Dodge Dakota 2002 2WD V8 5.9L, Dakota 2002 Quad Cab 2WD 5.9L VIN Z LDC Workshop Manual

dodge :: Dodge Truck Dakota Quad Cab 2WD V8-

5.9L VIN Z LDC (2002)

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations

Alarm Module: Locations

The SKIM is located in the steering column, near the ignition lock cylinder housing.

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 7

Sentry Key Immobilizer Module

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Alarm Module: Description and Operation

Fig.10 Sentry Key Immobilizer Module

SENTRY KEY IMMOBILIZER MODULE

(SKIM) (SKIS)

The Sentry Key Immobilizer Module is the primary component of the Sentry Key Immobilizer System . The SKIM is located inthe steering column, near the ignition lock cylinder housing. The SKIM has an integral molded plastic halo- like antenna ring that extends fromone side.
The SKIM cannot be adjusted or repaired. If faulty or damaged, the entire SKIM unit must be replaced.

(RF)

(PCI) (PCM)

The Sentry Key Immobilizer Module (SKIM) contains a Radio Frequency transceiver and a microprocessor. The SKIM transmits RF signalsto, and receives RF signals from the Sentry Key transponder through a tuned antenna enclosed within the molded plastic antenna ring integral tothe SKIM housing. If this antenna ring is not mounted properly around the ignition lock cylinder housing, communication problems between theSKIM and the transponder may arise. These communication problems will result in Sentry Key transponder-related faults. The SKIM alsocommunicates over the Programmable Communications Interface data bus with the Powertrain Control Module , the Central TimerModule (CTM), and/or the DRB III scan tool.

The SKIM retains in memory the ID numbers of any Sentry Key transponder that is programmed into it. A maximum of eight Sentry Keytransponders can be programmed into the SKIM. For added system security, each SKIM is programmed with a unique Secret Key code. This codeis stored in memory, sent over the PCI data bus to the PCM, and is encoded to the transponder of every Sentry Key that is programmed into theSKIM. Therefore, the Secret Key code is a common element that is found in every component of the Sentry Key Immobilizer System (SKIS).Another security code, called a PIN, is used to gain access to the SKIM Secured Access Mode. The Secured Access Mode is required duringservice to perform the SKIS initialization and Sentry Key transponder programming procedures. The SKIM also stores the Vehicle IdentificationNumber in its memory, which it learns through a PCI data bus message from the PCM during SKIS initialization.(VIN)

In the event that a SKIM replacement is required, the Secret Key code can be transferred to the new SKIM from the PCM using the DRB III scantool and the SKIS initialization procedure. Proper completion of the SKIS initialization will allow the existing Sentry Keys to be programmed intothe new SKIM so that new keys will not be required. In the event that the original Secret Key code cannot be recovered, SKIM replacement willalso require new Sentry Keys. The DRB III scan tool will alert the technician during the SKIS initialization procedure if new Sentry Keys arerequired.

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 9

Dakota Quad Cab 2WD V8-5.9L VIN Z LDC (2002)

When the ignition switch is turned to the ON position, the SKIM transmits an RF signal to the transponder in the ignition key. The SKIM thenwaits for an RF signal response from the transponder. If the response received identifies the key as valid, the SKIM sends a valid key message tothe PCM over the PCI data bus. If the response received identifies the key as invalid, or if no response is received from the key transponder, theSKIM sends an invalid key message to the PCM. The PCM will enable or disable engine operation based upon the status of the SKIM messages. Itis important to note that the default condition in the PCM is an invalid key; therefore, if no message is received from the SKIM by the PCM, theengine will be disabled and the vehicle immobilized after of running.two seconds

