Dodge Diegs Service Manual
BR/BE WIRING 8W - 1
WIRING
TABLE OF CONTENTS
page page
AIRBAG SYSTEM .................... 8W-43-1
AIR CONDITIONING-HEATER ........... 8W-42-1
ALL WHEEL ANTILOCK BRAKES ........ 8W-35-1
AUDIO SYSTEM ..................... 8W-47-1
BUS COMMUNICATIONS .............. 8W-18-1
CENTRAL TIMER MODULE............. 8W-45-1
CHARGING SYSTEM.................. 8W-20-1
COMPONENT INDEX.................. 8W-02-1
CONNECTOR/GROUND/SPLICE
LOCATION ........................ 8W-91-1
CONNECTOR PIN-OUTS ............... 8W-80-1
FRONT LIGHTING.................... 8W-50-1
FUEL/IGNITION SYSTEM .............. 8W-30-1
GROUND DISTRIBUTION .............. 8W-15-1
HORN/CIGAR LIGHTER/POWER OUTLET.. 8W-41-1
INSTRUMENT CLUSTER............... 8W-40-1
INTERIOR LIGHTING.................. 8W-44-1
JUNCTION BLOCK.................... 8W-12-1
OVERHEAD CONSOLE................. 8W-49-1
POWER DISTRIBUTION ............... 8W-10-1
POWER DISTRIBUTION ............... 8W-97-1
POWER DOOR LOCKS ................ 8W-61-1
POWER MIRRORS ................... 8W-62-1
POWER SEATS ...................... 8W-63-1
POWER WINDOWS................... 8W-60-1
REAR LIGHTING ..................... 8W-51-1
REAR WHEEL ANTILOCK BRAKES....... 8W-34-1
SPLICE INFORMATION................ 8W-70-1
STARTING SYSTEM .................. 8W-21-1
TRAILER TOW....................... 8W-54-1
TRANSMISSION CONTROL SYSTEM ..... 8W-31-1
TURN SIGNALS...................... 8W-52-1
VEHICLE SPEED CONTROL ............ 8W-33-1
VEHICLE THEFT SECURITY SYSTEM..... 8W-39-1
WIPERS............................ 8W-53-1
WIRING DIAGRAM INFORMATION....... 8W-01-1
BR/BE 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 1
8W-01 WIRING DIAGRAM INFORMATION
TABLE OF CONTENTS
page page
WIRING DIAGRAM INFORMATION
DESCRIPTION
DESCRIPTION - HOW TO USE WIRING
DIAGRAMS ...........................1
DESCRIPTION - CIRCUIT INFORMATION ....4
DESCRIPTION - CIRCUIT FUNCTIONS ......4
DESCRIPTION - SECTION IDENTIFICATION
AND INFORMATION ....................6
DESCRIPTION - CONNECTOR, GROUND
AND SPLICE INFORMATION ..............6
WARNINGS - GENERAL ...................7
DIAGNOSIS AND TESTING - WIRING
HARNESS ............................7
STANDARD PROCEDURE
STANDARD PROCEDURE -
ELECTROSTATIC DISCHARGE (ESD)
SENSITIVE DEVICES ...................8
STANDARD PROCEDURE - TESTING OF
VOLTAGE POTENTIAL...................8
STANDARD PROCEDURE - TESTING FOR
CONTINUITY ..........................9
WIRING DIAGRAM
INFORMATION
DESCRIPTION
DESCRIPTION - HOW TO USE WIRING
DIAGRAMS
DaimlerChrysler Corporation wiring diagrams are
designed to provide information regarding the vehicles wiring content. In order to effectively use the
wiring diagrams to diagnose and repair
DaimlerChrysler Corporation vehicles, it is important
to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+)
side of the circuit is placed near the top of the page,
and the ground (B-) side of the circuit is placed near
the bottom of the page (Fig. 1).
