect ABS wiring harness at ABS valve. 2. Disconnect wiring harness at ABS electronic control module, then disconnect front brake lines at ABS valve. 3. Remove bolts and stud nuts securing ABS valve and electronic control to inner fender panel, then remove valve and module from vehicle. 4. Reverse procedure to install, noting the following: a. Torque ABS valve mounting bolt and stud nuts to 8-10 ft. lbs. and hydraulic fittings to 14-16 ft. lbs. b. Bleed brake system as described under Antilock Brake System/Service and Repair. Page 653 8. Remove the PINK with BLACK tracer (A2) wire from cavity 43 of the 84-way bulkhead connector (Figure 14). 9. Remove the RED wedge from the 7-way ignition switch connector (Figure 15). 10. Remove the BLACK with ORANGE tracer (A22) wire from cavity 5 of the 7-way ignition switch connector (Figure 15). Then, remove the wire from the wiring takeout bundle back to the base of the steering column. 11. Install the supplied blower relay wiring harness so that the X-wrap is located near the base of the steering column (Figure 16). Secure the harness with a tie strap. Light Duty Engines Crankshaft Position Sensor: Service and Repair Light Duty Engines REMOVAL The sensor is bolted to the top of the cylinder block near the rear of right cylinder head. Fig. 25 Crankshaft Position Sensor - Typical 1. Remove the air cleaner intake tube. 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 N.m (70 in. lbs.) torque. 3. Connect main harness electrical connector to sensor. 4. Install air cleaner tube. Page 342 8W-80-6 Page 674 14. Place the ignition switch against the lock housing opening on the steering column. Ensure that the ignition switch park lock dowel pin enters the slot in the park lock slider linkage in the steering column. 15. Install the ignition switch screws (Figure 8). Tighten the screws to 26 in-lbs (3 Nm). 16. Connect the key-in/halo light electrical connector to the new ignition switch (Figure 7). NOTE: DO NOT connect the 7-way ignition switch connector. D. Install Blower Motor Relay and Overlay Harness 1. Remove the 30-amp fuse from the fuseblock F2 -- Blower Motor location (Figure 13). 2. Remove the TAN wedge from the fuseblock (Figure 13). 3. Remove the BLACK with ORANGE tracer (A22) wire from cavity 11 of the fuseblock (Figure 13); then cut the terminal off and tape the wire back to the harness. 4. Remove the DARK GREEN (C1) wire from cavity 12 of the fuseblock (Figure 13). 5. Disconnect the 84-way bulkhead connector. 6. Remove the cover from the rear of the 84-way connector. 7. Remove the BLUE wedge from the 84-way connector. Locations Low Pressure Sensor / Switch: Locations Fig 25 High Pressure Cut-off Switch -- Typical HIGH PRESSURE CUT-OFF SWITCH The high pressure cut-off switch is located on the discharge line near the compressor. Fig 28 Low Pressure Cycling Clutch Switch LOW PRESSURE CYCLING CLUTCH SWITCH The low pressure cycling clutch switch is mounted on top of the accumulator. Page 337 8W-70-19 Page 279 51 Testing and Inspection Body Control Module: Testing and Inspection Page 247 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-92-00-90 0.2 Hrs. Perform Repair Procedure A 08-92-00-91 0.2 Hrs. Perform Repair Procedure B 08-92-00-92 0.2 Hrs. Perform Repair Procedure C FAILURE CODE: XX - Service Adjustment Repair Procedure A This Repair Procedure installs an RFI filter in series with the blower fan circuit. 1. Record the radio station presets. 2. Disconnect and isolate the battery negative cable. 3. Remove the glove box door by disconnecting the lanyard on the left side of the door, depressing the stop tab at the rear of the bin and then pulling the door away from the instrument panel. 4. Locate the orange, two-wire connector which is visible through the opening in the rear of the glove box cavity. Disconnect the connector. 5. Mate the connectors on the filter with those on the fan motor. Check both pairs of connectors to make sure that they are properly mated. 6. Apply foam tape (P/N 4318028) around RFI filter and upper connector end. 7. Install the glove box door and lanyard. 8. Remove the kick panel in front of the passenger-side door. 9. Locate the wiring harness ground termination on the sheet metal behind the kick panel. 10. Remove the ground termination bolt. Install one eyelet of the new ground wire (wire located in kit) on the termination bolt and secure the bolt. 11. Remove one of the bolts that secures the blower motor housing to the HVAC housing. Install the other end of the ground wire to the bolt and re-attach the bolt. 12. Install the kick panel. 13. Connect the negative cable and reset the clock and reprogram the radio to the station presets identified in step one. Repair Procedure B This Repair Procedure installs an RFI filter in series with the electric fuel pump motor. 1. Record the radio station presets. 2. Disconnect and isolate the battery negative cable. 3. Disconnect the fuel pump module connector located 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. 4. Connect the RFI module to the harness and to the fuel pump module connector. Secure the connectors by sliding the red lock tab back into its original position. 5. Apply foam tape (P/N 4318028) to the back of the RFI module. 6. Secure the RFI module by tie strapping it to the truss bracket. The truss bracket is adjacent to the fuel tank rail and chassis rail. 7. Connect the negative cable and reset the clock and reprogram the radio to the station presets identified in step one. Repair Procedure C Locations Page 776 Page 416 Fig. 8 5. Insert all of the wire terminals into their proper locations in the supplied connector EXCEPT TERMINALS "B2" and "R". Retape the wiring bundle as necessary. Fig. 8 6. For vehicles WITHOUT headlamp switch connector or terminal heat damage: Remove the PINK w/RED TRACER wire from location "B2" and the BLACK w/YELLOW TRACER wire from location "R" of the headlamp switch connector using a small screwdriver, Miller Special Tool # 8197 or equivalent. Fig. 9 7. Insert the wire terminals that were originally in locations "B2" and "R" of the headlamp wiring connector into the supplied 2-way wiring connector. Insert the PINK wired TRACER wire into the (+) cavity. Insert the BLACK w/YELLOW TRACER wire into the (-) cavity. Secure the terminals with the provided 2-way wedge. Page 460 Camshaft Position Sensor: Testing and Inspection Helpful Information - Circuit K6 splices to supply 5 Volts to the crank-shaft 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 Page 141 - 3/4 Shift Solenoid (open/short) - Speed Control Vacuum and Vent Solenoids (open/short) FUNCTIONALITY/RATIONALITY CHECKS - These tests determine if a component is working correctly through methods other than voltage limit tests and open/short tests. Solenoids in this section are checked for proper operation (functionality) and sensors are checked for meaningful output values (rationality). The components/systems checked are: Cam Sensor Pulses Present - Crank Sensor Pulses Present - MAP Sensor Output in Range - Coolant Temperature in Range - Throttle Position Sensor in Range - Vehicle Speed Sensor Output Correct - Park/Neutral Switch Working - Fuel Level Sensor Output Correct - Transmission Temperature Sensor Output Correct - Transmission Governor Pressure in Range - Output Shaft Speed Sensor Output Correct - AIS Motor Working - Lock-up Solenoid Working - 3/4 Shift Solenoid Working - Governor Pressure Solenoid Working - O2 Sensor 1/1 Output Voltage Low - O2 Sensor 1/2 Output Voltage Low - O2 Sensor 2/1 Output Voltage Low - O2 Sensor 2/2 Output Voltage Low - Charging System Working - Power Steering Switch Working - Thermostat Working - O2 Sensor 1/1 (open circuit or high voltage) - O2 Sensor 1/2 (open circuit or high voltage) - O2 Sensor 2/1 (open circuit or high voltage) - O2 Sensor 2/2 (open circuit or high voltage) Cruise Control CRUISE CONTROL The Powertrain Control Module (PCM) controls vehicle speed by operation of the speed control servo vacuum and vent solenoids. Energizing the vacuum solenoid applies vacuum to the servo to increase throttle position. Operation of the vent solenoid slowly releases the vacuum allowing throttle position to decrease. A special dump solenoid allows immediate release of throttle position caused by braking, cruise control turn off, or ignition key off. Exhaust Gas Recirculation EXHAUST GAS RECIRCULATION The Powertrain Control Module (PCM) controls a solenoid which enables/disables EGR. Control of exhaust gas recirculation (using exhaust gas pressure to modulate the vacuum supply to the EGR valve) is enabled only after the engine has warmed. Fuel Vapor Recovery System FUEL VAPOR RECOVERY SYSTEM (DUTY CYCLE PURGE CONTROL) Duty Cycle Purge is a system that feeds fuel gases from the purge canister and gasoline tank into the throttle body for mixing with incoming air. Metering of the gases is performed by duty cycling the purge solenoid by the Powertrain Control Module (PCM). The system is disabled during wide open throttle conditions and while the engine is below a specified coolant temperature. When engine temperature becomes greater than a calibrated parameter, duty cycle purge is delayed for a calibrated time. Once purge delay is over, purge will be ramped in to soften the effect of dumping additional fuel into the engine. The PCM provides a modulated 5 Hz signal (at closed throttle) or 10 Hz signal (at open throttle) to control this system. Modulation of the signal is based upon a calculated air flow (based upon known fuel flow through the injector at a given pulse width and RPM) and is adjusted to compensate for changes in flow due to varying engine vacuum. Overview OVERVIEW The Powertrain Control Module (PCM) features a multi-processor environment (one 16 bit microcomputer, two 8 bit micro-computers) allowing parallel processing of time critical operations. Dedication of one 8 bit processor (K4) to spark control and the other 8 bit processor (D3) to fuel control allows increases in throughput and reduced software complexity in the 16 bit microcomputer (Z2). The result is increased capability in the Z2 to handle overall strategy implementation, OBDII, and other computation-intensive processes. This approach allows control of up to a ten Page 822 Four-Wheel Drive (4WD) Switch: Description and Operation Rear CIRCUIT OPERATION From circuit G107, the Controller Antilock Brakes (CAB) senses when the four-wheel drive switch CLOSES. Circuit G107 connects to cavity 4 of the CAB. Page 419 6. Connect the single wire connector from the overlay harness to the ground terminal on the headlamp switch assembly. Fig. 4 7. Tuck the relay pack into the instrument panel pocket on the left side between the demister duct and the HVAC duct and then install the headlamp switch into the instrument panel. Tighten the three attaching screws securely. 8. Connect the lighter wiring connector. 9. Connect the auxiliary power outlet wiring connector to the power outlet on the cluster bezel. Fig. 3 10. Install the cluster bezel and engage the cluster bezel snap-clip retainers to the instrument panel. Fig. 2 11. Install the ash receiver bracket. Tighten the bracket screws securely. 12. Install the ash receiver. Page 7 Brake Fluid Pump Relay: Description and Operation CIRCUIT OPERATION When the Controller Anti Lock Brake (CAB) grounds the ABS pump relay on circuit B116, the relay contacts CLOSE connecting circuit A10 from the Power Distribution Center (PDC) and circuit B120. Circuit A10 connects to fuse 5 in the PDC. Circuit A20 from the fuse 14 in the fuse block splices to feed the coil side of the ABS warning lamp relay and the pump motor relay. From the ABS pump relay, circuit B120 splices to supply voltage to the ABS pump motor and all solenoids in the hydraulic control unit. Circuit B120 also supplies power to the solenoids in the Rear Wheel Anti Lock (RWAL) valve. Additionally, circuit B120 provides an input to cavity 34 of the CAB. The input tells the CAB that voltage has been supplied to the pump motor. Page 281 57 Page 490 8W-70-19 Page 286 71 Page 69 8W-02-3 Page 313 8W-02-2 Recall - Headlamp Switch Technical Service Bulletin # 819 Date: 990601 Recall - Headlamp Switch June 1999 Dealer Service Instructions for: Safety Recall No. 819 - Headlamp Switch MODELS 1994-1997 (BR) Dodge Ram 3500 Series Trucks NOTE: This recall applies only to 3500 series trucks built through October 21, 1996 (MDH 1021XX). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service as determined by using the DIAL VIP System. SUBJECT Extended operation of the lights on about 79,000 of the above vehicles can overheat the headlamp switch and cause a fire. An overheated headlamp switch can also result in a sudden loss of headlamp and/or parklamp operation and cause an accident without warning. REPAIR The headlamp switch must be replaced and a parklamp circuit relay wiring harness must be installed. In addition, the headlamp switch electrical connector must be inspected and any damaged wires must be replaced. PARTS INFORMATION Part Number Description CAJM8190 Headlamp Switch Package Each package contains the following components: Quantity Description 1 Headlamp Switch 1 Overlay Relay Harness 1 2-Way Female Connector 1 2-Way Wedge 1 Headlamp Switch Connector 1 Headlamp Switch Connector Wedge 1 Wire Kit (Contains 9 individual wires with terminals at one end) 9 Heat Shrink Tubing Each dealer, to whom vehicles in the recall were invoiced (or the current dealer at the same street address), will receive enough Headlamp Switch Packages to service about 25% of those vehicles. SERVICE PROCEDURE A. Remove the Headlamp Switch Assembly: 1. Disconnect the negative battery cable(s). Note: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. Fig. 1 2. Open the cup holder and remove the two (2) screws that secure the cup holder assembly to the instrument panel. Page 89 8W-33-3 Revisions to the Splice Information. Page 761 8. Remove the PINK with BLACK tracer (A2) wire from cavity 43 of the 84-way bulkhead connector (Figure 14). 9. Remove the RED wedge from the 7-way ignition switch connector (Figure 15). 10. Remove the BLACK with ORANGE tracer (A22) wire from cavity 5 of the 7-way ignition switch connector (Figure 15). Then, remove the wire from the wiring takeout bundle back to the base of the steering column. 11. Install the supplied blower relay wiring harness so that the X-wrap is located near the base of the steering column (Figure 16). Secure the harness with a tie strap. Page 935 Drive Belt: Adjustments 1. A new beltrun for 15 minutes is considered a used belt. 2. On models with 3.9L/V6-238 & 5.2L/V8-318 engines equipped with automatic belt tensioner, no adjustment is provided. 3. All engines equipped with automatic belt tensioner, no adjustment is provided. Page 702 PARTS REQUIRED: Locations Testing and Inspection Clutch Switch: Testing and Inspection Bosch & Nippondenso Starters The clutch pedal switch is a normally open type switch. 1. Locate and disconnect clutch pedal switch connector. 2. Using a suitable continuity tester, check circuit through switch with pedal released, there should be no continuity. 3. With continuity tester still attached, push clutch pedal to floor, tester should show full continuity. 4. Tester should not show continuity until pedal is fully depressed, replace switch if it fails any test. Page 138 Cruise or Idle Mode CRUISE OR IDLE MODE When the engine is at normal operating temperature, this is a closed loop mode. During certain idle conditions, the Powertrain Control Module (PCM) may enter into a variable idle speed strategy. At this time, the PCM adjusts engine speed based on the following inputs: throttle position - battery voltage - engine coolant temperature Deceleration Mode DECELERATION MODE This is a closed loop mode. The Powertrain Control Module (PCM) recognizes a decrease in throttle position and an increase in Manifold Vacuum as engine load decreases. In response, the PCM decreases the injector pulse width to meet the decreased load. Engine Start-Up Mode ENGINE START-UP MODE This is an open loop mode. The following actions occur when the starter motor is engaged: 1. The auto shutdown and fuel pump relays are energized. If the Powertrain Control Module (PCM) does not receive the camshaft and crankshaft signals within approximately one second, these relays are de-energized. 2. The PCM energizes all fuel injectors until it determines crankshaft position from the camshaft and crankshaft signals. The PCM determines crankshaft position within one engine revolution. After the crankshaft position has been determined, the PCM energizes the fuel injectors in sequences. The PCM adjusts the injector pulse width and synchronizes the fuel injectors by controlling the fuel injectors' ground paths. Once the auto shutdown and fuel pump relays have been energized, the PCM determines the fuel injector pulse width based on the following: engine coolant temperature - manifold absolute pressure - intake air temperature - engine revolutions - throttle position The PCM determines the spark advance based on the following: engine coolant temperature - crankshaft position - camshaft position - intake air temperature - manifold absolute pressure - throttle position Engine Warm-Up Mode ENGINE WARM-UP MODE This is an open loop mode. The Powertrain Control Module (PCM) adjusts injector pulse width and controls injector synchronization by controlling the fuel injectors' ground paths. The PCM adjusts ignition timing and engine idle speed. The PCM adjusts the idle speed by controlling the idle air control motor. General Description PCM OPERATING MODES As Input signals to the Powertrain Control Module (PCM) change, the PCM adjusts its response to output devices. For example, the PCM must calculate a different injector pulse width and ignition timing for idle than it does for wide open throttle. There are several different modes of operation that determine how the PCM responds to the various input signals. There are two types of engine control operation: open loop and closed loop. In open loop operation, the PCM receives input signals and responds according to preset programming. Inputs from the heated oxygen sensors are not monitored. In closed loop operation, the PCM monitors the inputs from the heated oxygen sensors. This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air/fuel ratio of 14.7 parts air to 1 part fuel. By monitoring the exhaust oxygen content through the oxygen sensor, the PCM can fine tune injector pulse width. Fine tuning injector pulse width allows the PCM to achieve optimum fuel economy combined with low emissions. The engine start-up (crank), engine warm-up, and wide open throttle modes are open loop modes. Under most operating conditions, the acceleration, deceleration, and cruise modes, with the engine at operating temperature, are closed loop modes. Service and Repair Fuel Pump Pickup Filter: Service and Repair Fig. 23 Fuel Pump Module Components - Typical The fuel pump inlet strainer (in-tank fuel filter) is not serviced separately. If it needs service, the fuel pump module assembly must be replaced. Refer to Fuel Pump/Service and Repair. Page 58 Power Distribution (Part 3 Of 3) Locations Power Distribution (Part 1 Of 3) Page 481 8W-30-45 Page 763 29. Disconnect the ground eyelet near the airbag squib connector (Figure 17). 30. Double stack the ground eyelet on the BLACK blower relay harness wire onto the ground screw. Install the ground screw and tighten securely. 31. Attach the blower relay onto one of the horizontal relay mounting tabs on the bracket located on the brake pedal support just above the brake lamp switch and pedal (Figure 18). NOTE: For early 1994 model year vehicles that do not have a relay bracket or if two relays are already attached to the bracket, secure the relay to the wiring harness with a tie strap. 32. Re-tape all of the portions of the ignition switch wiring harness from which tape was removed. 33. Position the ignition switch wires back inside of the wiring trough. 34. Snap the steering column wiring trough back on to the steering column using the supplied clips as necessary. 35. Connect the 7-way ignition switch electrical connector. 36. Install the lower steering column shroud (Figure 4). 37. Install the upper and lower steering column covers (Figure 4). 38. Install the steering column tilt lever (Figure 4). 39. Install the knee blocker and tighten the screws securely (Figure 3). 