(EMIC)

three seconds

The SKIM also sends security indicator status messages to the CTM over the PCI data bus to tell the CTM how to operate the security indicator.The CTM then controls the security indicator in the ElectroMechanical Instrument Cluster through a hard wired security indicator drivercircuit. The security indicator status message from the SKIM tells the CTM to turn the indicator ON for about each time the ignitionswitch is turned to the ON position as a bulb test. After completion of the bulb test, the SKIM sends security indicator status messages to the CTMto turn the indicator OFF, turn the indicator ON, or to flash the indicator on and off. If the security indicator flashes or stays on solid after the bulb

test, it signifies a SKIS fault. If the SKIM detects a system malfunction and/or the SKIS has become inoperative, the security indicator will stay onsolid. If the SKIM detects an invalid key or if a key transponder-related fault exists, the security indicator will flash. If the vehicle is equipped withthe Customer Learn transponder programming feature, the SKIM will also send messages to the CTM to flash the security indicator whenever theCustomer Learn programming mode is being utilized. (Refer to VEHICLE THEFT SECURITY - STANDARD PROCEDURE - SENTRY KEYTRANSPONDER PROGRAMMING).

(DTC's)

The SKIS performs a self-test each time the ignition switch is turned to the ON position, and will store fault information in the form of DiagnosticTrouble Codes in SKIM memory if a system malfunction is detected. The SKIM can be diagnosed, and any stored DTC's can be retrievedusing a DRB III scan tool. Refer to the appropriate diagnostic information.

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 10

Alarm Module: Service and Repair
REMOVAL

1. Disconnect and isolate the battery negative cable.2. Remove the steering column opening cover from the instrument panel.3. Remove the tilt steering column knob.4. Remove the outboard screws that secure the upper shroud to the lower shroud.5. Release the snap features that secure it to the lower shroud.6. Remove the upper shroud from the lower shroud.7. Remove the center screw that secures the lower shroud to the steering column lock housing.8. Remove the lower shroud from the steering column.

Fig.10 Sentry Key Immobilizer Module

9. Disconnect the instrument panel wire harness connector from the SKIM.

10. Remove the screw that secures the SKIM to the steering column.11. Disengage the SKIM antenna ring from around the ignition lock cylinder housing.

INSTALLATION

1. Position the Sentry Key Immobilizer Module onto the steering column with the antenna ring oriented around the ignition lock cylinder(SKIM)

housing.

2 Nm (20 in. lbs.)

2 Nm (20 in. lbs.)

2 Nm (20 in. lbs.)

2. Install and tighten the screw that secures the SKIM to the steering column lock housing. Tighten the screw to .3. Reconnect the instrument panel wire harness connector for the SKIM to the SKIM connector receptacle.4. Position the lower shroud onto the steering column.5. Install and tighten the center screw that secures the lower shroud to the steering column lock housing. Tighten the screw to .6. Position the upper shroud onto the steering column.7. Align the snap features on the upper and lower shroud, and apply hand pressure to snap them together.8. Install and tighten the screws that secure the upper shroud to the lower shroud. Tighten the screws to .9. Install the tilt lever knob.

10. Reinstall the steering column opening cover.11. Reconnect the battery negative cable.

> Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Locations

Door Module: Locations

A Driver Door Module located on the drivers door trim panel.(DDM)

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Door Module: Diagrams

Driver Door Module C1 (EXcept Base)

Driver Door Module C2 (Except Base)

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Door Module: Description and Operation
DRIVER DOOR MODULE

(DDM)

A Driver Door Module located on the drivers door trim panel, is used on all models equipped with power locks, power windows, andpower mirrors. The DDM can be serviced without removing the front door trim panel. The DDM houses the following switches:-

Power Lock Switch - The DDM includes a two-way momentary, resistor multiplexed switch to control the power lock system.

­Power Mirror Selector Switch - A three-position rocker switch in the DDM selects the right or left power mirror for adjustment, or turns thepower mirror system OFF.

­Power Mirror Adjustment Switches - Four momentary arrowhead shaped, directional switches allow the driver to adjust the selected powermirror in the Up, Down, Right, or Left directions.

-

Power Window Lockout Switch - A two-way latching, push-button switch in the DDM allows the vehicle operator to lock out the powerwindow switches on each passenger door so that the passenger door power windows may be operated only from the master switches in theDDM.