STANDARD PROCEDURE - TESTING FOR A
SHORT TO GROUND ...................9
STANDARD PROCEDURE - TESTING FOR A
SHORT TO GROUND ON FUSES
POWERING SEVERAL LOADS ............9
STANDARD PROCEDURE - TESTING FOR A
VOLTAGE DROP .......................9
SPECIAL TOOLS
WIRING/TERMINAL .....................9
CONNECTOR
REMOVAL .............................10
INSTALLATION .........................10
DIODE
REMOVAL .............................13
INSTALLATION .........................13
TERMINAL
REMOVAL .............................13
INSTALLATION .........................13
WIRE
STANDARD PROCEDURE - WIRE SPLICING . . 13
All switches, components, and modules are shown
in the at rest position with the doors closed and the
key removed from the ignition (Fig. 2).
Components are shown two ways. A solid line
around a component indicates that the component is
complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference
number to indicate the page where the component is
shown complete.
It is important to realize that no attempt is made
on the diagrams to represent components and wiring
as they appear on the vehicle. For example, a short
piece of wire is treated the same as a long one. In
addition, switches and other components are shown
as simply as possible, with regard to function only.
8W - 01 - 2 8W-01 WIRING DIAGRAM INFORMATION BR/BE
WIRING DIAGRAM INFORMATION (Continued)
Fig. 1 WIRING DIAGRAM EXAMPLE 1
BR/BE 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 3
WIRING DIAGRAM INFORMATION (Continued)
Fig. 2 WIRING DIAGRAM EXAMPLE 2
8W - 01 - 4 8W-01 WIRING DIAGRAM INFORMATION BR/BE
WIRING DIAGRAM INFORMATION (Continued)
SYMBOLS
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world (Fig. 3).
TERMINOLOGY
This is a list of terms and definitions used in the
wiring diagrams.
LHD.................Left Hand Drive Vehicles
RHD................Right Hand Drive Vehicles
ATX . . Automatic Transmissions-Front Wheel Drive
MTX....Manual Transmissions-Front Wheel Drive
AT....Automatic Transmissions-Rear Wheel Drive
MT .....Manual Transmissions-Rear Wheel Drive
SOHC ...........Single Over Head Cam Engine
DOHC ..........Double Over Head Cam Engine
Built-Up-Export........Vehicles Built For Sale In
Markets Other Than North America
Except-Built-Up-Export . . Vehicles Built For Sale In
North America
DESCRIPTION - CIRCUIT INFORMATION
Each wire shown in the diagrams contains a code
which identifies the main circuit, part of the main
circuit, gage of wire, and color (Fig. 4).
WIRE COLOR CODE CHART
COLOR CODE COLOR
BL BLUE
BK BLACK
BR BROWN
DB DARK BLUE
DG DARK GREEN
GY GRAY
LB LIGHT BLUE
LG LIGHT GREEN
OR ORANGE
PK PINK
RD RED
TN TAN
VT VIOLET
WT WHITE
YL YELLOW
* WITH TRACER
DESCRIPTION - CIRCUIT FUNCTIONS
All circuits in the diagrams use an alpha/numeric
code to identify the wire and it’s 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 IDENTIFICATION CODE CHART
CIRCUIT FUNCTION
A BATTERY FEED
B BRAKE CONTROLS
C CLIMATE CONTROLS
D DIAGNOSTIC CIRCUITS
E DIMMING ILLUMINATION
CIRCUITS
F FUSED CIRCUITS
G MONITORING CIRCUITS
(GAUGES)
H OPEN
I NOT USED
J OPEN
K POWERTRAIN CONTROL
MODULE
L EXTERIOR LIGHTING
M INTERIOR LIGHTING
N NOT USED
O NOT USED
P POWER OPTION (BATTERY
FEED)
Q POWER OPTIONS (IGNITION
FEED)
R PASSIVE RESTRAINT
S SUSPENSION/STEERING
T TRANSMISSION/TRANSAXLE/
TRANSFER CASE
U OPEN
V SPEED CONTROL, WIPER/
WASHER
W OPEN
X AUDIO SYSTEMS
Y OPEN
Z GROUNDS
BR/BE 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 5
WIRING DIAGRAM INFORMATION (Continued)
Fig. 3 WIRING DIAGRAM SYMBOLS
8W - 01 - 6 8W-01 WIRING DIAGRAM INFORMATION BR/BE