40. Connect the negative battery cable(s). Page 288 177 Page 805 Overdrive Switch: Description and Operation CIRCUIT OPERATION Automatic transmission equipped vehicles may have an overdrive switch. The operator disables or enables overdrive when the switch is depressed. The overdrive system consists of a switch connected to the Powertrain Control Module (PCM) and an overdrive ON/OFF indicator lamp. If overdrive is currently enabled, it is disabled when the operator depresses the overdrive switch. Also, if the operator already disabled overdrive, 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. Circuit Z1 provides ground for the switch. In the START and RUN position, the ignition switch connects circuit A1 from fuse 3 in the Power Distribution Center (PDC) with circuit A21. Circuit A21 connects to the bus bar in the fuse block that powers circuit F12 through fuse 11. Circuit F12 supplies power for the overdrive ON/OFF indicator lamp. The PCM turns the overdrive ON/OFF indicator lamp ON or OFF by providing a ground for the lamp on circuit T18. Page 137 Powertrain Control Module: Description and Operation Hardware HARDWARE ARCHITECTURE The design of the Powertrain Control Module (PCM) can be broken up into about eight major sections. The main microcontroller, a Motorola MC68HC16Z2, is attached to a 256k byte memory device (flash memory) which is programmed after manufacture of the module. (This memory can be reprogrammed at the factory or at a dealership. The MC68HC11D3 and MC68HC11K4 microcomputers have memories which are permanently programmed during their manufacture, and therefore cannot be reprogrammed.) The microcomputers communicate over a bus which allows for rapid transmission of high priority messages. The Z2 executes the primary powertrain control strategy; transmits fuel and spark requirements to the D3 and K4; communicates with outside devices; and processes 14 analog inputs and about half of the one bit inputs and outputs. The D3 microcomputer controls fuel injector timing pulses and a small number of one bit inputs and outputs. The K4 controls spark timing pulses, processes 8 analog inputs and a number of one bit inputs and outputs. Other major sections of the PCM design include the power supply, input conditioning circuits, output driver circuits, serial communication interface circuits, and a device which controls ignition coil currents. Software SOFTWARE ARCHITECTURE The 68HC16Z2 microcontroller is the main computing unit of the Powertrain Control Module (PCM). The 68HC11D3 and K4 microcontrollers control fuel and spark respectively. They handle the critical timing requirements of their tasks, communicating with the Z2 using high level commands. The Z2 operating system is the heart of the software and was written expressly for this PCM. Every 500 microseconds the Z2 interrupts what it is doing to perform periodic tasks such as updating sensor inputs values and checking for the occurrence of a crank position pulse. If this pulse is observed, a program known as the decision maker is executed and performs high priority tasks such as fuel and spark calculations, and RPM processing. Low priority tasks (i.e. OBDII processing, SCI and CCD communications) are executed during the time between crank pulses. The Z2 software is divided into a main operating strategy and three separate calibration areas. The main strategy contains information specific to the various engines and transmissions supported by this PCM. Once installed, the information contained in this area is fixed for a given engine and transmission. Changes to this data, if required, can be performed only by computer programming personnel. The calibration areas (engine, transmission and OBDII) contain information relating to emissions, fuel economy and driveability and can be altered directly by calibration personnel. Battery Feed CIRCUIT OPERATION Circuit A14 from fuse 8 in the Power Distribution Center (PDC) supplies battery voltage to cavity A22 of the Powertrain Control Module (PCM). Ground CIRCUIT OPERATION 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. Fuel Control FUEL CONTROL The Powertrain Control Module (PCM) controls the air/fuel ratio of the engine by varying fuel injector ON time. Mass air flow is calculated using the speed density method using engine speed, manifold absolute pressure, and air charge temperature. Different fuel calculation strategies are used dependent on the operational state of the engine. During crank mode, a prime shot fuel pulse is delivered followed by fuel pulses determined by a crank time strategy. Cold engine operation is determined via an open loop strategy until the O2 sensors have reached operating temperature. At this point, the strategy enters a closed loop mode where fuel requirements are based upon the state of the O2 sensors, engine speed, MAP, throttle position, air temperature, battery voltage, and coolant temperature. Additional factors can influence fuel pulse width. Asynchronous acceleration enrichment is a technique whereby the duration of injector ON time can be increased for injectors already firing, providing improved acceleration response. The D3 microcomputer controls fuel injector timing in response to high level commands from the Z2 microcomputer. Injector timing with respect to engine position is determined by the D3 and is transparent to the Z2. Acceleration Mode ACCELERATION MODE This is a closed loop mode. The Powertrain Control Module (PCM) recognizes an increase in throttle position and a decrease in manifold vacuum as engine load increases. In response, the PCM increases the injector pulse width to meet the increased load. Page 197 Air Bag Control Module: Description and Operation DESCRIPTION The Airbag Control Module (ACM) contains the safing sensor, and a microprocessor that monitors the safing and impact sensor signals, as well as the air-bag system electrical circuits to determine the system readiness. The ACM contains On-Board Diagnostics (OBD), and will light the airbag warning 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 airbag 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 airbag. CIRCUIT OPERATION Two circuits provide battery voltage to the Airbag Control Module (ACM); F14 and F23. Circuits F14 and F23 are connected to separate bus bars in the fuse block. Different circuits from the Power Distribution Center (PDC) and the ignition switch supply battery voltage to the fuse block bus bars. Circuit F23 supplies battery voltage to the ACM only when the ignition switch is in the RUN position. Circuit F14 powers the ACM when the ignition switch is in either the START or RUN position. In either the START or RUN position, the ignition switch connects circuit A1 from fuse 3 in the PDC with circuit A21. Circuit A21 circuit supplies battery voltage to the fuse block bus bar that feeds circuit F14. Fuse 12, a 15 Amp, in the fuse block protects circuit F14. When the ignition switch is in the RUN position, it connects circuit A2 from fuse 2, a 40 Amp, in the PDC to circuit A22. Circuit A22 supplies battery voltage to the fuse block bus bar that feeds circuit F23. Fuse 16, a 15 Amp, in the fuse block protects circuit F23. The ACM is case grounded and has an external dedicated ground, circuit Z6. Page 110 Powertrain Control Module: Locations PCM The Powertrain Control Module (PCM) is located in the right-rear side of the engine compartment. Page 672 1. Remove the ignition switch mounting screws (Figure 8). Use a tamper-proof torx bit (Snap-on PN TTXR2OA2 or equivalent) to remove the screws. 2. Remove the ignition switch from the steering column. 3. Insert the ignition key into the key cylinder and turn the key to the LOCK position. 4 Depress the key cylinder retaining pin or, if equipped, use the tamper-proof torx bit to remove the key cylinder retaining screw and bracket (Figure 9). 5. Turn the ignition key to the OFF position. The key cylinder will then unseat from the ignition switch. When the key cylinder is unseated, it will be approximately 1/8" away from the ignition switch halo light ring. Do NOT attempt to remove the key cylinder at this time. 6. With the key cylinder unseated, turn the ignition key to the LOCK position and then remove the key. Page 735 5. Remove the ignition switch wires from the wiring trough. Remove any tape from the ignition switch wires. 6. Stagger cut all of the ignition switch wires (7) on the vehicle harness side about 1/2" apart. Make sure that all wires are cut so that the wire splices will be located inside the wiring trough and towards the bottom of the steering column. NOTE: Splices that are located towards the top of the steering column are more susceptible to damage. 7. Strip about 1" of wire insulation from each wire on the vehicle wire harness. 8. Stagger cut the matching wires on the supplied ignition switch pigtail to match up with the harness side. Allow sufficient length for the soldered connections. Make sure that the overall length of the wiring is the same as the original harness. NOTE: Be sure to cut the supplied ignition switch pigtail wires so that they match the wire color of the vehicle wire harness. On some vehicles, the YELLOW harness wire matches with the BLUE/YELLOW* vehicle wire and the BLACK harness wire matches with the GRAY/BLACK* vehicle wire. 9. Strip about 1" of wire insulation from each wire on the ignition switch pigtail. 10. Slide a piece of heat shrink tubing onto each wire of the new pigtail. 11. Connect the supplied switch pigtail harness to the vehicle harness by twisting all wire ends together. Be sure to match all wire colors. 12. Solder the twisted wire ends using rosin core solder. CAUTION: Wire splices must be soldered. Do NOT use solderless connectors. 13. Center the pieces of heat shrink tubing over each of the splices. Heat the tubing with a heat source until sealant comes out each end of the tubing. 14. Connect the multi-function switch electrical connector (Figure 7). 15. Connect the clockspring electrical connector (Figure 7). 16. ^ If the ignition switch was damaged and must be replaced, as determined by the inspection in Section "B," continue with Section "D -- Replace Ignition Switch Assembly." ^ If the ignition switch was NOT damaged, as determined by the inspection in Section "B," continue with Section "E - Install Blower Motor Relay and Overlay Harness." D. Replace Ignition Switch Assembly IMPORTANT: Only those vehicles that had ignition switch damage as determined by the inspection in Section "B," require ignition switch replacement. Very few vehicles are expected to require this repair. 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 Page 104 Powertrain Control Module: 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 Page 316 8W-80-2 Revision to the plant diagnostic connector circuit. Page 170 Automatic Shut Down (ASD) Relay: Description and Operation CIRCUIT OPERATION When the ignition switch is in the START or RUN position, it connects circuit A1 from fuse 3 in the Power Distribution Center (PDC) to circuit A21. Circuit A21 powers circuit F18 through fuse 9 in the fuse block. Circuit F18 supplies battery voltage 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 PCM grounds the ASD relay, the relay contacts close and connect circuit A16 from fuse 4 in the PDC to circuit A142. Circuit A142 splices to supply voltage to the fuel injectors, ignition coil, and heated oxygen sensors. Circuit A142 also connects to cavity C12 of the PCM. Diagrams Relay Box: Diagrams Power Distribution (Part 1 Of 3) Page 898 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. Page 654 12. Install the PINK with BLACK tracer blower relay harness wire (with a blade terminal) into cavity 43 of the 84-way connector (Figure 14 and Figure 16). 13. Install the BLUE wedge into the 84-way connector. 14. Install the cover onto the rear of the 84-way connector. 15. Connect the 84-way bulkhead connector. 16. Disconnect the WHITE electrical connector on the blower relay harness. Install the PINK with BLACK tracer wire that was removed from the 84-way connector into the WHITE connector opening (Figure 16). Reconnect the WHITE connector. Secure the connector near the bulkhead connector with a tie strap. 17. Install the BLACK with ORANGE tracer blower relay harness wire into cavity 5 of the 7-way ignition switch connector (Figure 16). 18. Disconnect the BLACK 2-way electrical connector on the blower relay harness (Figure 16). Remove the BLUE wedge and then install the BLACK with ORANGE tracer wire that was removed from the ignition switch connector into cavity 2 of the BLACK connector. Install the wedge and reconnect the BLACK 2-way connector. Secure the connector and any excess wiring near the base of the steering column with a tie strap. 19. Cut off the terminal and then strip about 1" of wire insulation from the end of the DARK GREEN wire that was removed from the fuseblock earlier. 20. Strip about 1" of wire insulation from the end of the DARK GREEN with WHITE blower relay harness wire (Figure 16). 21. Slide a piece of heat shrink tubing onto the wire. 22. Connect the DARK GREEN and DARK GREEN with WHITE tracer wires by twisting the wire ends together. 23. Solder the twisted wire ends using rosin core solder. CAUTION: Wire splice must be soldered. Do NOT use a solderless connector. 24. Center the piece of heat shrink tubing over the splice. Heat the tubing with a heat source until sealant comes out each end of the tubing. 25. Install the DARK GREEN blower relay harness wire into cavity 12 of the fuseblock (Figure 16). 26. Install the PINK with BLACK tracer blower relay harness wire into cavity 11 of the fuseblock (Figure 16). 27. Install the TAN fuseblock wedge (Figure 13). 28. Reinstall the 30-amp fuse in the fuseblock F2 Blower Motor location (Figure 13). Page 284 67 Page 413 3. Remove the cup holder assembly from the instrument panel. 4. Remove the ash receiver from the ash receiver bracket. Fig. 2 5. Remove the two (2) screws that secure the ash receiver bracket to the instrument panel. 6. Remove the ash receiver bracket from the instrument panel. Fig. 3 7. Carefully pry the cluster bezel away from the instrument panel to disengage the eight (8) snap-clip retainers. 8. Unplug the wiring harness connector from the lighter. 9. Unplug the wiring harness connector from the auxiliary power outlet. 10. Set the cluster bezel aside. Fig. 4 11. Remove the three (3) screws that secure the headlamp switch bezel to the instrument panel. 12. Pull the headlamp switch and bezel out from the instrument panel and then unplug the wiring harness connector(s). Locations High Pressure Sensor / Switch: Locations Fig 25 High Pressure Cut-off Switch -- Typical HIGH PRESSURE CUT-OFF SWITCH The high pressure cut-off switch is located on the discharge line near the compressor. Fig 28 Low Pressure Cycling Clutch Switch LOW PRESSURE CYCLING CLUTCH SWITCH The low pressure cycling clutch switch is mounted on top of the accumulator. Page 106 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). Page 276 43 Page 135 Powertrain Control Module: Description and Operation Modes of Operation Acceleration Mode ACCELERATION MODE This is a closed loop mode. The Powertrain Control Module (PCM) recognizes an increase in throttle position and a decrease in manifold vacuum as engine load increases. In response, the PCM increases the injector pulse width to meet the increased load. Cruise or Idle Mode CRUISE OR IDLE MODE When the engine is at normal operating temperature, this is a closed loop mode. During certain idle conditions, the Powertrain Control Module (PCM) may enter into a variable idle speed strategy. At this time, the PCM adjusts engine speed based on the following inputs: throttle position - battery voltage - engine coolant temperature Deceleration Mode DECELERATION MODE This is a closed loop mode. The Powertrain Control Module (PCM) recognizes a decrease in throttle position and an increase in Manifold Vacuum as engine load decreases. In response, the PCM decreases the injector pulse width to meet the decreased load. Engine Start-Up Mode ENGINE START-UP MODE This is an open loop mode. The following actions occur when the starter motor is engaged: 1. The auto shutdown and fuel pump relays are energized. If the Powertrain Control Module (PCM) does not receive the camshaft and crankshaft signals within approximately one second, these relays are de-energized. 2. The PCM energizes all fuel injectors until it determines crankshaft position from the camshaft and crankshaft signals. The PCM determines crankshaft position within one engine revolution. After the crankshaft position has been determined, the PCM energizes the fuel injectors in sequences. The PCM adjusts the injector pulse width and synchronizes the fuel injectors by controlling the fuel injectors' ground paths. Once the auto shutdown and fuel pump relays have been energized, the PCM determines the fuel injector pulse width based on the following: engine coolant temperature - manifold absolute pressure - intake air temperature - engine revolutions - throttle position The PCM determines the spark advance based on the following: - engine coolant temperature - crankshaft position - camshaft position - intake air temperature - manifold absolute pressure - throttle position Engine Warm-Up Mode ENGINE WARM-UP MODE This is an open loop mode. The Powertrain Control Module (PCM) adjusts injector pulse width and controls injector synchronization by controlling the fuel injectors' ground paths. The PCM adjusts ignition timing and engine idle speed. The PCM adjusts the idle speed by controlling the idle air control motor. General Description PCM OPERATING MODES As Input signals to the Powertrain Control Module (PCM) change, the PCM adjusts its response to output devices. For example, the PCM must calculate a different injector pulse width and ignition timing for idle than it does for wide open throttle. There are several different modes of operation that determine how the PCM responds to the various input signals. There are two types of engine control operation: open loop and closed loop. In open loop operation, the PCM receives input signals and responds according to preset programming. Inputs from the heated oxygen sensors are not monitored. Page 457 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 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. Page 139 Ignition Switch On (Engine Off) Mode IGNITION SWITCH ON (ENGINE OFF) MODE When the ignition switch activates the fuel injection system, the following actions occur: 1. The Powertrain Control Module (PCM) determines atmospheric air pressure form the MAP sensor input to determine basic fuel strategy. 2. The PCM monitors the engine coolant temperature sensor and throttle position sensor input. The PCM modifies fuel strategy based on this input. When the Ignition key is in the "on" position and the engine is not running (zero rpm), the auto shutdown relay and fuel pump relay are not energized. Therefore, voltage is not supplied to the fuel pump, ignition coil, and fuel injectors. Wide Open Throttle Mode WIDE OPEN THROTTLE MODE This is an open loop mode. The throttle position sensor notifies the Powertrain Control Module (PCM) of a wide open throttle condition. The PCM adjusts injector pulse width to supply a predetermined amount of additional fuel. Non-Monitored Circuits NON-MONITORED CIRCUITS The Powertrain Control Module (PCM) does not monitor the following circuits, systems, and conditions even though they could have malfunctions that result in driveability problems. A diagnostic code may not be displayed for the following conditions. However, problems with these systems may cause a diagnostic code to be displayed for other systems. For example, a fuel pressure problem will not register a diagnostic code directly, but could cause a rich or lean condition. This could cause an oxygen sensor, fuel system, or misfire monitor trouble code to be stored in the PCM. Engine Timing - The PCM cannot detect an incorrectly indexed timing chain, camshaft sprocket, or crankshaft sprocket. The PCM also cannot detect an incorrectly indexed distributor. Fuel Pressure (Monitored on CNG) - Fuel pressure is controlled by the fuel pressure regulator. The PCM cannot detect a clogged fuel pump inlet filter, clogged in-line fuel filter, or a pinched fuel supply. Fuel Injectors - The PCM cannot detect if the fuel injector is clogged, the pintle is sticking, or the wrong injectors are installed. Fuel Requirements - Poor quality gasoline can cause problems such as hard starting, stalling, and stumble. Use of methanol-gasoline blends may result in starting and driveability problems. (See individual symptoms and their definitions in Section 12.0 (Glossary of Terms) at the back of this book.) PCM Grounds - The PCM cannot detect a poor system ground. However, a diagnostic trouble code may be stored in the PCM as a result of this condition. Throttle Body Air Flow - The PCM cannot detect a clogged or restricted air cleaner inlet or filter element. Exhaust System - The PCM cannot detect a plugged, restricted, or leaking exhaust system. Cylinder Compression - The PCM cannot detect uneven, low, or high engine cylinder compression. Excessive Oil Consumption - Although the PCM monitors the exhaust stream oxygen content through the oxygen sensor when the system is in a closed loop, it cannot determine excessive oil consumption. NOTE: Any of these conditions could result in a rich or lean condition causing an oxygen sensor trouble code to be stored in the PCM, or the vehicle may exhibit one or more of the driveability symptoms listed in TEST NTC-1A - No Trouble Code Test Menu. On-Board Diagnostics ON BOARD DIAGNOSTICS The Powertrain Control Module (PCM) has been programmed to monitor many different circuits of the fuel injection system. This monitoring is called "on-board diagnosis." Certain criteria, or "arming conditions," must be met for a trouble code to be entered into the PCM memory. The criteria may be a range of: engine rpm, engine temperature, and/or input voltage to the PCM. If a problem is sensed with a monitored circuit, and all of the criteria or arming conditions are met, a trouble code will be stored in the PCM. It is possible that a trouble code for a monitored circuit may not be entered into the PCM memory even though a malfunction has occurred. This may happen because one of the trouble code criteria (arming conditions) has not been met. The PCM compares input signal voltages from each input device with specifications (the established high and low limits of the range) that are programmed into it for that device. If the input voltage is not within specifications and other trouble code criteria (arming conditions) are met, a Locations Power Distribution (Part 1 Of 3) Page 717 Battery Temperature Sensor: Description and Operation 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. Page 364 Speed Control Switch: Testing and Inspection 1. Disconnect battery ground cable. 2. Remove speed control switch. Speed Control Switch Continuity 3. Inspect switch continuity as shown. 