-

Power Window Switches - The DDM houses a two-way momentary power window switch for the driver side front door. This switch also has asecond detent in the Down direction and internal circuitry to provide an Auto-Down feature for the driver side front door power window. Inaddition to the power window switch for its own door, the DDM houses individual master switches for each passenger door power window.

(LEDs)

The DDM also incorporates several green Light- Emitting Diodes that illuminate the power lock and power window switch paddles, andthe power mirror switch directional buttons. The DDM cannot be adjusted or repaired and, if faulty or damaged, the entire DDM unit must bereplaced.

The Driver Door Module (DDM) combines a power lock switch, a driver power window switch with an Auto-down feature, master switches foreach passenger door power window, a power window lockout switch, a power mirror selector switch, and four power mirror adjustment switchesin a single unit. The switches in the DDM can be diagnosed using conventional diagnostic tools and methods.

Power Lock Switch

(CTM)

(JB)

The DDM power lock switch circuitry is connected in series between ground and the driver door switch mux input of the Central Timer Module . Each power lock switch position (Lock, Unlock, and Neutral) provides a different resistance value to the CTM input, which allows theCTM to sense the switch position. Based upon the power lock switch input, the CTM controls the battery and ground feed outputs to the individualpower lock motors to lock or unlock the door and liftgate latches. The Light-Emitting Diode (LED) in the DDM power lock switch is connected tobattery current through the power window circuit breaker in the Junction Block on a fused ignition switch output (RUN/ACC) circuit so thatthe switch will be illuminated whenever the ignition switch is in the ON or Accessory positions.

Power Window Switches

The DDM power window switch circuitry is connected to battery current through a circuit breaker in the Junction Block (JB) on a fused ignitionswitch output (RUN/ACC) circuit so that the power windows will operate whenever the ignition switch is in the ON or Accessory positions. Eachtwo-way, momentary master passenger power window switch in the DDM provides battery current and ground to the individual power windowswitches on each passenger door so that the power window switch controls the battery current and ground feeds to its respective power windowmotor. The DDM switch for the driver side front door power window is labeled with the text "Auto" and includes an auto-down feature. When thisswitch is depressed to a second momentary detent position and released, the driver door power window is automatically operated through aninternal circuit and relay to its fully lowered position. The Auto-down event is cancelled if the switch paddle is depressed a second time in eitherthe Up or Down direction. When the two position window lockout switch in the DDM is depressed and latched in the lockout position, the batterycurrent feed to each of the individual passenger power window switches is interrupted so that the passenger door power windows can only beoperated from the master switches in the DDM. The window lockout switch also controls the battery current feed for the LED in each passengerpower window switch so that the switch will not be illuminated when it is locked out.

Power Mirror Switches

The DDM power mirror switch circuitry is connected to battery current through a fuse in the JB on a fused B(+) circuit so that the power mirrorsremain operational regardless of the ignition switch position. A rocker type selector switch has three positions, one to select the right mirror, one toselect the left mirror, and a neutral OFF position. After the right or left mirror is selected, one of four directional buttons is depressed to move theselected mirror Up, Down, Right or Left. The DDM power mirror switch circuitry controls the battery current and ground feeds to each of the four(two in each mirror head) power mirror motors. The Light-Emitting Diode (LED) in the DDM power mirror switch is connected to battery currentthrough the power window circuit breaker in the Junction Block (JB) on a fused ignition switch output (RUN/ACC) circuit so that the switchdirectional buttons will be illuminated whenever the ignition switch is in the ON or Accessory positions.

> Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Locations > Page 17

Door Module: Testing and Inspection

(LED) (DDM)

(JB)

The Light-Emitting Diode illumination lamps for all of the Driver Door Module power window, power lock, and power mirror switchesreceive battery current through the power window circuit breaker in the Junction Block . If all of the LEDs are inoperative in the DDM, be certain todiagnose the power window system before replacing the switch unit. (Refer to POWER WINDOWS - DIAGNOSIS AND TESTING). If only one LEDin the DDM is inoperative, replace the faulty DDM. If the driver side front door power window operates in a normal manner, but the Auto-Down featureis inoperative, replace the faulty DDM.