WIRING DIAGRAM INFORMATION (Continued)
GROUP TOPIC
8W-40 thru
8W-49
8W-50 thru
8W-59
8W-60 thru
8W-69
8W-70 Splice Information
8W-80 Connector Pin Outs
8W-91 Connector, Ground and Splice
Body Electrical items and A/C
Exterior Lighting, Wipers and
Trailer Tow
Power Accessories
Locations
DESCRIPTION - CONNECTOR, GROUND AND
Fig. 4 WIRE CODE IDENTIFICATION
1 - COLOR OF WIRE (LIGHT BLUE WITH YELLOW TRACER
2 - GAGE OF WIRE (18 GAGE)
3 - PART OF MAIN CIRCUIT (VARIES DEPENDING ON
EQUIPMENT)
4 - MAIN CIRCUIT IDENTIFICATION
SPLICE INFORMATION
CAUTION: Not all connectors are serviced. Some
connectors are serviced only with a harness. A typical example might be the Supplemental Restraint
System connectors. Always check parts availability
before attempting a repair.
DESCRIPTION - SECTION IDENTIFICATION AND
INFORMATION
The wiring diagrams are grouped into individual
sections. If a component is most likely found in a particular group, it will be shown complete (all wires,
connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be
found in Group 30, so it is shown there complete. It
can, however, be shown partially in another group if
it contains some associated wiring.
Splice diagrams in Section 8W-70 show the entire
splice and provide references to other sections the
splices serves. Section 8W-70 only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams.
Section 8W-80 shows each connector and the circuits involved with that connector. The connectors
are identified using the name/number on the diagram pages.
WIRING SECTION CHART
GROUP TOPIC
8W-01 thru
8W-09
8W-10 thru
8W-19
8W-20 thru
8W-29
8W-30 thru
8W-39
General information and Diagram
Overview
Main Sources of Power and
Vehicle Grounding
Starting and Charging
Powertrain/Drivetrain Systems
IDENTIFICATION
In-line connectors are identified by a number, as
follows:
• In-line connectors located in the engine compart-
ment are C100 series numbers
• In-line connectors located in the Instrument
Panel area are C200 series numbers.
• In-line connectors located in the body are C300
series numbers.
• Jumper harness connectors are C400 series
numbers.
• Grounds and ground connectors are identified
with a “G” and follow the same series numbering as
the in-line connectors.
• Splices are identified with an “S” and follow the
same series numbering as the in-line connectors.
• Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier.
LOCATIONS
Section 8W-91 contains connector/ground/splice
location illustrations. The illustrations contain the
connector name (or number)/ground number/splice
number and component identification. Connector/
ground/splice location charts in section 8W-91 reference the figure numbers of the illustrations.
The abbreviation T/O is used in the component
location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations
BR/BE 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 7
WIRING DIAGRAM INFORMATION (Continued)
WARNINGS - GENERAL
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.
WARNING: USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
WARNING: BE SURE THAT THE IGNITION SWITCH
ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
WARNING: SET THE PARKING BRAKE WHEN
WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL
TRANSMISSION SHOULD BE IN NEUTRAL.
WARNING: OPERATE THE ENGINE ONLY IN A
WELL-VENTILATED AREA.
WARNING: KEEP AWAY FROM MOVING PARTS
WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
WARNING: NEVER USE A JUMPER WIRE ACROSS
A LOAD, SUCH AS A MOTOR, CONNECTED
BETWEEN A BATTERY FEED AND GROUND.
• Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good
ground and the red lead to the positive side of the
circuit.
CAUTION: Most of the electrical components used
in today’s vehicles are Solid State. When checking
voltages in these circuits, use a meter with a 10 megohm or greater impedance rating.
• Ohmmeter - Used to check the resistance
between two points of a circuit. Low or no resistance
in a circuit means good continuity.
CAUTION: Most of the electrical components used
in today’s vehicles are Solid State. When checking
resistance in these circuits use a meter with a 10 megohm or greater impedance rating. In addition,
make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle’s
electrical system can cause damage to the equipment and provide false readings.
• Probing Tools - These tools are used for probing
terminals in connectors (Fig. 5). 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.
WARNING: TO PREVENT SERIOUS BURNS, AVOID
CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER.
WARNING: DO NOT ALLOW FLAME OR SPARKS
NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
WARNING: ALWAYS REMOVE RINGS, WATCHES,
LOOSE HANGING JEWELRY AND AVOID LOOSE
CLOTHING.
DIAGNOSIS AND TESTING - WIRING HARNESS
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.
Fig. 5 PROBING TOOL
1 - SPECIAL TOOL 6801
2 - PROBING END
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
8W - 01 - 8 8W-01 WIRING DIAGRAM INFORMATION BR/BE
WIRING DIAGRAM INFORMATION (Continued)
• 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 WIRING PROBLEMS
When troubleshooting wiring problems there are
six steps which can aid in the procedure. The steps
are listed and explained below. Always check for nonfactory items added to the vehicle before doing any
diagnosis. If the vehicle is equipped with these items,
disconnect them to verify these add-on items are not
the cause of the problem.
(1) Verify the problem.
(2) Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
(3) Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where
the problem most likely is occurring and where the
diagnosis will continue.
(4) Isolate the problem area.
(5) Repair the problem area.
(6) Verify the proper operation. For this step,
check for proper operation of all items on the
repaired circuit. Refer to the wiring diagrams.
(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 pakage,
ground the pakage to a known good ground on the
vehicle.
Fig. 6 ELECTROSTATIC DISCHARGE SYMBOL
STANDARD PROCEDURE - TESTING OF
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
STANDARD PROCEDURE - ELECTROSTATIC
DISCHARGE (ESD) SENSITIVE DEVICES
All ESD sensitive components are solid state and a
symbol (Fig. 6) is used to indicate this. When handling any component with this symbol, comply with
the following procedures to reduce the possibility of
electrostatic charge build up on the body and inadvertent discharge into the component. If it is not
known whether the part is ESD sensitive, assume
that it is.
(1) Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding
across a seat, sitting down from a standing position,
or walking a distance.
(2) Avoid touching electrical terminals of the part,
unless instructed to do so by a written procedure.
Fig. 7 TESTING FOR VOLTAGE POTENTIAL
BR/BE 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 9
WIRING DIAGRAM INFORMATION (Continued)
STANDARD PROCEDURE - 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 (Fig. 8).
(3) Connect the other lead to the other end of the
circuit being tested. Low or no resistance means good
continuity.
(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.
STANDARD PROCEDURE - TESTING FOR A
VOLTAGE DROP
(1) Connect the positive lead of the voltmeter to
the side of the circuit closest to the battery (Fig. 9).
(2) Connect the other lead of the voltmeter to the
other side of the switch, component or circuit.
(3) Operate the item.
(4) The voltmeter will show the difference in voltage between the two points.
Fig. 8 TESTING FOR CONTINUITY
1 - FUSE REMOVED FROM CIRCUIT
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 six to eight inches apart and watch
the voltmeter/test lamp.
(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.
Fig. 9 TESTING FOR VOLTAGE DROP
SPECIAL TOOLS
WIRING/TERMINAL
PROBING TOOL PACKAGE 6807
8W - 01 - 10 8W-01 WIRING DIAGRAM INFORMATION BR/BE
WIRING DIAGRAM INFORMATION (Continued)
CONNECTOR
REMOVAL
(1) Disconnect battery.