4. If continuity is not as specified, replace switch. Master Window Switch Power Window Switch: Description and Operation Master Window Switch Left Window Operation CIRCUIT OPERATION When the window switch is moved to the window DOWN position, voltage is supplied on the F21 circuit through the CLOSED contacts in the switch to the Q21 circuit. The Q21 circuit connects from the switch to the left front window motor. Grounding is provided on circuit Q11 from the motor back to the switch. The ground is passed through the switch to ground on the Z3 circuit. When window UP operation is selected, the power and ground circuits are reversed. Circuit Q11 is the feed and circuit Q21 is the ground. Right Window Operation CIRCUIT OPERATION When the window switch is moved to the window DOWN position, voltage is supplied on the F21 circuit through the CLOSED contacts in the switch to the Q26 circuit. The Q26 circuit connects from the master switch to the right window switch. A bus bar internal to the right switch passes the voltage through the switch to circuit Q22. Circuit Q22 connects from the switch to the right window motor. Grounding is provided on circuit Q12 from the motor back to the right switch. The ground is passed through the switch on a bus bar to circuit Q16. Circuit Q16 then connects to the master switch. The ground is passed through the switch to ground on the Z3 circuit. When window UP operation is selected, the power and ground circuits are reversed. Circuits Q16 and Q12 are the feeds and circuits Q22 and Q26 are the grounds. Page 716 Page 345 8W-80-26 Locations Starter Relay: Locations Power Distribution (Part 1 Of 3) Page 758 1. Remove the ignition switch mounting screws (Figure 8). Use a tamper-proof torx bit (Snap-on PN TTXR2OA2 or equivalent) to remove the screws. 2. Remove the ignition switch from the steering column. 3. Insert the ignition key into the key cylinder and turn the key to the LOCK position. 4 Depress the key cylinder retaining pin or, if equipped, use the tamper-proof torx bit to remove the key cylinder retaining screw and bracket (Figure 9). 5. Turn the ignition key to the OFF position. The key cylinder will then unseat from the ignition switch. When the key cylinder is unseated, it will be approximately 1/8" away from the ignition switch halo light ring. Do NOT attempt to remove the key cylinder at this time. 6. With the key cylinder unseated, turn the ignition key to the LOCK position and then remove the key. Page 351 Coolant Temperature Sensor/Switch (For Computer): Description and Operation CIRCUIT OPERATION The engine coolant temperature 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 engine 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. Page 225 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. Page 576 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. Page 601 EGR Temperature Sensor: Description and Operation EGR Intake Air Temperature Sensor CIRCUIT OPERATION The EGR intake air temperature sensor provides an input to the EGR Control Module (PCM) on circuit K321. Circuit K321 connects to cavity 4 of the EGR control module. From circuit K321, the intake air temperature sensor draws voltage from the EGR control module. 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 through circuit K2O4. Circuit K2O4 connects to cavity 5 of the EGR control module. Locations Page 472 8W-15-12 Description and Operation Daytime Running Lamp Control Unit: Description and Operation 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 is OPEN. Circuit L10 from fuse 15 in the fuse block supplies voltage to the DRL module. Circuit A3 from the Power Distribution Center (PDC) connects to DRL module. The DRL module receives information on park brake switch position on circuit G11. Circuit L4 powers the low beams of the headlamps. When the headlamp switch is OFF, the DRL module powers the low beams on circuit L4. When the head-lamps are ON, the multi-function switch powers the low beams on circuit L4. Circuit L3 feeds the high beams of the headlamps. When the operator flashes the headlamps with the stalk of the multi-function switch, the DRL senses voltage on circuit L3 and stops supplying power to the low beams on circuit L4. Circuit Z1 provides ground for the DRL module. Lock Power Door Lock Switch: Description and Operation Lock Left Door Switch CIRCUIT OPERATION When the door lock switch is moved to the LOCK position, voltage is supplied on the P35 circuit to the bus bar located inside the right door switch, LOCK side. Battery voltage is passed through the switch to the door motors on circuit P35. Grounding is provided through the P34 circuit for both door motors back to the right door switch. The ground is passed through the bus bar internal to the switch, UNLOCK side, to the P36 circuit. The P36 circuit connects to the left front switch to a bus bar, internal to the switch, and then to the Z3 circuit. The Z3 circuit provides ground. Right Door Switch CIRCUIT OPERATION When the switch is moved to the LOCK position, voltage is supplied to the P33 circuit, and then to the door lock motors. The ground path is provided on the P34 circuit back to the right door switch. The ground is passed through the switch internal bus bar to the P36 circuit. The P36 circuit connects to the left door switch and through to ground on circuit Z3. Page 107 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). Locations Locations Locations Oxygen Sensor: Locations Page 500 8W-80-36 Recall 99V023000: Unexpected Air Bag Deployment Air Bag Control Module: All Technical Service Bulletins Recall 99V023000: Unexpected Air Bag Deployment If water/road salt gets on the interior floor of the vehicle in the proximity of the air bag electronic control module (AECM), the AECM can corrode. The resulting corrosion can cause the driver side air bag to deploy inadvertently. Deployment of the air bag without warning could cause a driver to lose vehicle control, increasing the risk of a crash and personal injury. Dealers will replace the AECM with an AECM that is sealed from moisture intrusion. Owner notification began March 8, 1999. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chrysler at 1-800-992-1997. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Locations Crankshaft Position Sensor: Locations Fig. 25 Crankshaft Position Sensor - Typical The sensor is located on the top of cylinder block near the rear of right cylinder head. Page 328 8W-30-45 Page 550 Oxygen Sensor: Application and ID Page 287 173 Page 906 COIL WIRE TEST To test ignition coil-to-distributor cap cable, do not remove the cable from the cap. Connect ohmmeter to rotor button (center contact) of distributor cap and terminal at ignition coil end of cable. If resistance is not within specifications as found in the Spark Plug Cable Resistance chart, remove the cable from the distributor cap. Connect the ohmmeter to the terminal ends of the cable. If resistance is not within specifications as found in the Spark Plug Cable Resistance chart, replace the cable. Inspect the ignition coil tower for cracks, burns or corrosion. Page 99 8W-80-22 Page 754 a. Turn the ignition switch to the ON position. b. Turn the blower motor on LOW and verify that the blower is operating. c. Disconnect the relay. ^ If the blower motor stops, this relay is for the blower motor. ^ If the blower motor does not stop, this relay is NOT for the blower motor. d. Turn the ignition switch OFF and connect the relay. 4. ^ If a blower motor relay is NOT present, continue with Section "B - Inspect Ignition Switch and Wiring." ^ If a blower motor relay is present, no further action is necessary. Return the vehicle to the customer. B. Inspect Ignition Switch and Wiring 1. Disconnect the negative battery cable(s). NOTE: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Remove the five (5) screws that secure the knee blocker to the lower instrument panel and then remove the knee blocker (Figure 3). 3. Remove the steering column tilt lever by turning it counter-clockwise. Page 127 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. Page 100 8W-80-26 Page 96 8W-70-26 Revisions to the Connector Pin-outs. Page 589 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. Page 260 Power Mirror Switch: Testing and Inspection - Check the IOD fuse located in the fuse block - Circuit M1 supplies voltage to the radio, cargo lamp, dome lamp, time delay relay, glove box lamp, and vanity lamps. Check for proper operation of these items - Move the switch to its various positions and listen for the motors to click or try to move. Some movement or clicking indicates a poor connection or a mechanical problem with a mirror - Check the ground for the power mirror switch Recall 99V023000: Unexpected Air Bag Deployment Air Bag Control Module: Recalls Recall 99V023000: Unexpected Air Bag Deployment If water/road salt gets on the interior floor of the vehicle in the proximity of the air bag electronic control module (AECM), the AECM can corrode. The resulting corrosion can cause the driver side air bag to deploy inadvertently. Deployment of the air bag without warning could cause a driver to lose vehicle control, increasing the risk of a crash and personal injury. Dealers will replace the AECM with an AECM that is sealed from moisture intrusion. Owner notification began March 8, 1999. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chrysler at 1-800-992-1997. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Page 578 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 Page 507 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 Page 708 Impact Sensor: Description and Operation DESCRIPTION Two impact sensors and a safing sensor provide verification of the direction and severity of an impact. The safing sensor is located inside the Airbag Control Module (ACM), which is mounted to a bracket on the floor transmission tunnel, under the instrument panel. The two impact sensors are mounted on the inner fender extension panels behind the grille opening reinforcement, on the left and right sides of the vehicle. OPERATION The impact sensors are threshold sensitive switches that complete an electrical circuit when an impact provides a sufficient deceleration force to close the switch. The safing sensor is an accelerometer that senses the rate of deceleration. The sensors are calibrated for the specific vehicle, and are sensitive to both the severity and the direction of an impact. The microprocessor in the ACM monitors the sensor signals. A pre-programmed decision algorithm in the microprocessor determines when the deceleration rate indicates an impact that is severe enough to require airbag system protection. When the programmed conditions are met, the ACM sends an electrical signal to deploy the driver side airbag. REPLACEMENT The impact sensors and safing sensor cannot be repaired or adjusted and, if faulty or damaged, they must be replaced. The impact sensors are available for service replacement. The safing sensor is only serviced as part of the ACM. CIRCUIT OPERATION Two airbag impact sensors provide input to the Air-bag Control Module (ACM). Each sensor has two circuits that connect to the ACM. From the left impact sensor, Circuit R47 connects to the ACM at cavity 1 of the 13-way connector. Circuit R49 connects to one cavity of the 13-way connector. From the right impact sensor, Circuit R46 connects to the ACM at cavity 13 of the 13-way connector. Circuit R48 connects to cavity 12 of the 13-way connector. Page 785 Page 382 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. Air Bag Control Module 4 Way Connector Locations Customer Safety Information Air Bag Control Module: Customer Safety Information WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the event of an accident. NOTE: Service and general information labels about the air bag system can be found on the driver's sun visor, the glove box door, and in the engine compartment. PRECAUTIONS Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air bag module. Because this system is a sensitive, complex electro-mechanical unit, before attempting to diagnose, remove or install any air bag system component, you must first disarm air bag system as outlined. Failure to do this could result in accidental airbag deployment and possible personal injury. The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible compounds. In addition, the passenger airbag module contains argon gas pressurized to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding 93° C (200° F). The fasteners, screws and bolts used for air bag components have special coatings and are specifically designed for the air bag system. They must never be replaced with substitutes. If fastener replacement is required, use correct fasteners provided in service package. Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog. Substitute parts may appear interchangeable, but internal differences may result in inferior occupant protection. When a steering column has an airbag module attached, never place the column on the floor or any other surface with the steering wheel or air bag module face down. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Accidental airbag deployment could occur. Page 75 8W-30-15 Revision to the ASD relay circuit. Page 278 47 Page 901 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 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. Page 365 Speed Control Switch: Service and Repair 1. Disconnect battery ground cable. 2. Turn ignition switch to the Off position. 3. Remove two screws from back of steering wheel. 4. Rock switch away from air bag or horn pad while lifting switch from steering wheel. 5. Disconnect four-way electrical connector. 6. Reverse procedure to install. Page 101 8W-80-35 Page 592 Vehicle Speed Sensor: Description and Operation Circuit Operation Circuit K7 supplies 5 Volts from the Powertrain Control Module (PCM) to the vehicle speed sensor. The K7 circuit connects to cavity B31 of the PCM connector. 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 Engine Controls/Electrical - Service Manual Revisions Coolant Temperature Sensor/Switch (For Computer): Technical Service Bulletins Engine Controls/Electrical - Service Manual Revisions NUMBER: 26-03-96 GROUP: Miscellaneous DATE: Mar. 1996 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1996 Ram Truck - Publication Number 81-370-6108 DESCRIPTION OF CHANGES Revisions to the index. Cab and Chassis Caster Correction Measurement Alignment: Service and Repair Cab and Chassis Caster Correction Measurement Cab-Chassis Measurement NOTE:To determine the correct caster alignment angle for Cab-Chassis vehicles the following procedure must be performed. 1. Take a height measurement to the center of the front gauge hole in the frame. Take another measurement to the center of the rear spring hanger bolt. Take these measurements on both sides of the vehicle. Caster Correction Chart 2. Subtract the front measurement from the rear measurement and use the average between the right and left side. Use this number with the Caster Page 486 8W-31-5 Recall 00V135000: Ignition Switch Wiring Defect Ignition Switch: Recalls Recall 00V135000: Ignition Switch Wiring Defect The affected vehicles were built with an ignition switch and wiring that could overheat. High electrical current loads pass through the switch when the blower motor is operated on high for an extended periods of time. This could cause the ignition switch and wiring to overheat. Dealers will install a relay and overlay harness. Owner notification began June 26, 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). Page 128 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. Light Duty Engines Oxygen Sensor: Service and Repair Light Duty Engines Fig. 9 Upstream/Downstream Oxygen Sensors - LDC Engines 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 N.m (22 ft. lbs.) torque. 2. Connect the 02S sensor wire connector. 3. Lower the vehicle. Page 483 8W-30-47 Page 900 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. Page 675 8. Remove the PINK with BLACK tracer (A2) wire from cavity 43 of the 84-way bulkhead connector (Figure 14). 9. Remove the RED wedge from the 7-way ignition switch connector (Figure 15). 10. Remove the BLACK with ORANGE tracer (A22) wire from cavity 5 of the 7-way ignition switch connector (Figure 15). Then, remove the wire from the wiring takeout bundle back to the base of the steering column. 11. Install the supplied blower relay wiring harness so that the X-wrap is located near the base of the steering column (Figure 16). Secure the harness with a tie strap. Page 94 8W-70-24 Component Test Throttle Position Sensor: Testing and Inspection Component Test Fig. 40 Sensor And IAC Location - Typical The Throttle Position Sensor (TPS) can be tested with a digital voltmeter. The center 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 must be greater than 200 millivolts. At wide open throttle, TPS output voltage must be less than 4.8 volts. The output voltage should increase gradually as the throttle plate is slowly opened from idle to WOT. NOTE: For additional testing information and circuit diagnosis see Testing and Inspection/Test TC-26A or TC-27A Page 151 Automatic Shut Down (ASD) Relay: Description and Operation CIRCUIT OPERATION When the ignition switch is in the START or RUN position, it connects circuit A1 from fuse 3 in the Power Distribution Center (PDC) to circuit A21. Circuit A21 powers circuit F18 through fuse 9 in the fuse block. Circuit F18 supplies battery voltage 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 PCM grounds the ASD relay, the relay contacts close and connect circuit A16 from fuse 4 in the PDC to circuit A142. Circuit A142 splices to supply voltage to the fuel injectors, ignition coil, and heated oxygen sensors. Circuit A142 also connects to cavity C12 of the PCM. Page 204 Page 772 6. Install retaining screw into bracket, then torque screw to 22-30 in-lbs. 7. Install steering column covers and torque retaining screws to 17 in-lbs 8. On models with tilt column, install tilt lever. 9. Connect battery ground cable, then ensure proper operation of ignition switch in each position. Page 484 8W-30-48 Page 270 Parking Brake Warning Switch: Testing and Inspection - In the START position, the ignition switch connects circuit A1 from the power distribution center (PDC) to circuit A41. A 40 amp fuse in cavity 3 of the PDC protects circuits A1 and A41. - The Park/Neutral position switch and backup lamp switch are molded together. Page 198 Air Bag Control Module: Service and Repair WARNING: ^ The airbag control module contains one of the impact sensors, which enable the system to deploy the airbag. Never strike or kick the air bag control module. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components you must first disconnect and isolate the battery negative (ground) cable. Then wait two minutes for the system capacitor to discharge before further system service. This is the only sure way to disable the air bag system. Failure to do this could result in accidental airbag deployment and possible personal injury. ^ The airbag control module must never be relocated from its factory-installed position. The plastic airbag control module protective cover must always be reinstalled following any service removal. Care should be exercised to protect the airbag control module from direct spray or submersion in water or other liquids. Never strike the airbag control module with tools or other objects. Never stand on or place objects on the airbag control module. Failure to heed these warnings could result in accidental airbag deployment, or non-deployment of the airbag when needed, and possible personal injury. 1. Disconnect and isolate the battery negative cable. If the airbag has not been deployed, wait two minutes for the system capacitor to discharge before further service. 2. Remove the two screws that secure the airbag control module trim cover to the mounting bracket on the floor pan transmission tunnel under the instrument panel. 3. Using a wide flat-bladed tool such as a trim stick, gently pry the top of the trim cover away from the mounting bracket to release the snap clip retainer that secures it to the mounting bracket. NOTE: Always remove and replace the airbag control module and its mounting bracket as a unit. Replacement modules include a replacement mounting bracket. Do not transfer the module to another mounting bracket. 4. Remove the four screws that secure the airbag control module mounting bracket to the floor pan transmission tunnel. 5. Slide the airbag control module out from under the instrument panel far enough to unplug the wire harness connectors from the module. 6. Remove the airbag control module and mounting bracket as a unit. 7. When installing the airbag control module and mounting bracket, position the unit with the arrow on the module housing pointing forward. 8. Plug in the wire harness connectors to the air-bag control module. Be certain that the connector latches are fully engaged. 9. Attach the airbag control module to the floor pan transmission tunnel with the four mounting screws. Tighten the mounting screws to 11.8 to 16.3 N.m (105 to 145 in. lbs.). 10. Install the airbag control module trim cover. 11. Do not connect the battery negative cable at this time. See Airbag System Arming for proper procedure. Page 122 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. Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Page 320 8W-30-15 Revision to the ASD relay circuit. Page 965 The two types of coolant should not be mixed. The standard testers for measuring freeze protection will not provide an accurate reading when this occurs. If the cooling system is changed to propylene glycol, all the ethylene glycol coolant should be removed using an approved cooling system flush procedure. The freeze protection of propylene glycol cannot be measured with a standard cooling system hydrometer. A refractometer or hydrometer calibrated for propylene glycol is the preferred test tool. POLICY: Information Only Page 404 Brake Light Switch: Service and Repair Removal 1. Pull connector from switch, then remove switch from bracket by depressing brake pedal and rotating switch counterclockwise 1/8 turn. 2. Pull switch rearward and remove from bracket. Installation 1. Ensure adjustable switch plunger is fully extended by pulling out until plunger reaches end of travel. Plunger end should extend approximately 3/4 inch from switch collar. 2. With brake pedal depressed, align key on switch locking collar with slot in mounting bracket square hole, then press switch forward into bracket until collar seats flush to bracket. 