1. Disconnect and isolate the battery negative cable. Remove the DDM from the door trim panel. Disconnect the door wire harness connectors for the
DDM from the DDM connector receptacles.

Fig.2 Driver Door Module Connector C1 Receptacle

Fig.3 Driver Door Module Connector C2 Receptacle

> Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Locations > Page 18

Dakota Quad Cab 2WD V8-5.9L VIN Z LDC (2002)

Driver Door Module Switch Test (Part 1 Of 2)

Driver Door Module Switch Test (Part 2 Of 2)

2. Test the DDM switch continuity. See the Driver Door Module Switch Tests chart to determine if the continuity is correct for the suspect switches
in each switch position and/or. If not OK, replace the faulty DDM as required.

> Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Locations > Page 19

Door Module: Service and Repair
REMOVAL

1. Disconnect and isolate the battery negative cable.

Fig.4 Driver Door Module

2. Using a trim stick or another suitable wide flat bladed tool and starting at the rear of the Driver Door Module bezel, gently pry the DDM(DDM)

up and out from the driver side front door trim panel.

3. Pull the DDM away from the trim panel opening far enough to access the two connector receptacles on the back of the unit.4. Disconnect the two door wire harness connectors for the DDM from the DDM connector receptacles.5. Remove the DDM from the door trim panel.

INSTALLATION

1. Position the Driver Door Module (DDM) to the opening in the driver side front door trim panel.2. Reconnect the two door wire harness connectors for the DDM to the DDM connector receptacles.3. Insert the front of the DDM bezel into the opening in the driver side front door trim panel.4. Using hand pressure, gently and evenly press down on the rear of the DDM bezel until it snaps into place.5. Reconnect the battery negative cable.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Specifications

Controller Antilock Brake: Specifications

Controller Antilock Brake Mounting Screws ............................................................................................................................................ 6 Nm (53 in. lbs.)

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Locations > EBC 125

EBC 125 (RWAL)

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EBC 325 (ABS)

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Controller Antilock Brake <--> [Electronic Brake Control Module] > Component Information > Diagrams > Diagram Information and Instructions

Controller Antilock Brake: Diagram Information and Instructions

How to Use Wiring Diagrams

DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use thewiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics.

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Dakota Quad Cab 2WD V8-5.9L VIN Z LDC (2002)

General Information (Part 1 of 2)

Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placednear the bottom of the page (Fig. 1).

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Dakota Quad Cab 2WD V8-5.9L VIN Z LDC (2002)

General Information (Part 2 of 2)

All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2).

Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the componentindicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the componentis shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short

piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only.

Circuit Functions

Circuit Identification Code Chart

All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to theCircuit 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

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Dakota Quad Cab 2WD V8-5.9L VIN Z LDC (2002)

Wire Code Identification

Wire Color Code Chart

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Dakota Quad Cab 2WD V8-5.9L VIN Z LDC (2002)

Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color.

Connector, Ground and Splice Information

CAUTION:

Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental RestraintSystem connectors. Always check parts availability before attempting a repair.

IDENTIFICATION

Connectors, grounds, and splices are identified as follows:-

In-line connectors located in the engine compartment are series numbersC100

-

In-line connectors located in the Instrument Panel area are series numbers.C200

-

In-line connectors located in the body are series numbers.C300

-

Jumper harness connectors are series numbers.C400

-

Grounds and ground connectors are identified with a "" and follow the same series numbering as the in-line connectors.G

-

Splices are identified with an "" and follow the same series numbering as the in-line connectors.S

­Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc.identifier.

Electrostatic Discharge (ESD) Sensitive Devices

Electrostatic Discharge Symbol

All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol comply with thefollowing procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is notknown whether the part is ESD sensitive, assume that it is.

1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding
across a seat, sitting down from a standing position, or walking a distance.

2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.3. When using a voltmeter, be sure to connect the ground lead first.4. Do not remove the part from its protective packing until it is time to install the part.5. Before removing the part from its package, ground the package to a known good ground on the vehicle.

Notes, Cautions and Warnings

Additional important information is presented in three ways: Notes, Cautions, and Warnings.

NOTES

are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate differentconditions that may appear on the vehicle. For example, an up-to and after condition.

are used to indicate information that could prevent making an error that may damage the vehicle.CAUTIONS

WARNINGS

provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time avehicle is being serviced.

WARNING:

- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.

- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.

­BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TOBE ON.

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Dakota Quad Cab 2WD V8-5.9L VIN Z LDC (2002)

­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 THEBATTERY.

- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING.

Symbols

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Dakota Quad Cab 2WD V8-5.9L VIN Z LDC (2002)

Wiring Diagram Symbols

International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3).

Take Outs

The abbreviation is used in the component location section to indicate a point in which the wiring harness branches out to a component.T/O

Terminology

This is a list of terms and definitions used in the wiring diagrams.

LHD ............................................................................................................................................................................................... Left Hand Drive VehiclesRHD ............................................................................................................................................................................................. Right Hand Drive VehiclesATX ................................................................................................................................................................. Automatic Transmissions-Front Wheel DriveMTX ..................................................................................................................................................................... Manual Transmissions-Front Wheel DriveAT ..................................................................................................................................................................... Automatic Transmissions-Rear Wheel DriveMT ........................................................................................................................................................................ Manual Transmissions-Rear Wheel DriveSOHC ..................................................................................................................................................................................... Single Over Head Cam EngineDOHC ................................................................................................................................................................................... Double Over Head Cam EngineBUX ............................................................................................................................................................................................................. Built-Up-ExportBuilt-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America

Section Identification and Information

Section Identification

The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires,connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. Itcan, however, be shown partially in another group if it contains some associated wiring.

Connector Replacement
REMOVAL

1. Disconnect battery

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Dakota Quad Cab 2WD V8-5.9L VIN Z LDC (2002)

Fig. 10 Removal Of Dress Cover

2. Release Connector Lock (Fig. 10).3. Disconnect the connector being repaired from its mating half/component.4. Remove the dress cover (if applicable) (Fig. 10).

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Dakota Quad Cab 2WD V8-5.9L VIN Z LDC (2002)

Fig. 11 Examples Of Connector Secondary Terminal Locks

5. Release the Secondary Terminal Lock, if required (Fig. 11).

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Dakota Quad Cab 2WD V8-5.9L VIN Z LDC (2002)

Fig. 12 Terminal Removal

6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the

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Dakota Quad Cab 2WD V8-5.9L VIN Z LDC (2002)

connector (Fig. 12).

INSTALLATION

1. Insert the removed terminal in the same cavity on the repair connector.2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out
identification, refer to the wiring diagrams.

3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out.4. Replace dress cover (if applicable).5. Connect connector to its mating half/component.6. Connect battery and test all affected systems.

Diode Replacement
REMOVAL

1. Disconnect the battery.2. Locate the diode in the harness, and remove the protective covering.

Diode Identification

3. Remove the diode from the harness, pay attention to the current flow direction.

INSTALLATION

1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig.

13).

3. Solder the connection together using rosin core type solder only Do not use acid core solder.4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements.5. Re-connect the battery and test affected systems.

Terminal Replacement
REMOVAL

1. Follow steps for removing terminals described in Connector Replacement.2. Cut the wire from the back of the connector.6 inches

INSTALLATION

one-half (1/2) inch

1-1/2 inches 2 inches

1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired.2. Cut the repair wire to the proper length and remove of insulation.3. Splice the repair wire to the wire harness (see wire splicing procedure).4. Insert the repaired wire into the connector.5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component.6. Re-tape the wire harness starting at behind the connector and past the repair.7. Connect battery and test all affected systems.

Wire Splicing
STANDARD PROCEDURE - WIRE SPLICING

When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams.

one-half (1/2) inch

1. Remove of insulation from each wire that needs to be spliced.2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire

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Dakota Quad Cab 2WD V8-5.9L VIN Z LDC (2002)

repair area.