3. Rotate switch clockwise 1/8 turn, then release brake pedal. Switch plunger will adjust to correct setting. 4. Plug connector into switch. Page 474 8W-11-22 Revision to the Coolant Temperature Sensor and EGR solenoid descriptions. Page 652 14. Place the ignition switch against the lock housing opening on the steering column. Ensure that the ignition switch park lock dowel pin enters the slot in the park lock slider linkage in the steering column. 15. Install the ignition switch screws (Figure 8). Tighten the screws to 26 in-lbs (3 Nm). 16. Connect the key-in/halo light electrical connector to the new ignition switch (Figure 7). NOTE: DO NOT connect the 7-way ignition switch connector. D. Install Blower Motor Relay and Overlay Harness 1. Remove the 30-amp fuse from the fuseblock F2 -- Blower Motor location (Figure 13). 2. Remove the TAN wedge from the fuseblock (Figure 13). 3. Remove the BLACK with ORANGE tracer (A22) wire from cavity 11 of the fuseblock (Figure 13); then cut the terminal off and tape the wire back to the harness. 4. Remove the DARK GREEN (C1) wire from cavity 12 of the fuseblock (Figure 13). 5. Disconnect the 84-way bulkhead connector. 6. Remove the cover from the rear of the 84-way connector. 7. Remove the BLUE wedge from the 84-way connector. Page 698 Air Bag Deactivation Switch: Technical Service Bulletins Air Bag System - ON-OFF Switch Availibility NO: 08-17-98 Rev. C GROUP: Electrical DATE: Dec. 30, 1998 SUBJECT: Airbag On-Off Switches THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-17-98 Rev. B DATED SEPTEMBER 18, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL MODELS HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: **1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan** 1995 - **1999** (AB) Ram Van/Wagon **1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon** 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/Convertible 1994 -**1999** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan/Voyager **1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue** 1994 - **1999** (BR) Ram Pickup **1995 - 1996 (B7) Stealth** 1998 - **1999** (DN) Durango **1995 - 1999 (FJ) Avenger/Sebring/Talon** 1995 - **1999** (JA) Breeze/Cirrus/Stratus 1996 - **1999** (JX) Sebring Convertible 1993 -**1999** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - **1999** (NS) Town & Country/Caravan/ Voyager 1995 - **1999** (PL) Neon 1996 - 1997 (SR) Viper 1997 - **1999** (TJ) Wrangler 1997 - **1999** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. Other applicable passenger vehicles will be announced as soon as the switches are available. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. Page 384 High Pressure Sensor / Switch: Service and Repair Fig 25 High Pressure Cut-off Switch -- Typical HIGH PRESSURE CUT-OFF SWITCH Removal 1. Disconnect and isolate the battery negative cable. 2. Unplug the wire harness connector from the switch. 3. Unscrew the switch from the discharge line fitting. Installation 1. Install and tighten the switch. 2. Unplug the wire harness connector into the switch. 3. Connect the battery negative cable. Fig 28 Low Pressure Cycling Clutch Switch LOW PRESSURE CYCLING CLUTCH SWITCH 1. Disconnect and isolate the battery negative cable. 2. Unplug the wire harness connector from the switch on the top of the accumulator. 3. Unscrew the switch from the fitting on the accumulator. 4. Reverse the removal procedures to install. Page 828 Power Window Switch: Description and Operation Passenger Side Switch Operation CIRCUIT OPERATION When the window switch is moved to the window DOWN position, voltage is supplied on the F21 circuit through the CLOSED contacts in the switch to the Q22 circuit. The Q22 circuit connects from the switch to the right front window motor. Grounding is provided on circuit Q12 from the motor back to the switch. The ground is passed through the switch to the Q16 circuit. The Q16 circuit connects from the right switch to the master switch. Ground is passed through the master switch to ground on the Z3 circuit. When window UP operation is selected, the power and ground circuits are reversed. Circuit Q12 is the feed and circuits Q22 and Q26 are the ground. Page 595 Vehicle Speed Sensor: Service and Repair Fig. 18 Vehicle Speed Sensor Location - 2WD REMOVAL 1. Raise and support vehicle. 2. Disconnect the electrical connector from the sensor. 3. Remove the sensor mounting bolt. Fig. 105 Sensor Removal/Installation 4. Remove the sensor (pull straight out) from the speedometer pinion gear adapter. 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 N.m (20 in. lbs.) torque. 4. Connect electrical connector to sensor. Page 93 8W-70-22 Page 671 5. Remove the ignition switch wires from the wiring trough. Remove any tape from the ignition switch wires. 6. Stagger cut all of the ignition switch wires (7) on the vehicle harness side about 1/2" apart. Make sure that all wires are cut so that the wire splices will be located inside the wiring trough and towards the bottom of the steering column. NOTE: Splices that are located towards the top of the steering column are more susceptible to damage. 7. Strip about 1" of wire insulation from each wire on the vehicle wire harness. 8. Stagger cut the matching wires on the supplied ignition switch pigtail to match up with the harness side. Allow sufficient length for the soldered connections. Make sure that the overall length of the wiring is the same as the original harness. NOTE: Be sure to cut the supplied ignition switch pigtail wires so that they match the wire color of the vehicle wire harness. On some vehicles, the YELLOW harness wire matches with the BLUE/YELLOW* vehicle wire and the BLACK harness wire matches with the GRAY/BLACK* vehicle wire. 9. Strip about 1" of wire insulation from each wire on the ignition switch pigtail. 10. Slide a piece of heat shrink tubing onto each wire of the new pigtail. 11. Connect the supplied switch pigtail harness to the vehicle harness by twisting all wire ends together. Be sure to match all wire colors. 12. Solder the twisted wire ends using rosin core solder. CAUTION: Wire splices must be soldered. Do NOT use solderless connectors. 13. Center the pieces of heat shrink tubing over each of the splices. Heat the tubing with a heat source until sealant comes out each end of the tubing. 14. Connect the multi-function switch electrical connector (Figure 7). 15. Connect the clockspring electrical connector (Figure 7). 16. ^ If the ignition switch was damaged and must be replaced, as determined by the inspection in Section "B," continue with Section "D -- Replace Ignition Switch Assembly." ^ If the ignition switch was NOT damaged, as determined by the inspection in Section "B," continue with Section "E - Install Blower Motor Relay and Overlay Harness." D. Replace Ignition Switch Assembly IMPORTANT: Only those vehicles that had ignition switch damage as determined by the inspection in Section "B," require ignition switch replacement. Very few vehicles are expected to require this repair. Page 165 Fuel Pump Relay: Service and Repair Power Distribution Center REMOVAL 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION 1. Install relay to PDC. 2. Install cover to PDC. Page 650 1. Remove the ignition switch mounting screws (Figure 8). Use a tamper-proof torx bit (Snap-on PN TTXR2OA2 or equivalent) to remove the screws. 2. Remove the ignition switch from the steering column. 3. Insert the ignition key into the key cylinder and turn the key to the LOCK position. 4 Depress the key cylinder retaining pin or, if equipped, use the tamper-proof torx bit to remove the key cylinder retaining screw and bracket (Figure 9). 5. Turn the ignition key to the OFF position. The key cylinder will then unseat from the ignition switch. When the key cylinder is unseated, it will be approximately 1/8" away from the ignition switch halo light ring. Do NOT attempt to remove the key cylinder at this time. 6. With the key cylinder unseated, turn the ignition key to the LOCK position and then remove the key. Page 114 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. Page 569 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. Page 864 Air Cleaner Housing: Service and Repair Heavy Duty Engines REMOVAL CAUTION: Do not attempt to remove the air cleaner element (filter) from the housing by removing the top cover only. To prevent damage to the air cleaner housing, the entire air cleaner housing assembly must be removed from the engine for air cleaner element replacement. Fig. 95 Air Cleaner Housing 1. Remove the air inlet tube at the side of the air cleaner housing. 2. A band-type screw clamp secures the air cleaner housing to the throttle body Loosen, but do not remove, this screw clamp. Note the clamp positioning tabs on the air cleaner housing. 3. All Engines: Disconnect the breather hose at the rear of air cleaner housing. 4. Disconnect the air pump hose at the air cleaner housing. 5. The bottom/front of the air cleaner housing is equipped with a rubber grommet. A mounting stud is attached to the intake manifold and is used to position the air cleaner housing into this grommet. Lift the assembly from the throttle body while slipping the assembly from the mounting stud. 6. Check condition of gasket at throttle body and replace as necessary. 7. The housing cover is equipped with three (3) spring clips and is hinged at the rear with plastic tabs. Unlatch the clips from the top of air cleaner housing and tilt the housing cover up and rearward for cover removal. 8. Remove the air cleaner element from air cleaner housing. INSTALLATION 1. Before installing a new air cleaner element, clean inside of air cleaner housing. 2. Position air cleaner cover to tabs on rear of air cleaner housing. Latch the three spring clips to seal cover to housing. 3. Position the air cleaner housing assembly to the throttle body while guiding the rubber grommet over the mounting stud. The lower part of the screw clamp should be below the top lip of the throttle body. 4. Push down on air cleaner housing at rubber grommet to seat housing at intake manifold. 5. Tighten throttle body-to-air cleaner housing clamp to 4 N.m (35 in. lbs.) torque. 6. Install the air inlet tube at air cleaner housing inlet. Page 586 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 Page 324 8W-30-14 Page 71 8W-80-2 Revision to the plant diagnostic connector circuit. Page 417 Fig. 9 8. Connect the 2-way wiring connector to the mating connector on the provided overlay relay harness. Fig. 8 9. Insert the two wire terminals from the overlay harness into the headlamp switch connector. Insert the PINK wIRED TRACER wire into the "B2" cavity. Insert the BLACK w/YELLOW TRACER wire into the "R" cavity. 10. Secure the wire terminals in the headlamp switch connector with the provided 9-way wedge. C. Install the Headlamp Switch Assembly: 1. Install the headlamp switch bezel bracket on the new switch assembly. 2. Install the headlamp switch bezel on the mounting bracket. Tighten the three (3) mounting screws securely. Fig. 10 Page 921 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). Page 960 Brake Fluid: Service and Repair Aluminum Master Cylinder NOTES: - With disc brakes, fluid level can be expected to fall as the brake pads wear. - Check master cylinder fluid level twice annually. - Master cylinder reservoirs are marked with the words "fill to bottom of rings". 1. Wipe caps and reservoir clean to prevent dirt and foreign matter from dropping into the reservoir. 2. Remove the caps to check the level. - On aluminum master cylinder add DOT 3 fluid to bring the level to the bottom of the primary split ring. - On the cast iron master cylinder, add DOT 3 fluid to bring the level to within a 1/4 inch of the top of reservoir. CAUTION: Use fluid other than DOT 3 that may have a lower boiling point -- such as fluid identified as 7OR1 or unidentified as to specification -- could result in brake failure during long, hard braking. CAUTION: Do not use fluid which has been stored in an unsealed container. Brake fluid stored in this manner will absorb moisture which could result in brake failure during long, hard braking. CAUTION: Use of petroleum based fluids will result in seal damage. EGR Engine Coolant Temperature Sensor EGR Temperature Sensor: Description and Operation EGR Engine Coolant Temperature Sensor CIRCUIT OPERATION The EGR engine coolant temperature sensor provides an input to the EGR control module on circuit K2. From circuit K2, the sensor draws voltage from the EGR control module. The sensor is a variable resistor. As coolant temperature changes, the resistance in the sensor changes, causing a change in current draw. The EGR control module provides ground for the sensor signal (circuit K2) on circuit K304. Page 90 8W-70-13 Page 332 8W-30-49 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 Page 349 Page 346 8W-80-35 Page 794 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 Page 849 Alignment: Service and Repair Front Alignment With the front wheels in straight ahead position, loosen the clamps at each end of both adjusting tubes. Adjust toe-in by turning the tie rod sleeve which will "center" the steering wheel spokes. If the steering wheel was centered, make the toe-in adjustment by turning both sleeves an equal amount. Position sleeve clamps so ends do not align in the sleeve slot. Refer to "Front Wheel Alignment Specifications" for correct settings. Description and Operation Blower Motor Switch: Description and Operation Fig 3 Heater-Air Conditioner Control Panels The heater-only or heater-A/C blower motor is controlled by a rotary switch mounted in the heater-A/C control panel. The switch allows for the selection of four blower motor speeds and an Off position, but will only operate with the ignition switch in the On position, and the heater-A/C mode control switch in any position except Off. The blower motor switch is connected in series with the blower motor ground path through the heater-Air mode control switch. The blower motor switch directs this ground path to the blower motor through the blower motor resistor wires, or directly to the blower motor as required to achieve the selected blower motor speed. The blower motor switch cannot be repaired and, if faulty or damaged, it must be replaced. The switch is serviced only as a part of the heater-only or heater- A/C control assembly The blower motor switch knob is serviced separately. Page 575 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 Sensor Test Manifold Pressure/Vacuum Sensor: Testing and Inspection Sensor Test Fig. 58 Rubber L-Shaped Fitting - MAP Sensor-to-Throttle Body 1. Inspect the rubber L-shaped fitting from the Manifold Absolute Pressure (MAP) sensor to the throttle body. Repair as necessary. CAUTION: When testing the MAP sensor, be sure that the harness wires are not damaged by the test meter probes. Fig. 59 MAP Sensor Connector Terminals 2. Test the MAP sensor output voltage at the MAP sensor connector between terminals A and B. 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 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 and PCM connector A-4. Repair the wire harness if necessary. Page 669 4. Remove the upper and lower steering column covers (Figure 4). 5 Remove the lower steering column shroud (Figure 4). 6. Disconnect the 7-way ignition switch electrical connector (Figure 5). 7. Inspect the 7-way ignition switch connector for heat damage near the 4th and 5th terminals (BLACK with ORANGE tracer and PINK with BLACK tracer wires) (Figure 5). ^ Look for brown or black discoloration of the wire insulation or melting of the wire insulation near the connector. ^ Check the wiring terminals for discoloration. ^ Inspect the connector for indications of melting or deformation. Page 230 Transmission Control System Relay: Description and Operation CIRCUIT OPERATION The electronic transmission relay powers the overdrive solenoid, torque convertor clutch solenoid, and variable force solenoid. All three solenoids are molded together. When the ignition switch is in the START or RUN positions, it connects circuit A1 from fuse 3 in the Power Distribution Center (PDC) to circuit A21. Circuit A21 powers circuit F18 through fuse 9 in the fuse block. Circuit F18 powers the coil side of the electronic transmission relay. The Powertrain Control Module (PCM) provides ground for the relay on circuit K30. Circuit K30 connects to cavity B3O of the PCM. When the PCM grounds the relay, the relay contacts connect circuit A14 from fuse 8 in the PDC to circuit Tl6. Circuit T16 powers the solenoids. Page 631 Crankshaft Position Sensor: Testing and Inspection Helpful Information - Circuit K6 splices to supply 5 volts to the camshaft 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 Page 126 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. Page 403 Brake Light Switch: Description and Operation Rear Wheel Antilock Brakes CIRCUIT OPERATION Circuit V40 provides an input to the Controller Anti Lock Brake (CAB) as to when the operator is applying the brakes. The V40 circuit connects to cavity 7 of the CAB. Page 478 8W-30-18 Recall - Ignition Switch Wiring Overheating Technical Service Bulletin # 875 Date: 000601 Recall - Ignition Switch Wiring Overheating June 2000 Safety Recall No.875 Ignition Switch Wiring Models 1994-1996 (BR) Dodge Ram Trucks NOTE: This recall applies only to the above vehicles built at the: ^ Warren Assembly Plant ("S" in the 11th VIN position) through April 4, 1996 (MDH O4O4XX); ^ St. Louis North Assembly Plant ("J" in the 11th VIN position) through March 23, 1996 (MDH 0323XX); ^ Lago Alberto Assembly Plant ("M" in the 11th VIN position) through April 14, 1996 (MDH 0414XX); or ^ Saltillo Assembly Plant ("G"in the 11th VIN position) through April 14, 1996 (MDH 0414XX). 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 ignition switch and/or steering column wiring on about 710,000 of the above vehicles may overheat when the blower motor is operated at high speed for an extended period of time. This can cause stalling, loss of blower motor or power window operation, ABS or airbag lamp illumination or a steering column/instrument panel fire. Repair A blower motor relay and overlay harness must be installed to remove the blower motor circuit from the ignition switch. In addition, the ignition switch and electrical connector must be inspected for damage and replaced if necessary. Parts Information A. Ignition Switch Wiring Package Part Number Description CBXR875O Ignition Switch Wiring Package Each package contains the components listed: Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Ignition Switch Wiring Packages to service about 10% of those vehicles. B. Ignition Switch Assembly Page 290 181 Page 920 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. Page 72 8W-10-6 Page 326 8W-30-42 Page 476 Revisions to the Powertrain Control Module wiring. Page 904 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. Locations Page 84 8W-30-46 Page 340 8W-70-25 Four Wheel Antilock Brakes Wheel Speed Sensor: Description and Operation Four Wheel Antilock Brakes CIRCUIT OPERATION The all wheel Anti-Lock 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 it transmits to the Controller Anti Lock Brake (CAB). A pair of twisted wires connect to each sensor and provide signals to the CAB. Circuits B6 and B7 provide signals to CAB from right front wheel speed sensor. Circuit B6 which provides the LOW signal, connects to cavity 15 of the CAB. Circuit B7 connects to cavity 2 of the CAB and provides the HIGH signal. Circuits B8 and B9 provide signals to CAB from left front wheel speed sensor. Circuit B8 which provides the LOW signal, connects to cavity 16 of the CAB. Circuit B9 connects to cavity 3 of the CAB and provides the HIGH signal. Circuit B114 connects to cavity 14 of the CAB and to the rear wheel speed sensor. Circuit B113 connects to cavity 1 of the CAB and to the rear wheel speed sensor. Circuit B114 provides the rear wheel speed sensor LOW input while circuit B113 provides the HIGH input. Description and Operation Transmission Speed Sensor: Description and Operation CIRCUIT OPERATION 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 R25 of the PCM. Circuit T14 connects to cavity B28. Page 764 41. Verify that the blower motor operates properly. Page 140 trouble code will be stored in the PCM memory. The On Board Diagnostics have evolved to the second Generation of Diagnostics referred to as OBDII. These OBDII Diagnostics control the functions necessary to meet the requirements of California OBDII and Federal OBD regulations. These requirements specify the inclusion of a malfunction indicator light (MIL) located on the instrument panel for all 1994 and subsequent model-year passenger cars, light duty trucks, and medium-duty vehicles. The purpose of the MIL is to inform the vehicle operator in the event of malfunction of any powertrain components which can affect emissions and which provide input to, or receive output from, the engine controller module. Control of OBDII functions is separated into two areas: the Task Manager and the Comprehensive Component Manager. Task Manager The Task Manager controls the execution of some component/systems tests, control of MIL illumination, storage of fault codes, and storage of vehicle data at time of fault detection (freeze frame). This routine performs the following monitoring requirements: Fuel System Monitoring - Misfire Detection - EGR System Monitor - Oxygen Sensor Upstream Heater Monitor - Oxygen Sensor Upstream Monitor - Evaporative System Monitor - Catalyst Monitor - Purge Flow Monitor - 02 Heater Downstream Monitor - 02 Sensor Downstream Monitor Another function of the task manager is control of the Disable Tables. These tables are used to discontinue testing when a condition specified in the tables are met. Testing of a component or system is disabled if a fault or failure occurs which would render the test useless. (For example, the "Catalyst Monitor" test will not be run unless the "O2 Sensor" test has passed.) Comprehensive Component Manager The Comprehensive Component Manager controls the testing of all powertrain components/ systems which can affect emissions and were not otherwise tested by the Task Manager. This routine is organized into three areas: D3 and K4 CIRCUIT CHECKS - Performed on sensor inputs connected to the D3 and K4 to determine out-of-range or high/flow input conditions. Performed on outputs to check for open/short conditions. The components tested are: Idle Air Control (IAC) Open/Short Circuit - Generator Field - Torque Converter Clutch (TCC) Solenoid - Fan Relay - A/C Relay - Air Switch / Shift Lock Solenoid - Transmission Relay Output - Automatic Shutdown (ASD) Relay - Fuel Pump Relay - EVAP Purge Solenoid - EGR Solenoid - Ignition Coils - Injector Failure Z2 CIRCUIT CHECKS - Performed on sensor inputs connected to the Z2 to determine out-of-range or high/low input conditions. Performed on outputs to check for open/short conditions. The components tested are: MAP Sensor Voltage (high/low) - Intake Air Temperature (IAT) Sensor Voltage (high/low) - Engine Coolant Temperature (ECT) Sensor Voltage (high/low) - Throttle Position Sensor (TPS) Voltage (high/low) - Manifold Absolute Pressure (MAP) Sensor 5 Volt Supply Check - Compressed Natural Gas (CNG) Pressure Sensor Voltage (high/low) - CNG Temperature Sensor Voltage (high/low) - Battery Temperature Sensor Voltage (high/low) - Fuel Level Sensor Voltage (high/low) - Transmission Temperature Sensor Voltage (high/low) - Governor Pressure Sensor Voltage (high/low) - Governor Pressure Solenoid (open/short) - ASD Relay Voltage (out of range) - Battery Voltage (too high) - Overdrive Override Switch (fault) - Leak Detection Pump Solenoid (open/short) Page 538 Page 336 8W-70-17 Page 887 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. Page 29 Compressor Clutch Relay: Service and Repair Fig 24 Power Distribution Center 1. Disconnect and isolate the battery negative cable. 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC for compressor clutch relay identification and location. 4. Unplug the compressor clutch relay from the PDC. 5. Install the compressor clutch relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 6. Install the PDC cover. 7. Connect the battery negative cable(s). 8. Test the relay operation. Engine Controls/Electrical - Service Manual Revisions Powertrain Control Module: Technical Service Bulletins Engine Controls/Electrical - Service Manual Revisions NUMBER: 26-03-96 GROUP: Miscellaneous DATE: Mar. 1996 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1996 Ram Truck - Publication Number 81-370-6108 DESCRIPTION OF CHANGES Revisions to the index. Page 318 8W-11-20 Page 695 Page 334 8W-33-3 Revisions to the Splice Information. Diagrams Drive Belt: Diagrams Fig. 40 Serpentine Drive Belt Routing Fig. 40 Serpentine Drive Belt Routing 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) Page 325 8W-30-18 Page 57 Power Distribution (Part 2 Of 3) Page 461 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. Page 922 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. Page 289 179 Locations Power Distribution (Part 1 Of 3) Page 499 8W-80-35 Page 684 Ignition Switch: Service and Repair REMOVAL 1. Disconnect battery ground cable. 2. On models with tilt column, remove tilt lever. 3. Remove upper and lower covers, then the ignition switch mounting screws using a suitable Torx tool. 4. Remove switch from column, then the seven terminal connector from switch. 5. Remove key-in-switch/halo light four terminal connector from ignition switch. 6. Remove key cylinder from switch as follows: a. Insert key and ensure switch is in lock position. Fig. 5 Key Cylinder Retaining Pin Depression b. Using a torx tool remove key cylinder retaining screw and bracket. Locations Engine - Coolant Recommendations Coolant: Technical Service Bulletins Engine - Coolant Recommendations NO: 07-03-97 GROUP: Cooling DATE: May 9, 1997 SUBJECT: Engine Coolant Usage THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 07-05-93 DATED NOV. 26, 1993 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE 1993 TECHNICAL SERVICE BULLETIN BOOK (PUBLICATION NO. 81-699-94000). THE COMPLETE BULLETIN IS REVISED. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1997 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Pickup/Ram Cab & Chassis/Ramcharger/ Power Ram/Power Ram Cab & Chassis 1989 - 1993 (AG) Daytona 1989 (AH) Lancer/LeBaron GTS 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - 1997 (AN) Dakota 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 1997 (BR) Ram Truck 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1997 (FJ) Sebring/Avenger/Talon 1996 - 1997 (GS) Chrysler Voyager (European Market) 1995 - 1997 (JA) Cirrus/Stratus/Breeze 1996 - 1997 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1989 - 1992 (MJ) Comanche 1996 - 1997 (NS) Town & Country/Caravan/Voyager 1995 - 1997 (PL) Neon 1997 (PR) Prowler 1992 - 1997 (SR) Viper/Viper Coupe 1997 (TJ) Wrangler 1989 - 1997 (XJ) Cherokee 1989 - 1995 (YJ) Wrangler 1993 - 1997 (ZJ) Grand Cherokee DISCUSSION: Some owners have expressed interest in using engine coolants made with propylene glycol instead of ethylene glycol due to its lower toxicity and resultant reduced hazards to children and animals. Based on recent test data, most owners should not experience significant effects on cooling system performance when using propylene glycol based coolant. The use of national brand propylene glycol based engine coolant that meets the same Chrysler ethylene glycol specification of MS-7170 (or equivalent ASTM D5216) is acceptable for Chrysler built vehicles. NOTE: ANTIFREEZE SOLD FOR PROTECTING PLUMBING ETC. (RV ANTIFREEZE) IS NOT A SUITABLE ENGINE COOLANT. However, owners should be discouraged from changing their engine coolant prior to the regularly scheduled maintenance period. Prematurely changing engine coolant unnecessarily adds to the risk of environmental exposure. Sufficient freeze protection for the region should be maintained. However, do not use more than a 55% solution (-35 F, -37 C). Use the chart that accompanies the propylene glycol coolant, since a higher concentration is required to obtain the same freeze points as ethylene glycol coolant. If the temperatures for your region fall below this, use ethylene glycol coolant. Under severe driving conditions (towing a trailer in hot weather etc.) there may be a slight loss in cooling performance. If this is noticed, the system should be changed back to ethylene glycol coolant. Page 905 Ignition Cable: Testing and Inspection INSPECTION Check the spark plug cable connections for good contact at the coil(s), distributor cap towers, and spark plugs. Terminals should be fully seated. The insulators should be in good condition and should fit tightly on the coil, distributor and spark plugs. Spark plug cables with insulators that are cracked or torn must be replaced. Clean high voltage ignition cables with a cloth moistened with a non-flammable solvent. Wipe the cables dry Check for brittle or cracked insulation. Fig. 31 Heat Shields Spark plug cable heat shields are pressed into the cylinder head to surround each spark plug cable boot and spark plug. These shields protect the spark plug boots from damage (due to intense engine heat generated by the exhaust manifolds) and should not be removed. After the spark plug cable has been installed, the lip of the cable boot should have a small air gap to the top of the heat shield. TESTING When testing secondary cables for damage with an oscilloscope, follow the instructions of the equipment manufacturer. If an oscilloscope is not available, spark plug cables may be tested as follows: CAUTION: Do not leave any one spark plug cable disconnected for longer than necessary during testing. This may cause possible heat damage to the catalytic converter. Total test time must not exceed ten minutes. ENGINE RUNNING TEST With the engine running, remove spark plug cable from spark plug (one at a time) and hold next to a good engine ground. If the cable and spark plug are in good condition, the engine rpm should drop and the engine will run poorly. If engine rpm does not drop, the cable and/or spark plug may not be operating properly and should be replaced. Also check engine cylinder compression. ENGINE OFF TEST With the engine not running, connect one end of a test probe to a good ground. Start the engine and run the other end of the test probe along the entire length of all spark plug cables. If cables are cracked or punctured, there will be a noticeable spark jump from the damaged area to the test probe. The cable running from the ignition coil to the distributor cap can be checked in the same manner. Cracked, damaged or faulty cables should be replaced with resistance type cable. This can be identified by the words ELECTRONIC SUPPRESSION printed on the cable jacket. Spark Plug Cable Resistance CHECKING FOR OPEN CIRCUITS Use an ohmmeter to test for open circuits, excessive resistance or loose terminals. If equipped, remove the distributor cap from the distributor. Do not remove cables from cap. Remove cable from spark plug. Connect ohmmeter to spark plug terminal end of cable and to corresponding electrode in distributor cap. Resistance should be 250 to 1000 Ohms per inch of cable. If not, remove cable from distributor cap tower and connect ohmmeter to the terminal ends of cable. If resistance is not within specifications as found in the Spark Plug Cable Resistance chart, replace the cable. Test all spark plug cables in this manner. Page 390 Low Pressure Sensor / Switch: Service and Repair Fig 25 High Pressure Cut-off Switch -- Typical HIGH PRESSURE CUT-OFF SWITCH Removal 1. Disconnect and isolate the battery negative cable. 2. Unplug the wire harness connector from the switch. 3. Unscrew the switch from the discharge line fitting. Installation 1. Install and tighten the switch. 2. Unplug the wire harness connector into the switch. 3. Connect the battery negative cable. Fig 28 Low Pressure Cycling Clutch Switch LOW PRESSURE CYCLING CLUTCH SWITCH 1. Disconnect and isolate the battery negative cable. 2. Unplug the wire harness connector from the switch on the top of the accumulator. 3. Unscrew the switch from the fitting on the accumulator. 4. Reverse the removal procedures to install. Helpful Information Fuel Pump Relay: Testing and Inspection Helpful Information - Circuit A14 also connects to cavity A22 of the PCM. Page 666 Part Number Description 04326622 Ignition Switch Assembly Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive two (2) ignition switch assemblies. Additional ignition switches should be ordered only after inspection determines that replacement is required. Very few vehicles are expected to require ignition switch replacement 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: Add the cost of the recall parts package and switch assembly, if necessary, 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 "0RD875". 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: Page 779 Neutral Safety Switch: Service and Repair 1. Raise and support vehicle, then place a suitable container beneath switch. 2. Unscrew switch from transmission case, allowing fluid to drain into container. 3. Move shift lever to Park and then to Neutral position and ensure switch operating lever is centered in switch opening in case. 4. Install a new seal on switch, then thread switch into transmission case. Torque to 25 ft-lbs then check and add transmission fluid as required. 5. Ensure switch operates properly. Page 98 8W-80-18 Page 493 8W-70-25 Page 136 In closed loop operation, the PCM monitors the inputs from the heated oxygen sensors. This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air/fuel ratio of 14.7 parts air to 1 part fuel. By monitoring the exhaust oxygen content through the oxygen sensor, the PCM can fine tune injector pulse width. Fine tuning injector pulse width allows the PCM to achieve optimum fuel economy combined with low emissions. The engine start-up (crank), engine warm-up, and wide open throttle modes are open loop modes. Under most operating conditions, the acceleration, deceleration, and cruise modes, with the engine at operating temperature, are closed loop modes. Ignition Switch On (Engine Off) Mode IGNITION SWITCH ON (ENGINE OFF) MODE When the ignition switch activates the fuel injection system, the following actions occur: 1. The Powertrain Control Module (PCM) determines atmospheric air pressure form the MAP sensor input to determine basic fuel strategy. 2. The PCM monitors the engine coolant temperature sensor and throttle position sensor input. The PCM modifies fuel strategy based on this input. When the Ignition key is in the "on" position and the engine is not running (zero rpm), the auto shutdown relay and fuel pump relay are not energized. Therefore, voltage is not supplied to the fuel pump, ignition coil, and fuel injectors. Wide Open Throttle Mode WIDE OPEN THROTTLE MODE This is an open loop mode. The throttle position sensor notifies the Powertrain Control Module (PCM) of a wide open throttle condition. The PCM adjusts injector pulse width to supply a predetermined amount of additional fuel. Page 581 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. 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 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. Page 625 Page 444 Headlamp Switch: Description and Operation CIRCUIT OPERATION When the headlamp switch is in the ON position, circuit A3 connects to circuit L2. Circuit L2 connects to the multi-function switch and feeds the low beams on circuit L4. When the operator selects high beam operation, circuit L2 connects to circuit L3. Left Impact Sensor Impact Sensor: Service and Repair Left Impact Sensor 1. Disconnect and isolate the battery negative cable. If the airbag module has not been deployed, wait two minutes for the system capacitor to discharge before further service. 2. Remove the plastic retainers that secure the rubber air seal to the radiator support on the driver side. 3. Working through the air seal opening, remove the three screws that secure the impact sensor to the front wheelhouse extension. 4. Unplug the wire harness connector from the sensor and remove the sensor. NOTE: Do not remove the tape that secures the sensor wire harness to the connector. 5. To install, plug in the sensor wire harness connector to the impact sensor. 6. Mount the sensor (arrow pointed forward) using the three screws provided with the new sensor. Tighten the screws to 5 to 6 N.m (45 to 55 in. lbs.). 7. Install the rubber air seal to the left radiator support. 8. Do not connect the battery negative cable at this time. See Testing and Inspection/Procedures for the proper procedures. Page 847 Correction Chart to obtain the preferred caster angle. Page 329 8W-30-46 Page 348 Coolant Temperature Sensor/Switch (For Computer): Specifications Switch Torque Switch Torque Cooling Fan Switch 8-18 ft.lb Page 582 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. Terminal Removal Page 607 Throttle Position Sensor: Description and Operation 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. Page 492 8W-70-24 Brake Warning Lamp Switch Parking Brake Warning Switch: Description and Operation Brake Warning Lamp Switch CIRCUIT OPERATION Circuit G9 provides an input to the Controller Anti Lock Brake (CAB). The CAB receives the input when either the ignition switch is in the START position, or the park brake warning lamp switch in the hydraulic combination valve CLOSES. Air Bag - On/Off Switches Air Bag Deactivation Switch: Technical Service Bulletins Air Bag - On/Off Switches NUMBER: 08-025-01 GROUP: Electrical DATE: Nov. 23, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-037-99, DATED NOVEMBER 12, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1999 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-00004). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS, PARTS, AND 2001 MODEL YEAR PROCEDURES. NOTE: THIS BULLETIN DOES NOT APPLY TO DIAMLERCHRYSLER CANADA DEALERS. SUBJECT: Airbag On-Off Switches MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - **2001** (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) Lebaron Coupe/Convertible 1994 - **2001** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - **2001** (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - **2001** (DN) Durango 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus **2001** (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 1993 - **2001** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - **2001** (PL) Neon 1997 (PR) Prowler **2001 (PT) PT Cruiser** **2001** (RS) Town & Country/Caravan/Voyager Page 205 Starter Relay: Testing and Inspection Fig 3 Starter Relay Terminal Identification 1. Remove starter relay from relay center. 2. Check resistance between ground and ignition terminals. Resistance value between ground and ignition terminals should be 70-80 ohms for resistor relays and 81-91 ohms for diode relays. 3. Apply battery voltage to relay ignition terminal and connect ground terminal to ground. Continuity should exist between battery and solenoid terminals. If continuity does not exist, replace relay. Page 733 4. Remove the upper and lower steering column covers (Figure 4). 5 Remove the lower steering column shroud (Figure 4). 6. Disconnect the 7-way ignition switch electrical connector (Figure 5). 7. Inspect the 7-way ignition switch connector for heat damage near the 4th and 5th terminals (BLACK with ORANGE tracer and PINK with BLACK tracer wires) (Figure 5). ^ Look for brown or black discoloration of the wire insulation or melting of the wire insulation near the connector. ^ Check the wiring terminals for discoloration. ^ Inspect the connector for indications of melting or deformation. Locations Power Distribution (Part 1 Of 3) Page 670 8. Inspect the ignition switch assembly for heat damage near the 4th and 5th terminals (Figure 6). ^ Check the ignition switch terminals for discoloration. ^ Inspect the ignition switch connector and body for indications of melting or deformation. 9. If the wiring connector and switch assembly are NOT damaged, continue with Section "E Install Blower Motor Relay and Overlay Harness." ^ If the 7-way switch wiring connector has indications of heat damage, the ignition switch wiring harness pigtail must be replaced. Continue with Section "C - Replace Ignition Switch Wiring Pigtail." ^ If the ignition switch assembly has indications of heat damage, the ignition switch assembly and the wiring harness pigtail must be replaced. Continue with Section "C - Replace Ignition Switch Wiring Pigtail." C. Replace Ignition Switch Wiring Pigtail IMPORTANT: Only those vehicles that had wiring and/or ignition switch damage as determined by the inspection in Section "B" require ignition switch wiring pigtail replacement. Very few vehicles are expected to require this repair. 1. Disconnect the ignition switch key-in/halo light electrical connector (Figure 7). 2. Disconnect the clockspring electrical connector from the clockspring (Figure 7). 3. Disconnect the multi-function switch electrical connector (Figure 7). 4. Remove the plastic steering column wiring trough from the steering column. The trough is attached to the column with three push clips. Page 74 8W-15-12 Page 778 Neutral Safety Switch: Testing and Inspection - In the START position, the ignition switch connects circuit A1 from the power distribution center (PDC) to circuit A41. A 40 amp fuse in cavity 3 of the PDC protects circuits A1 and A41. - The Park/Neutral position switch and backup lamp switch are molded together. Engine Controls/Electrical - Service Manual Revisions Coolant Temperature Sensor/Switch (For Computer): Technical Service Bulletins Engine Controls/Electrical - Service Manual Revisions NUMBER: 26-03-96 GROUP: Miscellaneous DATE: Mar. 1996 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1996 Ram Truck - Publication Number 81-370-6108 DESCRIPTION OF CHANGES Revisions to the index. Page 655 29. Disconnect the ground eyelet near the airbag squib connector (Figure 17). 30. Double stack the ground eyelet on the BLACK blower relay harness wire onto the ground screw. Install the ground screw and tighten securely. 31. Attach the blower relay onto one of the horizontal relay mounting tabs on the bracket located on the brake pedal support just above the brake lamp switch and pedal (Figure 18). NOTE: For early 1994 model year vehicles that do not have a relay bracket or if two relays are already attached to the bracket, secure the relay to the wiring harness with a tie strap. 32. Re-tape all of the portions of the ignition switch wiring harness from which tape was removed. 33. Position the ignition switch wires back inside of the wiring trough. 34. Snap the steering column wiring trough back on to the steering column using the supplied clips as necessary. 35. Connect the 7-way ignition switch electrical connector. 36. Install the lower steering column shroud (Figure 4). 37. Install the upper and lower steering column covers (Figure 4). 38. Install the steering column tilt lever (Figure 4). 39. Install the knee blocker and tighten the screws securely (Figure 3). 40. Connect the negative battery cable(s). Component Test Crankshaft Position Sensor: Testing and Inspection Component Test 1. Near the rear of the intake manifold, disconnect sensor pigtail harness connector from main wiring harness. Fig. 26 Sensor Connector 2. Place an ohmmeter across terminals B and C. Ohmmeter should be set to 1K-to-1OK scale for this test. The meter reading should be open (infinite resistance). Replace sensor if a low resistance is indicated. Page 305 Wheel Speed Sensor: Service and Repair Rear With Rear Wheel Antilock Brakes REMOVAL 1. Raise vehicle on hoist. 2. Remove brake line mounting nut and remove the brake line from the sensor stud. Rear Speed Sensor Mounting 3. Remove mounting stud from the sensor and shield. 4. Remove sensor and shield from differential housing. 5. Disconnect sensor wire harness and remove sensor. INSTALLATION 1. Connect harness to sensor. Be sure seal is securely in place between sensor and wiring connector. 