Fig. 14 Splice Band

3. Place the strands of wire overlapping each other inside of the splice clip (Fig. 14).

Fig. 15 Crimping Tool

4. Using crimping tool, Mopar P/N 05019912AA, crimp the splice clip and wires together (Fig. 15).

Fig. 16 Solder Splice

5. Solder the connection together using rosin core type solder only (Fig. 16).

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Dakota Quad Cab 2WD V8-5.9L VIN Z LDC (2002)

DO NOT USE ACID CORE SOLDER.CAUTION:

Fig. 17 Heat Shrink Tube

6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing (Fig. 17).

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Page 41

Controller Antilock Brake: Diagnostic Aids

Intermittent and Poor Connections
INTERMITTENT AND POOR CONNECTIONS

Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay tocause a problem. Before condemning a component or wiring assembly, check the following items.-

Connectors are fully seated

- Spread terminals, or terminal push out

- Terminals in the wiring assembly are fully seated into the connector/component and locked into position

- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem

- Damaged connector/component casing exposing the item to dirt or moisture

- Wire insulation that has rubbed through causing a short to ground

- Some or all of the wiring strands broken inside of the insulation

- Wiring broken inside of the insulation

Troubleshooting Tests

Fig.6 Electrostatic Discharge Symbol

STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES

All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, complywith the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If itis not known whether the part is ESD sensitive, assume that it is.

1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding
across a seat, sitting down from a standing position, or walking a distance.

2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.3. When using a voltmeter, be sure to connect the ground lead first.4. Do not remove the part form it's protective packing until it is time to install the part.5. Before removing the part from it's package, ground the package to a known good ground on the vehicle.

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Diagrams > Diagram Information and Instructions > Page 42

Dakota Quad Cab 2WD V8-5.9L VIN Z LDC (2002)

Fig.7 Testing For Voltage Potential

STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL

1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7).2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the
appropriate test procedure.

STANDARD PROCEDURE - TESTING FOR CONTINUITY

1. Remove the fuse for the circuit being checked or, disconnect the battery.

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Dakota Quad Cab 2WD V8-5.9L VIN Z LDC (2002)

Fig.8 Testing For Continuity

2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8).3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity.

STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND

1. Remove the fuse and disconnect all items involved with the fuse.2. Connect a test light or a voltmeter across the terminals of the fuse.3. Starting at the fuse block, wiggle the wiring harness about apart and watch the voltmeter/test lamp.6 - 8 inches

4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness.

STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS

1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits.2. Replace the blown fuse.3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery.4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated.

Fig.9 Testing For Voltage Drop

STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP

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 BATTERYFEED AND GROUND.

Voltmeter

Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit.

CAUTION:

Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter witha or greater impedance rating.10 mega-ohm

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Dakota Quad Cab 2WD V8-5.9L VIN Z LDC (2002)

1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9).2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit.3. Operate the item.4. The voltmeter will show the difference in voltage between the two points.

Ohmmeter

Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity.

CAUTION:

10 mega-ohm

Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meterwith a or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered upby the vehicle's electrical system can cause damage to the equipment and provide false readings.

Fig. 4 Probing Tool

Probing Tools

These tools are used for probing terminals in connectors (Fig. 4). Select the proper size tool from Special Tool Package 6807, and insert it into theterminal 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 fornonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-onitems 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.

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Page 45

Controller Antilock Brake: Connector Views

Controller Antilock Brake C2

Controller Antilock Brake C1

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Page 46

Controller Antilock Brake: Electrical Diagrams

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Diagrams > Diagram Information and Instructions > Page 47

Dakota Quad Cab 2WD V8-5.9L VIN Z LDC (2002)

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Controller Antilock Brake: Description and Operation
CONTROLLER REAR WHEEL ANTILOCK BRAKE

Fig.3 RWAL Cab

(CAB)

The Controller Antilock Brakes is a microprocessor which handles testing, monitoring and controlling the ABS brake system operation.The CAB functions are:-

Perform self-test diagnostics.