2. Install 0-ring on sensor (if removed). 3. Insert sensor in differential housing. 4. Install sensor shield. 5. Install the sensor mounting stud and tighten to 24 Nm (18 ft. lbs.). 6. Install the brake line on the sensor stud and install the nut. 7. Lower vehicle. With Four Wheel Antilock Brakes REMOVAL 1. Raise and support vehicle. Rear Wheel Speed Sensor Page 677 29. Disconnect the ground eyelet near the airbag squib connector (Figure 17). 30. Double stack the ground eyelet on the BLACK blower relay harness wire onto the ground screw. Install the ground screw and tighten securely. 31. Attach the blower relay onto one of the horizontal relay mounting tabs on the bracket located on the brake pedal support just above the brake lamp switch and pedal (Figure 18). NOTE: For early 1994 model year vehicles that do not have a relay bracket or if two relays are already attached to the bracket, secure the relay to the wiring harness with a tie strap. 32. Re-tape all of the portions of the ignition switch wiring harness from which tape was removed. 33. Position the ignition switch wires back inside of the wiring trough. 34. Snap the steering column wiring trough back on to the steering column using the supplied clips as necessary. 35. Connect the 7-way ignition switch electrical connector. 36. Install the lower steering column shroud (Figure 4). 37. Install the upper and lower steering column covers (Figure 4). 38. Install the steering column tilt lever (Figure 4). 39. Install the knee blocker and tighten the screws securely (Figure 3). 40. Connect the negative battery cable(s). Description and Operation Hose/Line HVAC: Description and Operation REFRIGERANT LINE The refrigerant lines are used to carry the refrigerant between the various air conditioning system components. A barrier hose design is used for the air conditioning system on this vehicle. The ends of the refrigerant hoses are made from lightweight aluminum, and use braze-less fittings. The refrigerant lines and hoses cannot be repaired and, if faulty or damaged, they must be replaced. Page 333 8W-31-5 Page 753 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 For Blower Motor Relay NOTE: Very few vehicles are expected to already be equipped with a blower motor relay. 1. Inspect the brake pedal support bracket for the presence of a blower motor relay attached to the brake lamp switch bracket (Figure 1) or locate a blower motor relay that is secured near the brake pedal bracket with a tie strap. NOTE: 1995 model year vehicles that were built with original equipment foglamps will have two (2) foglamp relays mounted on this bracket. 2. If a blower motor relay is NOT found, inspect the area near the 84-way bulkhead connector for a WHITE single wire connector with BLACK ends that connects two PINK with BLACK tracer wires (Figure 2). If the connector and wires are present, follow the wiring harness to locate the blower motor relay that is secured under the instrument panel. 3. If a relay was located in either Step 1 or Step 2, verify that this is a blower motor relay as follows: Recall - Ignition Switch Wiring Overheating Technical Service Bulletin # 875 Date: 000601 Recall - Ignition Switch Wiring Overheating June 2000 Safety Recall No.875 Ignition Switch Wiring Models 1994-1996 (BR) Dodge Ram Trucks NOTE: This recall applies only to the above vehicles built at the: ^ Warren Assembly Plant ("S" in the 11th VIN position) through April 4, 1996 (MDH O4O4XX); ^ St. Louis North Assembly Plant ("J" in the 11th VIN position) through March 23, 1996 (MDH 0323XX); ^ Lago Alberto Assembly Plant ("M" in the 11th VIN position) through April 14, 1996 (MDH 0414XX); or ^ Saltillo Assembly Plant ("G"in the 11th VIN position) through April 14, 1996 (MDH 0414XX). 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 ignition switch and/or steering column wiring on about 710,000 of the above vehicles may overheat when the blower motor is operated at high speed for an extended period of time. This can cause stalling, loss of blower motor or power window operation, ABS or airbag lamp illumination or a steering column/instrument panel fire. Repair A blower motor relay and overlay harness must be installed to remove the blower motor circuit from the ignition switch. In addition, the ignition switch and electrical connector must be inspected for damage and replaced if necessary. Parts Information A. Ignition Switch Wiring Package Part Number Description CBXR875O Ignition Switch Wiring Package Each package contains the components listed: Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Ignition Switch Wiring Packages to service about 10% of those vehicles. B. Ignition Switch Assembly Page 667 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 For Blower Motor Relay NOTE: Very few vehicles are expected to already be equipped with a blower motor relay. 1. Inspect the brake pedal support bracket for the presence of a blower motor relay attached to the brake lamp switch bracket (Figure 1) or locate a blower motor relay that is secured near the brake pedal bracket with a tie strap. NOTE: 1995 model year vehicles that were built with original equipment foglamps will have two (2) foglamp relays mounted on this bracket. 2. If a blower motor relay is NOT found, inspect the area near the 84-way bulkhead connector for a WHITE single wire connector with BLACK ends that connects two PINK with BLACK tracer wires (Figure 2). If the connector and wires are present, follow the wiring harness to locate the blower motor relay that is secured under the instrument panel. 3. If a relay was located in either Step 1 or Step 2, verify that this is a blower motor relay as follows: Page 756 8. Inspect the ignition switch assembly for heat damage near the 4th and 5th terminals (Figure 6). ^ Check the ignition switch terminals for discoloration. ^ Inspect the ignition switch connector and body for indications of melting or deformation. 9. If the wiring connector and switch assembly are NOT damaged, continue with Section "E Install Blower Motor Relay and Overlay Harness." ^ If the 7-way switch wiring connector has indications of heat damage, the ignition switch wiring harness pigtail must be replaced. Continue with Section "C - Replace Ignition Switch Wiring Pigtail." ^ If the ignition switch assembly has indications of heat damage, the ignition switch assembly and the wiring harness pigtail must be replaced. Continue with Section "C - Replace Ignition Switch Wiring Pigtail." C. Replace Ignition Switch Wiring Pigtail IMPORTANT: Only those vehicles that had wiring and/or ignition switch damage as determined by the inspection in Section "B" require ignition switch wiring pigtail replacement. Very few vehicles are expected to require this repair. 1. Disconnect the ignition switch key-in/halo light electrical connector (Figure 7). 2. Disconnect the clockspring electrical connector from the clockspring (Figure 7). 3. Disconnect the multi-function switch electrical connector (Figure 7). 4. Remove the plastic steering column wiring trough from the steering column. The trough is attached to the column with three push clips. Page 485 8W-30-49 Page 91 8W-70-17 Locations All Four-Wheel Drive (4WD) Switch: Description and Operation All CIRCUIT OPERATION From circuit G107, the Controller Antilock Brake (CAB) senses when the four-wheel drive indicator lamp switch closes. Circuit G107 connects to cavity 8 of the CAB and splices to the four-wheel drive indicator lamp switch and instrument panel four-wheel drive indicator lamp. Page 829 Power Window Switch: Testing and Inspection - Check the 40 Amp fuse located cavity 2 of the PDC - Check the 30 Amp circuit breaker located in the fuse block - Check the ground for the power window system-Check the 40 Amp fuse located cavity 2 of the PDC Page 740 12. Install the PINK with BLACK tracer blower relay harness wire (with a blade terminal) into cavity 43 of the 84-way connector (Figure 14 and Figure 16). 13. Install the BLUE wedge into the 84-way connector. 14. Install the cover onto the rear of the 84-way connector. 15. Connect the 84-way bulkhead connector. 16. Disconnect the WHITE electrical connector on the blower relay harness. Install the PINK with BLACK tracer wire that was removed from the 84-way connector into the WHITE connector opening (Figure 16). Reconnect the WHITE connector. Secure the connector near the bulkhead connector with a tie strap. 17. Install the BLACK with ORANGE tracer blower relay harness wire into cavity 5 of the 7-way ignition switch connector (Figure 16). 18. Disconnect the BLACK 2-way electrical connector on the blower relay harness (Figure 16). Remove the BLUE wedge and then install the BLACK with ORANGE tracer wire that was removed from the ignition switch connector into cavity 2 of the BLACK connector. Install the wedge and reconnect the BLACK 2-way connector. Secure the connector and any excess wiring near the base of the steering column with a tie strap. 19. Cut off the terminal and then strip about 1" of wire insulation from the end of the DARK GREEN wire that was removed from the fuseblock earlier. 20. Strip about 1" of wire insulation from the end of the DARK GREEN with WHITE blower relay harness wire (Figure 16). 21. Slide a piece of heat shrink tubing onto the wire. 22. Connect the DARK GREEN and DARK GREEN with WHITE tracer wires by twisting the wire ends together. 23. Solder the twisted wire ends using rosin core solder. CAUTION: Wire splice must be soldered. Do NOT use a solderless connector. 24. Center the piece of heat shrink tubing over the splice. Heat the tubing with a heat source until sealant comes out each end of the tubing. 25. Install the DARK GREEN blower relay harness wire into cavity 12 of the fuseblock (Figure 16). 26. Install the PINK with BLACK tracer blower relay harness wire into cavity 11 of the fuseblock (Figure 16). 27. Install the TAN fuseblock wedge (Figure 13). 28. Reinstall the 30-amp fuse in the fuseblock F2 Blower Motor location (Figure 13). Page 388 Low Pressure Sensor / Switch: Description and Operation Fig 28 Low Pressure Cycling Clutch Switch LOW PRESSURE CYCLING CLUTCH SWITCH The low pressure cycling clutch switch is mounted on top of the accumulator. The switch is connected in series with the high pressure cut-off switch in the A/C request signal circuit, between the heater-A/C mode control switch and the Powertrain Control Module (PCM). The switch contacts open and close causing the PCM to turn the compressor clutch on and off. This regulates the system pressure and controls evaporator temperature. Controlling evaporator temperature prevents condensate water on the evaporator fins from freezing and obstructing air conditioning system air flow. The switch contacts are normally open when the suction pressure is approximately 172 kPa (25 psi) or lower. The switch will close when the suction pressure rises to approximately 296 kPa (43 psi) or above. Lower ambient temperatures, below approximately -1~C (30~F) during cold weather, will also open the switch contacts. This is due to the pressure/temperature relationship of the refrigerant in the system. The low pressure cycling clutch switch is a factory-calibrated unit. This switch cannot be adjusted or repaired. If faulty or damaged, the switch must be replaced. Page 616 Camshaft Position Sensor: Diagrams Recall 99V024000: Possible Headlamp Switch Failure Headlamp Switch: Recalls Recall 99V024000: Possible Headlamp Switch Failure Operation of the headlamps over an extended period of time can result in Headlamp switch failure, causing the headlamps or park lamps to go out. If the lights fail, a visibility problem could occur, increasing the risk of a vehicle crash. Dealers will replace the Headlamp switch including a relay in the park lamp wiring circuit. Owner notification began June 14, 1999. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chrysler at 1-800-992-1997. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Page 473 8W-30-15 Revision to the ASD relay circuit. Page 38 Fuse Block (Part 2 Of 2) Page 739 8. Remove the PINK with BLACK tracer (A2) wire from cavity 43 of the 84-way bulkhead connector (Figure 14). 9. Remove the RED wedge from the 7-way ignition switch connector (Figure 15). 10. Remove the BLACK with ORANGE tracer (A22) wire from cavity 5 of the 7-way ignition switch connector (Figure 15). Then, remove the wire from the wiring takeout bundle back to the base of the steering column. 11. Install the supplied blower relay wiring harness so that the X-wrap is located near the base of the steering column (Figure 16). Secure the harness with a tie strap. Page 438 Fig. 1 13. Install the cup holder assembly. Tighten the cup holder screws securely. 14. Connect the negative battery cable(s). COMPLETION REPORTING AND REIMBURSEMENT Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerClrrysler to record recall service completions and provide dealer payments. Use one of the following labor operation numbers and time allowances: Labor Operation Time Number Allowance Replace headlamp switch and 08819182 0.5 hours install overlay harness Replace headlamp switch, install 08819183 0.9 hours overlay harness and replace 4 wires Replace headlamp switch, install 08819184 1.1 hours overlay harness and replace 5-9 wires Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions PARTS RETURN Not required. DEALER NOTIFICATION AND VEHICLE LIST All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the "TIL" will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL SYSTEM FUNCTIONS 53 AND VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall implementation for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD819". OWNER NOTIFICATION AND SERVICE SCHEDULING All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner notification letter is attached. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. VEHICLE NOT AVAIABLE If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: Page 338 8W-70-22 Locations Crankshaft Position Sensor: Locations Fig. 25 Crankshaft Position Sensor - Typical The sensor is located on the top of cylinder block near the rear of right cylinder head. Page 804 Component Testing Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Component Testing Fig. 66 Engine Coolant Temperature Sensor 1. Disconnect wire harness connector from coolant temperature sensor. 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. Sensor Resistance (OHMS) - Coolant Temperature Sensor/Intake Air Temperature Sensor 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 less than 1340 ohms with the engine warm. Refer to 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. 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. Page 452 Battery Temperature Sensor: Description and Operation 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. Page 580 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. 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. Locations Blower Motor Relay: Locations Fig 39 Blower Motor Relay Removal/Installation The relay is located in the passenger compartment on the stop lamp switch bracket. The stop lamp switch bracket is secured to the inboard side of the pedal support bracket under the driver side of the instrument panel. The relay case includes a molded-in plastic slot that snaps over the blade-type relay mount on the stop lamp switch bracket. Page 78 Revisions to the Powertrain Control Module wiring. Page 240 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-92-00-90 0.2 Hrs. Perform Repair Procedure A 08-92-00-91 0.2 Hrs. Perform Repair Procedure B 08-92-00-92 0.2 Hrs. Perform Repair Procedure C FAILURE CODE: XX - Service Adjustment Repair Procedure A This Repair Procedure installs an RFI filter in series with the blower fan circuit. 1. Record the radio station presets. 2. Disconnect and isolate the battery negative cable. 3. Remove the glove box door by disconnecting the lanyard on the left side of the door, depressing the stop tab at the rear of the bin and then pulling the door away from the instrument panel. 4. Locate the orange, two-wire connector which is visible through the opening in the rear of the glove box cavity. Disconnect the connector. 5. Mate the connectors on the filter with those on the fan motor. Check both pairs of connectors to make sure that they are properly mated. 6. Apply foam tape (P/N 4318028) around RFI filter and upper connector end. 7. Install the glove box door and lanyard. 8. Remove the kick panel in front of the passenger-side door. 9. Locate the wiring harness ground termination on the sheet metal behind the kick panel. 10. Remove the ground termination bolt. Install one eyelet of the new ground wire (wire located in kit) on the termination bolt and secure the bolt. 11. Remove one of the bolts that secures the blower motor housing to the HVAC housing. Install the other end of the ground wire to the bolt and re-attach the bolt. 12. Install the kick panel. 13. Connect the negative cable and reset the clock and reprogram the radio to the station presets identified in step one. Repair Procedure B This Repair Procedure installs an RFI filter in series with the electric fuel pump motor. 1. Record the radio station presets. 2. Disconnect and isolate the battery negative cable. 3. Disconnect the fuel pump module connector located 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. 4. Connect the RFI module to the harness and to the fuel pump module connector. Secure the connectors by sliding the red lock tab back into its original position. 5. Apply foam tape (P/N 4318028) to the back of the RFI module. 6. Secure the RFI module by tie strapping it to the truss bracket. The truss bracket is adjacent to the fuel tank rail and chassis rail. 7. Connect the negative cable and reset the clock and reprogram the radio to the station presets identified in step one. Repair Procedure C Recall 00V135000: Ignition Switch Wiring Defect Ignition Switch: All Technical Service Bulletins Recall 00V135000: Ignition Switch Wiring Defect The affected vehicles were built with an ignition switch and wiring that could overheat. High electrical current loads pass through the switch when the blower motor is operated on high for an extended periods of time. This could cause the ignition switch and wiring to overheat. Dealers will install a relay and overlay harness. Owner notification began June 26, 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). Description and Operation Ignition Relay: Description and Operation As one of its functions, the Automatic Shutdown (ASD) relay will supply battery voltage to the ignition coil. The ground circuit for the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM regulates ASD relay operation by switching the ground circuit on-and-off. Page 129 Powertrain Control Module: Connector Views (JTEC) Powertrain Control Module Connectors CAVITY CIRCUIT WIRE/COLORFUNCTION A1 K32 YL/GY Ignition Coil Driver #4 A2 F18 LG/BK Fused Ignition Switch Output A3 K18 RD/BK Ignition Coil Driver #3 A4 K4 BK/LB Sensor Ground A5 K43 DG/GY Ignition Coil Driver #5 A6 T41 BK/WT P/N Position Switch Sense A7 K19 8K/GY Ignition Coil Driver #1 A8 K24 GY/BK Crank Position Sensor Signal A9 K17 DB/WT Ignition Coil Driver #2 A10 K60 YL/BK Idle Air Control #2 Driver A11 K40 BR/WT Idle Air Control #3 Driver A15 K21 BK/RD Intake Air Temp. Sensor Signal A16 K2 TN/BK ECT Sensor Signal A17 K6 VT/WT 5-Volt Supply A18 K44 TN/YL Camshaft Position Sensor Signal A19 K39 GY/RD Idle Air Control #1 Driver A20 K59 VT/BK Idle Air Control #4 Driver A22 A14 RD/WT Fused B(+) A23 K22 OR/DB Throttle Position Sensor Signal A24 K141 TN/WT Upstream O2 Sensor Signal A24 K41 BK/DG Upstream O2 Sensor Signal A25 K341 OR/BK Downstream O2 Sensor Signal A26 K41 BK/DG Right Upstream O2 Sensor Signal A26 K241 BK/DG Right Upstream O2 Sensor Signal A27 K1 DG/RD MAP Sensor Signal A28 K242 DG/LB Fuel Pressure Sensor Signal A29 K441 TN/RD Center O2 Sensor Signal A31 Z12 BK/TN Ground A32 Z12 BK/TN Ground B1 K54 VT Trans. Temp. Sensor Signal B2 K26 VT/TN Injector #7 Driver B3 K115 TN Injector #9 Driver B4 K11 WT/DB Injector #1 Driver B5 K13 YL/WT Injector #3 Driver B6 K38 GY Injector #5 Driver B8 K88 VT/WT Governor Pressure Solenoid Control B10 K20 DG Generator Field Driver B11 K54 OR/BK TCC Solenoid Control B12 K58 BR/DB Injector #6 Driver B13 K28 GY/LB Injector #8 Driver B14 K116 WT/DB Injector #10 Driver B15 K12 TN Injector #2 Driver B16 K14 LB/BR Injector #4 Driver Page 696 Page 223 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. Page 858 Fuel Pressure: Testing and Inspection Fuel Pressure Test - Without Test Port Fig. 7 Fuel Pressure Test Port - Typical NOTE: The fuel pressure test port is used on certain engines only. If equipped, the test port will be located on the fuel rail near the throttle position sensor. If not equipped, refer to the following procedure: Fig. 8 Installing Adapter Tool And Pressure Gauge 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. With engine at idle speed, system fuel pressure should be 339 kPa +/- 34 kPa (49.2 psi +/- 5 psi). 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. 1. Release fuel pressure. Refer to the Fuel System Pressure Release Procedure. 2. Disconnect latch clip and fuel line at fuel rail. 3. Connect adapter tool number 6923 into the fuel rail. 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. Page 512 Steering - Caster Correction Chart Revision Alignment: Technical Service Bulletins Steering - Caster Correction Chart Revision NUMBER: 26-12-97A GROUP: Miscellaneous DATE: December, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1996 Ram Truck - Publication Number 81-370-6108 DESCRIPTION OF CHANGES Revisions to the caster correction chart 2-6 Page 343 8W-80-18 Page 70 8W-30-10 Two Way Radios - Poor Reception Technical Service Bulletin # 083096 Date: 960906 Two Way Radios - Poor Reception NO: 08-30-96 GROUP: Electrical DATE: Sept. 6, 1996 SUBJECT: Radio Interference To/From Two-Way Radio Receivers MODELS: 1995 - 1997 (BR) Ram Truck SYMPTOM/CONDITION: Customers may complain of intermittent poor reception on their two-way radios and/or the windshield wipers may operate intermittently during two-way radio communication (wipers off). 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 and/or HVAC blower motor. In addition, the windshield wiper delay module may be affected by radios operating within the 20 MHZ and 174 MHZ range. 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 - 148 MHZ) ^ Public Service High Band (148 - 174 MHZ) DIAGNOSIS: Turn the ignition key to the RUN position (HVAC controls must be OFF and wipers OFF). Operate the two-way radio and monitor for RFI/static/poor reception. Turn the HVAC controls ON and operate the blower fan through the different blower fan speeds while monitoring for RFI/static/poor reception. Start the engine and monitor for RFI. Next, key the microphone and monitor for intermittent wiper operation. If there is RFI with the ignition key turned to the RUN position (HVAC controls OFF, wiper OFF, and engine OFF), RFI is being emitted from something other than the fuel pump module's motor or the HVAC blower motor. If RFI is identified while the HVAC blower fan is operating, perform Repair Procedure A. If RFI is identified while the engine is running, perform Repair Procedure B. If the wiper motor intermittently operates during any radio operation, perform Repair Procedure C. 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 ALL THREE REPAIR PROCEDURES. PARTS REQUIRED: 1 (AR) 04883825AA RFI Filter For Fuel Pump Module 1 (AR) 04883826AA RFI Filter For HVAC Blower Fan Motor 1 (AR) 04883827AA RFI Filter For Windshield Wiper Motor Delay Module Page 738 14. Place the ignition switch against the lock housing opening on the steering column. Ensure that the ignition switch park lock dowel pin enters the slot in the park lock slider linkage in the steering column. 15. Install the ignition switch screws (Figure 8). Tighten the screws to 26 in-lbs (3 Nm). 16. Connect the key-in/halo light electrical connector to the new ignition switch (Figure 7). NOTE: DO NOT connect the 7-way ignition switch connector. D. Install Blower Motor Relay and Overlay Harness 1. Remove the 30-amp fuse from the fuseblock F2 -- Blower Motor location (Figure 13). 2. Remove the TAN wedge from the fuseblock (Figure 13). 3. Remove the BLACK with ORANGE tracer (A22) wire from cavity 11 of the fuseblock (Figure 13); then cut the terminal off and tape the wire back to the harness. 4. Remove the DARK GREEN (C1) wire from cavity 12 of the fuseblock (Figure 13). 5. Disconnect the 84-way bulkhead connector. 6. Remove the cover from the rear of the 84-way connector. 7. Remove the BLUE wedge from the 84-way connector. With Pressure Test Port Fuel Pressure Release: Service and Repair With Pressure Test Port Fuel Pressure Release Procedure - Typical 1. Remove the negative battery cable, and remove the fuel tank fill cap. 2. Place sufficient shop towels under the pressure test port (schrader valve) on the fuel rail. 3. Remove the cap from the pressure test port on the fuel rail. 4. Using an appropriate fuel pressure gauge hose, place one end of hose in an approved container and screw the other end of the hose onto the test port to relieve fuel pressure. Absorb any spilled fuel with shop towels. 5. Install cap on test port. Page 20 Blower Motor Relay: Testing and Inspection Blower Motor Relay Fig 39 Blower Motor Relay Removal/Installation RELAY TEST Remove the blower motor relay from its wire harness connector as described to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK. go to Step 2. If not OK, replace the faulty relay 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 +/- 5 ohms. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, see the Relay Circuit Test procedure. If not OK, replace the faulty relay. RELAY CIRCUIT TEST 1. The relay common feed terminal cavity (30) is connected to battery voltage and should be hot at all times. If OK go to Step 2. If not OK, repair the open circuit to the fuse block module as required. 2. The relay normally closed terminal cavity (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3. 3. The relay normally open terminal cavity (87) is connected to the blower motor. When the relay is energized, terminal 87 is connected to terminal 30 and provides full battery current to the blower motor. There should be continuity between this cavity and the blower motor relay output circuit cavity of the blower motor wire harness connector at all times. If OK, go to Step 4. If not OK, repair the open circuit to the blower motor as required. 4. The coil battery terminal cavity (86) is connected to the electromagnet in the relay. It is energized when the ignition switch is in the On position. Check for battery voltage at the cavity for relay terminal 86 with the ignition switch in the On position. If OK, go to Step 5. If not OK, repair the open circuit to the ignition switch through the Power Distribution Center (PDC) as required. 5. The coil ground terminal cavity (85) is connected to ground. This terminal supplies the ground for the relay electromagnetic coil. There should be continuity between the cavity for relay terminal 85 and a good ground at all times. If not OK, repair the open circuit as required. Locations Two Way Radios - Poor Reception Technical Service Bulletin # 083096 Date: 960906 Two Way Radios - Poor Reception NO: 08-30-96 GROUP: Electrical DATE: Sept. 6, 1996 SUBJECT: Radio Interference To/From Two-Way Radio Receivers MODELS: 1995 - 1997 (BR) Ram Truck SYMPTOM/CONDITION: Customers may complain of intermittent poor reception on their two-way radios and/or the windshield wipers may operate intermittently during two-way radio communication (wipers off). 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 and/or HVAC blower motor. In addition, the windshield wiper delay module may be affected by radios operating within the 20 MHZ and 174 MHZ range. 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 - 148 MHZ) ^ Public Service High Band (148 - 174 MHZ) DIAGNOSIS: Turn the ignition key to the RUN position (HVAC controls must be OFF and wipers OFF). Operate the two-way radio and monitor for RFI/static/poor reception. Turn the HVAC controls ON and operate the blower fan through the different blower fan speeds while monitoring for RFI/static/poor reception. Start the engine and monitor for RFI. Next, key the microphone and monitor for intermittent wiper operation. If there is RFI with the ignition key turned to the RUN position (HVAC controls OFF, wiper OFF, and engine OFF), RFI is being emitted from something other than the fuel pump module's motor or the HVAC blower motor. If RFI is identified while the HVAC blower fan is operating, perform Repair Procedure A. If RFI is identified while the engine is running, perform Repair Procedure B. If the wiper motor intermittently operates during any radio operation, perform Repair Procedure C. 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 ALL THREE REPAIR PROCEDURES. PARTS REQUIRED: 1 (AR) 04883825AA RFI Filter For Fuel Pump Module 1 (AR) 04883826AA RFI Filter For HVAC Blower Fan Motor 1 (AR) 04883827AA RFI Filter For Windshield Wiper Motor Delay Module Page 195 Air Bag Control Module: Technician Safety Information WARNING: Failure to have the air bag system properly serviced may lead to possible injury in the event of an accident. NOTE: Service and general information labels about the air bag system can be found on the driver's sun visor, the glove box door, and in the engine compartment. PRECAUTIONS Always wear safety glasses when servicing an air bag equipped vehicle or when handling an air bag module. Because this system is a sensitive, complex electro-mechanical unit, before attempting to diagnose, remove or install any air bag system component, you must first disarm air bag system as outlined. Failure to do this could result in accidental airbag deployment and possible personal injury. The airbag module inflator assembly contains sodium azide and potassium nitrate. These materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible compounds. In addition, the passenger airbag module contains argon gas pressurized to over 2,500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not puncture, incinerate, or bring into contact with electricity. Do not store at temperatures exceeding 93° C (200° F). The fasteners, screws and bolts used for air bag components have special coatings and are specifically designed for the air bag system. They must never be replaced with substitutes. If fastener replacement is required, use correct fasteners provided in service package. Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog. Substitute parts may appear interchangeable, but internal differences may result in inferior occupant protection. When a steering column has an airbag module attached, never place the column on the floor or any other surface with the steering wheel or air bag module face down. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Accidental airbag deployment could occur. Windshield Wiper Switch Wiper Switch: Service and Repair Windshield Wiper Switch Refer to "Multi-Function Switch, Replace" in this section. Page 203 Page 108 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. Page 673 7. Remove the key cylinder from the ignition switch (Figure 10). 8. Place the new ignition switch in the LOCK position. The switch is in the LOCK position when the column lock flag is parallel to the ignition switch terminals (Figure 11). 9. With the key cylinder in the LOCK position, insert the key cylinder into the new ignition switch until it bottoms. 10. Insert the ignition key into the key cylinder. While gently pushing the key cylinder in toward the ignition switch, rotate the ignition key clockwise to the end of travel (START position) and then back to the LOCK position. 11. If equipped, install the key cylinder retaining bracket and screw (Figure 9). Tighten the screw to 26 in-lbs (3 Nm). 12. Apply a light coating of grease to the ignition switch column lock flag and the park lock dowel pin (Figure 11). 13. Make sure that the transmission gear shift selector is in the PARK position. The park lock dowel pin must be properly indexed before installing the ignition switch (Figure 12). Page 498 8W-80-26 Page 587 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Sensor Operation Crankshaft Position Sensor: Description and Operation Sensor Operation DESCRIPTION Engine speed and crankshaft position are provided through the crankshaft position sensor. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. Fig. 5 Sensor Operation The flywheel/drive plate has 8 single notches, spaced every 45 degrees, at its outer edge. NOTE: The engine will not operate if the PCM does not receive a crankshaft position sensor input. OPERATION The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. For each engine revolution, there are 8 pulses generated on V-8 engines. The 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. Page 160 Except CNG Page 907 Ignition Cable: Service and Repair REMOVAL AND INSTALLATION 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. Engine Firing Order Install cables into the proper engine cylinder firing order. When replacing the spark plug and coil cables, route the cables correctly and secure in the proper retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise. It could also cause cross ignition of the plugs or short circuit the cables to ground. When installing new cables, make sure a positive connection is made. A snap should be felt when a good connection is made between the plug cable and the distributor cap tower. Page 433 Fig. 7 ^ Carefully inspect the connector and terminals B1, B2, R and H for signs of damage from overheating (melted connector and/or discolored terminal). If any one of these terminals shows signs of damage, ALL FOUR of these terminals MUST be replaced. Continue with Step 3. ^ Carefully inspect the connector and all other terminals. If any terminals in addition to B1, B2, R and H are damaged, terminals B1, B2, R, H and any other damaged terminals MUST be replaced. Continue with Step 3. ^ If there is no indication of heat damage, continue with Step 6. 3. For vehicles with headlamp switch wire terminal and connector heat damage: Remove any damaged wire terminals from the headlamp switch connector using a small screwdriver, Miller Special Tool #8197 or equivalent. If the connector is also damaged and cannot be reused, remove all wires and discard the connector. 4. Replace any damaged wires as determined in Step 2 as follows: a. Cut the electrical tape and remove the affected wire(s) from the bundle. b. Cut off the damaged wire approximately 10 inches from the terminal. NOTE: Stagger the wire splice locations by about 1/2 inch. c. Remove about 1 inch of insulation from the end of the wire. d. Remove about l inch of insulation from the end of the matching color and gauge wire and terminal provided in the parts package. e. Slip one piece of the provided heat shrink tubing over the new wire end. f. Twist the exposed wire ends of the harness wire and the replacement wire end together. g. Solder the twisted wire ends together using rosin core solder. CAUTION: All wiring splices must be soldered or future circuit failure may occur. h. Slide the heat shrink tubing over the wire splice and heat the tubing until the tubing shrinks tightly around the wire and sealant comes out both ends of the tubing. i. Repeat Steps A - H for all other damaged wires as necessary. Page 134 Powertrain Control Module: Description and Operation Fuel Control FUEL CONTROL The Powertrain Control Module (PCM) controls the air/fuel ratio of the engine by varying fuel injector ON time. Mass air flow is calculated using the speed density method using engine speed, manifold absolute pressure, and air charge temperature. Different fuel calculation strategies are used dependent on the operational state of the engine. During crank mode, a prime shot fuel pulse is delivered followed by fuel pulses determined by a crank time strategy. Cold engine operation is determined via an open loop strategy until the O2 sensors have reached operating temperature. At this point, the strategy enters a closed loop mode where fuel requirements are based upon the state of the O2 sensors, engine speed, MAP, throttle position, air temperature, battery voltage, and coolant temperature. Additional factors can influence fuel pulse width. Asynchronous acceleration enrichment is a technique whereby the duration of injector ON time can be increased for injectors already firing, providing improved acceleration response. The D3 microcomputer controls fuel injector timing in response to high level commands from the Z2 microcomputer. Injector timing with respect to engine position is determined by the D3 and is transparent to the Z2. Page 491 8W-70-22 Recall 99V024000: Possible Headlamp Switch Failure Headlamp Switch: All Technical Service Bulletins Recall 99V024000: Possible Headlamp Switch Failure Operation of the headlamps over an extended period of time can result in Headlamp switch failure, causing the headlamps or park lamps to go out. If the lights fail, a visibility problem could occur, increasing the risk of a vehicle crash. Dealers will replace the Headlamp switch including a relay in the park lamp wiring circuit. Owner notification began June 14, 1999. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chrysler at 1-800-992-1997. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Page 296 205 Component Testing Camshaft Position Sensor: Testing and Inspection Component Testing Camshaft Position Sensor The camshaft position sensor is located in the distributor on all engines. NOTE: For this test, an analog (non-digital) voltmeter is needed. Do not remove the distributor connector from the distributor. Using small paper clips, insert them into the backside of the distributor wire harness connector to make contact with the terminals. Be sure that the connector is not damaged when inserting the paper clips. Attach voltmeter leads to these paper clips. 1. Connect the positive (+) voltmeter lead into the sensor output wire. This is at done the distributor wire harness connector. 2. Connect the negative (-) voltmeter lead into the ground wire. 3. Set the voltmeter to the 15 Volt DC scale. 4. Remove distributor cap from distributor (two screws). Rotate (crank) the engine until the distributor rotor is pointed towards the rear of vehicle. The movable pulse ring should now be within the sensor pickup. 5. Turn ignition key to ON position. Voltmeter should read approximately 5.0 volts. 6. If voltage is not present, check the voltmeter leads for a good connection. 7. If voltage is still not present, check for voltage at the supply wire. 8. If 5 volts is not present at supply wire, check for voltage at PCM 32-way connector (cavity A-17). Leave the PCM connector connected for this test. 9. If voltage is still not present, perform vehicle test using the DRB scan tool. 10. If voltage is present at cavity A-17, but not at the supply wire: a. Check continuity between the supply wire. This is checked between the distributor connector and cavity A-17 at the PCM. If continuity is not present, repair the harness as necessary. b. Check for continuity between the camshaft position sensor output wire and cavity A-18 at the PCM. If continuity is not present, repair the harness as necessary. c. Check for continuity between the ground circuit wire at the distributor connector and ground. If continuity is not present, repair the harness as necessary. 11. While observing the voltmeter, crank the engine with ignition switch. The voltmeter needle should fluctuate between 0 and 5 volts while the engine is cranking. This verifies that the camshaft position sensor in the distributor is operating properly and a sync pulse signal is being generated. If sync pulse signal is not present, replacement of the camshaft position sensor is necessary Page 397 Parking Brake Warning Switch: Testing and Inspection - In the START position, the ignition switch connects circuit A1 from the power distribution center (PDC) to circuit A41. A 40 amp fuse in cavity 3 of the PDC protects circuits A1 and A41. - The Park/Neutral position switch and backup lamp switch are molded together. Page 927 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 0.89 mm (0.035 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 N.m (26-30 ft. lbs.) torque. 3. Install spark plug cables over spark plugs. Page 588 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. Page 534 Intake Air Temperature Sensor: Service and Repair REMOVAL 1. Remove air cleaner assembly. Fig. 69 Intake Manifold Air Temperature Sensor 2. Disconnect electrical connector at sensor. 3. Remove sensor from intake manifold. INSTALLATION 1. Install sensor to intake manifold. Tighten to 28 N.m (20 ft. lbs.) torque. 2. Install electrical connector. 3. Install air cleaner. Page 621 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. Page 164 Fuel Pump Relay: Testing and Inspection Relay Test Relay Terminals NOTES: - The relay terminal numbers can be found on the bottom of the relay. - Along with supplying voltage to the fuel pump relay contacts, circuit A14 splices to supply voltage to the contact side of the ASD relay. - Circuit F18 splices to supply battery voltage to the coil sides of the ASD relay and fuel pump relay. TERMINAL ID - Terminal number 30 is connected to battery voltage and can be switched or B+ (hot) at all times. - The center terminal number 87A is connected (a circuit is formed) to terminal 30 in the de-energized (normally OFF) position. - Terminal number 87 is connected (a circuit is formed) to terminal 30 in the energized (ON) position. Terminal number 87 then supplies battery voltage to the component being operated. - Terminal number 86 is connected to a switched (+) power source. - Terminal number 85 is grounded by the Powertrain Control Module (PCM). TESTING 1. Remove relay before testing. 2. Using an ohmmeter, perform a resistance test between terminals 85 and 86. Resistance value (ohms) should be 75 +/- 5 ohms for resistor equipped relays. 3. Connect the ohmmeter between terminals number 87A and 30. Continuity should be present at this time. 4. Connect the ohmmeter between terminals number 87 and 30. Continuity should not be present at this time. 5. Use a set of jumper wires (16 gauge or smaller). Connect one jumper wire between terminal number 85 (on the relay) to the ground side (-) of a 12 volt power source. 6. Attach the other jumper wire to the positive side (+) of a 12V power source. Do not connect this jumper wire to relay at this time. CAUTION: Do not allow the ohmmeter to contact terminals 85 or 86 during these tests. Damage to ohmmeter may result. 7. Attach the other jumper wire (12V +) to terminal number 86. This will activate the relay. Continuity should now be present between terminals number 87 and 30. Continuity should not be present between terminals number 87A and 30. 8. Disconnect jumper wires from relay and 12 volt power source. If continuity or resistance tests did not pass, replace relay. Page 777 Neutral Safety Switch: Description and Operation CIRCUIT OPERATION 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. Page 383 High Pressure Sensor / Switch: Testing and Inspection Fig 25 High Pressure Cut-off Switch -- Typical HIGH PRESSURE CUT-OFF SWITCH 1. Verify that the refrigerant system is properly charged. 2. Unplug the high pressure switch wire harness connector and test for continuity between the switch terminals. There should be continuity If OK, refer to the wiring diagrams and repair the circuits as required. If not OK, replace the faulty switch. Fig 28 Low Pressure Cycling Clutch Switch LOW PRESSURE CYCLING CLUTCH SWITCH Verify that the refrigerant system has the correct refrigerant charge. 1. Unplug the low pressure cycling clutch switch wire harness connector from the switch on the accumulator, and install a jumper wire between the two connector cavities. 