- Monitor the RWAL brake system for proper operation.

- Control the RWAL valve solenoids.

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Dakota Quad Cab 2WD V8-5.9L VIN Z LDC (2002)

Fig.4 CAB/HCU

The CAB is mounted on the top of the hydraulic control unit. The CAB operates the ABS system and is separate from other vehicle electricalcircuits. CAB voltage source is through the ignition switch in the RUN position.

NOTE:

If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programed into the new CAB.To program theCAB refer to the Chassis Diagnostic.

System self-test

When the ignition switch is turned-on the microprocessor is tested. If an error occurs during the test, a DTC will be set into the memory. Howeverit is possible the DTC will not be stored in memory if the error has occurred in the module were the DTC's are stored.

The CAB contains a self check program that illuminates the ABS warning light when a system fault is detected. Faults are stored in memory andare accessible with the DRB III scan tool.

ABS faults remain in memory until cleared, or until after the vehicle is started approximately 50 times. Stored faults are not erased if the battery isdisconnected.

CAB Inputs

The CAB continuously monitors the speed of the vehicle by monitoring signals generated by the rear wheel speed sensor. The CAB determines awheel locking tendency when it recognizes the axle is decelerating too rapidly. The CAB monitors the following inputs to determine when a wheellocking tendency may exists:-

Rear Wheel Speed Sensor

- Brake Lamp Switch

- Brake Warning Lamp Switch

- Reset Switch

- 4WD Switch (If equipped)

CAB Outputs

The CAB controls the following outputs for antilock braking and brake warning information:-

RWAL Valve

- ABS Warning Lamp

- Brake Warning Lamp

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Controller Antilock Brake: Service and RepairFour Wheel Antilock System

REMOVAL

If the antilock control assembly needs to be replaced, the rear axle type and tire revolutions per mile must be programed into the new CAB. NOTE:

(1) Disconnect battery negative cable. (2) Remove the brake lines from HCU. (3) Push the harness connector locks to release the locks, then remove the connectors from the CAB.

(4) Remove the nuts which attaches the assembly to the mounting bracket. (5) Remove the assembly from the vehicle.

INSTALLATION

If the antilock control assembly needs to be replaced, the rear axle type and tire revolutions per mile must be programed into the new CAB. NOTE:

14 - 15 Nm (10 - 12 ft. lbs.).

19 Nm (170 inch lbs.)

(1) Install the antilock assembly into the bracket and tighten bolts to (2) Connect the CAB harnesses. (3) Connect the brake lines to the HCU. Tighten brake line fittings to (4) Connect battery. (5) Bleed brake system

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Page 52

Controller Antilock Brake: Service and RepairRear Wheel Antilock System
REMOVAL

NOTE:

If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programed into the new CAB. To program the CABrefer to the Chassis Diagnostic.

1. Disconnect battery negative cable.

Fig.5 Harness Connector Locks

2. Release the CAB harness connector locks, and remove the harness connectors from the CAB.

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Service and Repair > Four Wheel Antilock System > Page 53

Dakota Quad Cab 2WD V8-5.9L VIN Z LDC (2002)

Fig.6 Pump Motor Connector

3. Disconnect the pump motor connector.

Fig.7 Controller Mounting Screws

4. Remove screws attaching CAB to the HCU.5. Remove the CAB.

INSTALLATION

NOTE:

If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programed into the new CAB. To program the CABrefer to the Chassis Diagnostic.

1. Place the CAB onto the HCU.

Insure the CAB seal is in position before installation.NOTE:

4 - 4.7 Nm (36 - 42 in. lbs.)

2. Install the mounting screws and tighten to .3. Connect the pump motor harness.4. Connect the harnesses to the CAB and lock the connectors.5. Connect battery.

> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations

Radiator Cooling Fan Motor Relay: Locations

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Dakota Quad Cab 2WD V8-5.9L VIN Z LDC (2002)

is located in the Power Distribution Center (PDC).Radiator Fan Relay

Power Distribution Center (PDC)

is located in the left front corner of the engine compartment, just behind the battery. Power Distribution Center (PDC)

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Radiator Cooling Fan Motor Relay: Diagrams

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Dakota Quad Cab 2WD V8-5.9L VIN Z LDC (2002)

Radiator Fan Relay

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Radiator Cooling Fan Motor Relay: Description and Operation

DESCRIPTION

(PDC)

The radiator cooling fan relay is a 5-pin, solenoid type, mini-relay. It is located in the Power Distribution Center . Refer to label on PDC coverfor relay location.

OPERATION

(PCM)

103C (217F)

98C (208F)

The electric radiator cooling fan is controlled by the Powertrain Control Module through the radiator cooling fan relay. The PCM will activatethe relay after receiving inputs from the engine coolant temperature sensor and/or an air conditioning on/off signal. Not Equipped With A/C: The relayis energized when coolant temperature is above approximately . It will then de-energize when coolant temperature drops toapproximately . Equipped With A/C: In addition to using coolant temperatures to control cooling fan operation, the cooling fan will alsobe engaged when the air conditioning system has been activated.

> Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations

Compressor Clutch Relay: Locations

> Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 66

Dakota Quad Cab 2WD V8-5.9L VIN Z LDC (2002)

is located in the Power Distribution Center (PDC).A/C Compressor Clutch Relay

Power Distribution Center (PDC)

is located in the left front corner of the engine compartment, just behind the battery. Power Distribution Center (PDC)

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Compressor Clutch Relay: Diagrams

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Dakota Quad Cab 2WD V8-5.9L VIN Z LDC (2002)

A/C Compressor Clutch Relay

> Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 69

Compressor Clutch Relay: Description and Operation
A/C COMPRESSOR CLUTCH RELAY

(ISO)

The a/c compressor clutch relay is a International Standards Organization micro relay The terminal designations and functions are the sameas a conventional ISO relay. However, the micro-relay terminal orientation (footprint) is different, the current capacity is lower, and the relay casedimensions are smaller than those of the conventional ISO relay.

(PCM)

The compressor clutch relay is a electromechanical device that switches battery current to the compressor clutch coil when the Powertrain ControlModule grounds the coil side of the relay The PCM responds to inputs from the a/c heater control, the a/c loss of charge switch, the a/cpressure transducer and the evaporator fin probe.

(PDC)

The compressor clutch relay is located in the Power Distribution Center in the engine compartment. Refer to the PDC label for relayidentification and location.
The compressor clutch relay cannot be repaired and, if faulty or damaged, it must be replaced.

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Compressor Clutch Relay: Testing and Inspection

Fig.12 Compressor Clutch Relay

RELAY TEST

(PDC)

The compressor clutch relay is located in the Power Distribution Center . Refer to the PDC label for relay identification and location. Removethe 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.

75 5 ohms

2. Resistance between terminals 85 and 86 (electromagnet) should be . 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 below. If not OK, replace the faulty relay

RELAY CIRCUIT TEST

1. The relay common feed terminal cavity (30) is connected to fused battery feed. There should be battery voltage at the cavity for relay terminal 30
at all times. If OK, go to Step 2.If not OK, repair the open circuit to the fuse in the PDC as required.

2. The relay normally closed terminal (87A) is not used in this application. Go to Step 3.3. The relay normally open terminal cavity (87) is connected to the compressor clutch coil. There should be continuity between this cavity and the
A/C compressor clutch relay output circuit cavity of the compressor clutch coil wire harness connector. If OK, go to Step 4.If not OK, repair theopen circuit as required.

4. The relay coil battery terminal (86) is connected to the fused ignition switch output (run/start) circuit. There should be battery voltage at the cavity
for relay terminal 86 with the ignition switch in the ON position. If OK, go to Step 5.If not OK, repair the open circuit to the fuse in the junctionblock as required.

5. The coil ground terminal cavity (85) is switched to ground through the Powertrain Control Module . There should be continuity between(PCM)

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 theopen circuit as required.