2. Connect a manifold gauge set to the refrigerant system service ports. 3. Place the heater-A/C mode control switch knob in any A/C position and start the engine. 4. Check the continuity between the two terminals of the low pressure switch. There should be continuity with a suction pressure reading of 296 kPa (43 psi) or above, and no continuity with a suction pressure reading of 172 kPa (25 psi) or below. If OK, test and repair the compressor clutch control circuit as required. If not OK, replace the faulty switch. Page 26 Pinout Page 757 5. Remove the ignition switch wires from the wiring trough. Remove any tape from the ignition switch wires. 6. Stagger cut all of the ignition switch wires (7) on the vehicle harness side about 1/2" apart. Make sure that all wires are cut so that the wire splices will be located inside the wiring trough and towards the bottom of the steering column. NOTE: Splices that are located towards the top of the steering column are more susceptible to damage. 7. Strip about 1" of wire insulation from each wire on the vehicle wire harness. 8. Stagger cut the matching wires on the supplied ignition switch pigtail to match up with the harness side. Allow sufficient length for the soldered connections. Make sure that the overall length of the wiring is the same as the original harness. NOTE: Be sure to cut the supplied ignition switch pigtail wires so that they match the wire color of the vehicle wire harness. On some vehicles, the YELLOW harness wire matches with the BLUE/YELLOW* vehicle wire and the BLACK harness wire matches with the GRAY/BLACK* vehicle wire. 9. Strip about 1" of wire insulation from each wire on the ignition switch pigtail. 10. Slide a piece of heat shrink tubing onto each wire of the new pigtail. 11. Connect the supplied switch pigtail harness to the vehicle harness by twisting all wire ends together. Be sure to match all wire colors. 12. Solder the twisted wire ends using rosin core solder. CAUTION: Wire splices must be soldered. Do NOT use solderless connectors. 13. Center the pieces of heat shrink tubing over each of the splices. Heat the tubing with a heat source until sealant comes out each end of the tubing. 14. Connect the multi-function switch electrical connector (Figure 7). 15. Connect the clockspring electrical connector (Figure 7). 16. ^ If the ignition switch was damaged and must be replaced, as determined by the inspection in Section "B," continue with Section "D -- Replace Ignition Switch Assembly." ^ If the ignition switch was NOT damaged, as determined by the inspection in Section "B," continue with Section "E - Install Blower Motor Relay and Overlay Harness." D. Replace Ignition Switch Assembly IMPORTANT: Only those vehicles that had ignition switch damage as determined by the inspection in Section "B," require ignition switch replacement. Very few vehicles are expected to require this repair. Page 755 4. Remove the upper and lower steering column covers (Figure 4). 5 Remove the lower steering column shroud (Figure 4). 6. Disconnect the 7-way ignition switch electrical connector (Figure 5). 7. Inspect the 7-way ignition switch connector for heat damage near the 4th and 5th terminals (BLACK with ORANGE tracer and PINK with BLACK tracer wires) (Figure 5). ^ Look for brown or black discoloration of the wire insulation or melting of the wire insulation near the connector. ^ Check the wiring terminals for discoloration. ^ Inspect the connector for indications of melting or deformation. Page 466 8W-02-2 Page 700 Description and Operation Brake Fluid Pressure Sensor/Switch: Description and Operation The switch activates a light on the dash panel to indicate that one of the hydraulic systems has failed. There are two basic types of switches. In some earlier models, as pressure falls in one system, the normal pressure of the other system forces the piston to the inoperative side where it contacts the switch terminal, causing the warning lights to illuminate. On most models, the brake warning switch is of the latching type. If a pressure loss occurs in one side of the system, the piston in the valve is forced toward the failed side where it latches in position and illuminates the warning light. Page 285 69 Page 496 8W-80-18 Page 899 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. Page 19 Blower Motor Relay: Description and Operation Fig 39 Blower Motor Relay Removal/Installation Blower Motor Relay OPERATION The blower motor relay is a International Standards Organization (ISO)-type relay. The relay is a electromechanical device that switches battery current from a fuse in the fuse block module to the blower motor, whenever the ignition switch is in the On position. This arrangement reduces the amount of battery current that must flow through the ignition switch. The relay is energized when the relay coil is provided a voltage signal by the ignition switch. When the relay is de-energized, the blower motor receives no battery feed. The relay is located in the passenger compartment on the stop lamp switch bracket. The stop lamp switch bracket is secured to the inboard side of the pedal support bracket under the driver side of the instrument panel. The relay case includes a molded-in plastic slot that snaps over the blade-type relay mount on the stop lamp switch bracket. The relay cannot be repaired and, if faulty or damaged, it must be replaced. CIRCUIT OPERATION Circuit C1 from fuse 2 in the Fuse Block supplies voltage to the contact side of the blower motor relay When the ignition switch is in the RUN position it connects Circuit A2 from fuse 2 in the Power Distribution Center (PDC) to Circuit A22. Circuit A22 connects to the coil side of the blower motor relay Circuit C1 connects to Circuit C11 through the blower motor relay contacts and supplies voltage to the blower motor. Circuit Z3 provides the ground path for the blower motor relay. Helpful Information 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 Page 488 8W-70-13 Page 771 c. Rotate key clockwise to Off position to unseat cylinder from ignition switch. d. With cylinder in unseated position rotate key counterclockwise to lock position, then remove key and cylinder. INSTALLATION 1. Install electrical connector to switch, then mount switch to column. 2. Ensure shifter is in park position. Park lock dowel pin in switch must engage with column park lock slider linkage. Fig. 7 Ignition Switch Park Lock Dowel Pin 4. With key cylinder and ignition in lock position, insert cylinder into ignition switch assembly until it bottoms. 5. Insert key and push inward on key cylinder, then rotate key clockwise to end of travel. Page 759 7. Remove the key cylinder from the ignition switch (Figure 10). 8. Place the new ignition switch in the LOCK position. The switch is in the LOCK position when the column lock flag is parallel to the ignition switch terminals (Figure 11). 9. With the key cylinder in the LOCK position, insert the key cylinder into the new ignition switch until it bottoms. 10. Insert the ignition key into the key cylinder. While gently pushing the key cylinder in toward the ignition switch, rotate the ignition key clockwise to the end of travel (START position) and then back to the LOCK position. 11. If equipped, install the key cylinder retaining bracket and screw (Figure 9). Tighten the screw to 26 in-lbs (3 Nm). 12. Apply a light coating of grease to the ignition switch column lock flag and the park lock dowel pin (Figure 11). 13. Make sure that the transmission gear shift selector is in the PARK position. The park lock dowel pin must be properly indexed before installing the ignition switch (Figure 12). Page 224 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 Page 14 Electronic Brake Control Module: Service and Repair With Rear Wheel Antilock System 1. Remove knee bolster; then, using a suitable long-shank screwdriver, remove electronic control module lower mounting screws. 2. Remove module upper mounting screw, then lower module and bracket assembly from underside of instrument panel. 3. Disconnect electrical harness from module; then, if necessary, separate module from bracket so that a new module may be installed. 4. Reverse procedure to install. Page 635 INSTALLATION 1. Position crankshaft position sensor to engine and install mounting bolts. Tighten bolts to 8 N.m (70 in. lbs.) torque. 2. Connect main harness electrical connector to sensor. 3. Clean the EGR tube and exhaust manifold (at EGR tube mounting point) of any old gasket material. 4. Install a new gasket to exhaust manifold end of EGR tube and install EGR tube to both manifolds. Tighten mounting nut at intake manifold. Tighten 2 mounting bolts at exhaust manifold to 23 N.m (204 in. lbs.) torque. 5. Coat the threads of the oil pressure sending unit with thread sealant. Do not allow any of the thread sealant to get into the sending unit opening, or the opening at the engine. Install sending unit to engine and tighten to 14 N.m (130 in. lbs.) torque. Install electrical connector to sending unit. 6. Clean the intake manifold and EGR valve of any old gasket material. 7. Install a new EGR valve gasket at intake manifold. 8. Install EGR valve to intake manifold. Tighten 2 bolts to 23 N.m (200 in. lbs.) torque. 9. Position EGR valve control and install its electrical connector. Connect hoses between EGR valve and EGR valve control. Connect hose between main vacuum harness and control valve. 10. Install spark plug cable loom and spark plug cables to valve cover mounting stud. 11. Install the air cleaner housing and plastic air intake tube. Specifications Page 420 Fig. 1 13. Install the cup holder assembly. Tighten the cup holder screws securely. 14. Connect the negative battery cable(s). COMPLETION REPORTING AND REIMBURSEMENT Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerClrrysler to record recall service completions and provide dealer payments. Use one of the following labor operation numbers and time allowances: Labor Operation Time Number Allowance Replace headlamp switch and 08819182 0.5 hours install overlay harness Replace headlamp switch, install 08819183 0.9 hours overlay harness and replace 4 wires Replace headlamp switch, install 08819184 1.1 hours overlay harness and replace 5-9 wires Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions PARTS RETURN Not required. DEALER NOTIFICATION AND VEHICLE LIST All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the "TIL" will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL SYSTEM FUNCTIONS 53 AND VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of recall implementation for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD819". OWNER NOTIFICATION AND SERVICE SCHEDULING All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner notification letter is attached. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. VEHICLE NOT AVAIABLE If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: Page 292 191 Page 648 8. Inspect the ignition switch assembly for heat damage near the 4th and 5th terminals (Figure 6). ^ Check the ignition switch terminals for discoloration. ^ Inspect the ignition switch connector and body for indications of melting or deformation. 9. If the wiring connector and switch assembly are NOT damaged, continue with Section "E Install Blower Motor Relay and Overlay Harness." ^ If the 7-way switch wiring connector has indications of heat damage, the ignition switch wiring harness pigtail must be replaced. Continue with Section "C - Replace Ignition Switch Wiring Pigtail." ^ If the ignition switch assembly has indications of heat damage, the ignition switch assembly and the wiring harness pigtail must be replaced. Continue with Section "C - Replace Ignition Switch Wiring Pigtail." C. Replace Ignition Switch Wiring Pigtail IMPORTANT: Only those vehicles that had wiring and/or ignition switch damage as determined by the inspection in Section "B" require ignition switch wiring pigtail replacement. Very few vehicles are expected to require this repair. 1. Disconnect the ignition switch key-in/halo light electrical connector (Figure 7). 2. Disconnect the clockspring electrical connector from the clockspring (Figure 7). 3. Disconnect the multi-function switch electrical connector (Figure 7). 4. Remove the plastic steering column wiring trough from the steering column. The trough is attached to the column with three push clips. Page 508 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. Page 354 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 Page 668 a. Turn the ignition switch to the ON position. b. Turn the blower motor on LOW and verify that the blower is operating. c. Disconnect the relay. ^ If the blower motor stops, this relay is for the blower motor. ^ If the blower motor does not stop, this relay is NOT for the blower motor. d. Turn the ignition switch OFF and connect the relay. 4. ^ If a blower motor relay is NOT present, continue with Section "B - Inspect Ignition Switch and Wiring." ^ If a blower motor relay is present, no further action is necessary. Return the vehicle to the customer. B. Inspect Ignition Switch and Wiring 1. Disconnect the negative battery cable(s). NOTE: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Remove the five (5) screws that secure the knee blocker to the lower instrument panel and then remove the knee blocker (Figure 3). 3. Remove the steering column tilt lever by turning it counter-clockwise. Page 291 187 Page 731 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 For Blower Motor Relay NOTE: Very few vehicles are expected to already be equipped with a blower motor relay. 1. Inspect the brake pedal support bracket for the presence of a blower motor relay attached to the brake lamp switch bracket (Figure 1) or locate a blower motor relay that is secured near the brake pedal bracket with a tie strap. NOTE: 1995 model year vehicles that were built with original equipment foglamps will have two (2) foglamp relays mounted on this bracket. 2. If a blower motor relay is NOT found, inspect the area near the 84-way bulkhead connector for a WHITE single wire connector with BLACK ends that connects two PINK with BLACK tracer wires (Figure 2). If the connector and wires are present, follow the wiring harness to locate the blower motor relay that is secured under the instrument panel. 3. If a relay was located in either Step 1 or Step 2, verify that this is a blower motor relay as follows: Page 530 Intake Air Temperature Sensor: Description and Operation 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. Locations Power Distribution (Part 1 Of 3) Component Testing Camshaft Position Sensor: Testing and Inspection Component Testing Camshaft Position Sensor The camshaft position sensor is located in the distributor on all engines. NOTE: For this test, an analog (non-digital) voltmeter is needed. Do not remove the distributor connector from the distributor. Using small paper clips, insert them into the backside of the distributor wire harness connector to make contact with the terminals. Be sure that the connector is not damaged when inserting the paper clips. Attach voltmeter leads to these paper clips. 1. Connect the positive (+) voltmeter lead into the sensor output wire. This is at done the distributor wire harness connector. 2. Connect the negative (-) voltmeter lead into the ground wire. 3. Set the voltmeter to the 15 Volt DC scale. 4. Remove distributor cap from distributor (two screws). Rotate (crank) the engine until the distributor rotor is pointed towards the rear of vehicle. The movable pulse ring should now be within the sensor pickup. 5. Turn ignition key to ON position. Voltmeter should read approximately 5.0 volts. 6. If voltage is not present, check the voltmeter leads for a good connection. 7. If voltage is still not present, check for voltage at the supply wire. 8. If 5 volts is not present at supply wire, check for voltage at PCM 32-way connector (cavity A-17). Leave the PCM connector connected for this test. 9. If voltage is still not present, perform vehicle test using the DRB scan tool. 10. If voltage is present at cavity A-17, but not at the supply wire: a. Check continuity between the supply wire. This is checked between the distributor connector and cavity A-17 at the PCM. If continuity is not present, repair the harness as necessary. b. Check for continuity between the camshaft position sensor output wire and cavity A-18 at the PCM. If continuity is not present, repair the harness as necessary. c. Check for continuity between the ground circuit wire at the distributor connector and ground. If continuity is not present, repair the harness as necessary. 11. While observing the voltmeter, crank the engine with ignition switch. The voltmeter needle should fluctuate between 0 and 5 volts while the engine is cranking. This verifies that the camshaft position sensor in the distributor is operating properly and a sync pulse signal is being generated. If sync pulse signal is not present, replacement of the camshaft position sensor is necessary Page 275 39 Page 121 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 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. Page 644 Part Number Description 04326622 Ignition Switch Assembly Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive two (2) ignition switch assemblies. Additional ignition switches should be ordered only after inspection determines that replacement is required. Very few vehicles are expected to require ignition switch replacement 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: Add the cost of the recall parts package and switch assembly, if necessary, 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 "0RD875". 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: Page 116 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 Page 355 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. Page 518 Crankshaft Position Sensor: Testing and Inspection Helpful Information - Circuit K6 splices to supply 5 volts to the camshaft 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 Page 321 8W-11-22 Revision to the Coolant Temperature Sensor and EGR solenoid descriptions. Description and Operation Audible Warning Device Control Module: Description and Operation CIRCUIT OPERATION The buzzer module sounds an audible warning tone. The tone sounds for seat belt warning, when the ignition key is in the ignition switch while the drivers door is OPEN, or the headlamps are left ON with the drivers door open. The tone also sounds when the ignition key is in the ON position while the drivers side seat belt is not buckled. Power for the buzzer module is supplied on circuit M1 from fuse 17, a 15 Amp, in the fuse block. This fuse is the Ignition-Off Draw fuse (IOD) and is HOT at all times. Power for the fuse is supplied on circuit A7. This circuit is protected by a 50 Amp fuse located in cavity 1 of the Power Distribution Center (PDC). When the parking lamps or headlamps are ON, the headlamp switch connects circuit G16 from the drivers side door jamb switch to circuit G26. Circuit G26 connects to the buzzer module and the key-in switch. Circuit G16 from the drivers side door jamb switch also connects to the key-in switch. Circuit G13 from the buzzer module powers the seat belt warning lamp in the instrument cluster. Circuit Z3 at the instrument cluster provides ground for the lamp. Circuit G10 from the buzzer module connects to the seat belt switch. When the seat belt switch CLOSES a path to ground is completed on circuit Z3. Circuit Z3 also grounds the buzzer module. Page 319 8W-15-12 Page 88 8W-31-5 Page 628 Crankshaft Position Sensor: Description and Operation Circuit Operation 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. Front Wheel Speed Sensor: Service and Repair Front 1. Raise and support vehicle. 2. Remove front wheels. 3. Remove disc brake caliper and support to frame using suitable wire. 4. Remove bolts attaching sensor to splash shield and steering knuckle. Retain special sensor bolts for installation. 5. Remove wire clamps and wire from control arm and steering knuckle. 6. Disconnect sensor harness connector and work sensor wire through fender panel, then remove sensor from vehicle. 7. Reverse procedure to install, noting the following: a. Torque special sensor bolt to 16-21 ft. lbs. Page 711 Impact Sensor: Service and Repair Right Impact Sensor 1. Disconnect and isolate the battery negative cable. If the airbag module has not been deployed, wait two minutes for the system capacitor to discharge before further service. 2. Remove the three screws that secure the impact sensor to the front wheelhouse extension. 3. Unplug the wire harness connector from the impact sensor and remove the sensor. NOTE: Do not remove the tape that secures the sensor wire harness to the connector. 4. To install, plug in the sensor wire harness connector to the impact sensor. 5. Mount the sensor (arrow pointed forward) using the three screws provided with the new sensor. Tighten the screws to 5 to 6 N.m (45 to 55 in. lbs.). 6. Do not connect the battery negative cable at this time. See Testing and Inspection/Procedures for the proper procedures. Page 344 8W-80-22 Page 565 Throttle Position Sensor: Service and Repair REMOVAL 1. Remove air intake tube at throttle body 2. Disconnect Throttle Position Sensor (TPS) electrical connector. Fig. 80 TPS Mounting Bolts 3. Remove two TPS mounting bolts. 4. Remove TPS from throttle body INSTALLATION Fig. 81 Installation The throttle shaft end of the throttle body slides into a socket in the TPS. The TPS must be installed so that it can be rotated a few degrees. If the sensor will not rotate, install the sensor with the throttle shaft on the other side of the socket tangs. The TPS will be under slight tension when rotated. 1. Install the TPS and two retaining bolts. 2. Tighten bolts to 7 N.m (60 in. lbs.) torque. 3. Manually operate the throttle control lever by hand to check for any binding of the TPS. 4. Connect TPS electrical connector to TPS. 5. Install air intake tube.

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