(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).
TERMINAL PICK TOOL SET 6680
TERMINAL REMOVING TOOLS 6932 AND 8638
TERMINAL REMOVING TOOL 6934
Fig. 10 REMOVAL OF DRESS COVER
1 - DRESS COVER
2 - CONNECTOR LOCK
3 - CONNECTOR
(5) Release the Secondary Terminal Lock, if
required (Fig. 11).
(6) Position the connector locking finger away from
the terminal using the proper special tool. Pull on
the wire to remove the terminal from the connector
(Fig. 12).
INSTALLATION
(1) Insert the removed terminal in the same cavity
on the repair connector.
(2) Repeat steps for each terminal in the connector, being sure that all wires are inserted into the
proper cavities. For additional connector pin-out
identification, refer to the wiring diagrams.
(3) When the connector is re-assembled, the secondary terminal lock must be placed in the locked
position to prevent terminal push out.
(4) Replace dress cover (if applicable).
(5) Connect connector to its mating half/component.
(6) Connect battery and test all affected systems.
BR/BE 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 11
CONNECTOR (Continued)
Fig. 11 EXAMPLES OF CONNECTOR SECONDARY TERMINAL LOCKS
1 - Secondary Terminal Lock
8W - 01 - 12 8W-01 WIRING DIAGRAM INFORMATION BR/BE
CONNECTOR (Continued)
1 - TYPICAL CONNECTOR
2 - PICK FROM SPECIAL TOOL KIT 6680
3 - APEX CONNECTOR
4 - PICK FROM SPECIAL TOOL KIT 6680
5 - AUGAT CONNECTOR
6 - SPECIAL TOOL 6932
7 - MOLEX CONNECTOR
Fig. 12 TERMINAL REMOVAL
8 - SPECIAL TOOL 6742
9 - THOMAS AND BETTS CONNECTOR
10 - SPECIAL TOOL 6934
11 - TYCO CONNECTOR
12 - SPECIAL TOOL 8638
BR/BE 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 13
DIODE
REMOVAL
(1) Disconnect the battery.
(2) Locate the diode in the harness, and remove
the protective covering.
(3) Remove the diode from the harness, pay atten-
tion to the current flow direction (Fig. 13).
Fig. 13 DIODE IDENTIFICATION
1 - CURRENT FLOW
2 - BAND AROUND DIODE INDICATES CURRENT FLOW
3 - DIODE AS SHOWN IN THE DIAGRAMS
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.
INSTALLATION
(1) Select a wire from the terminal repair kit that
best matches the color and gage of the wire being
repaired.
(2) Cut the repair wire to the proper length and
remove one–half (1/2) inch of insulation.
(3) Splice the repair wire to the wire harness (see
wire splicing procedure).
(4) Insert the repaired wire into the connector.
(5) Install the connector locking wedge, if required,
and reconnect the connector to its mating half/component.
(6) Re-tape the wire harness starting at 1–1/2
inches behind the connector and 2 inches past the
repair.
(7) Connect battery and test all affected systems.
WIRE
STANDARD PROCEDURE - WIRE SPLICING
When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams.
(1) Remove one-half (1/2) inch of insulation from
each wire that needs to be spliced.
(2) Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will
be long enough to cover and seal the entire repair
area.
(3) Place the strands of wire overlapping each
other inside of the splice clip (Fig. 14).
Fig. 14 SPLICE BAND
1 - SPLICE BAND
TERMINAL
REMOVAL
(1) Follow steps for removing terminals described
in the connector removal section.
(2) Cut the wire 6 inches from the back of the con-
nector.
(4) Using crimping tool, Mopar p/n 05019912AA,
crimp the splice clip and wires together (Fig. 15).
(5) Solder the connection together using rosin core
type solder only (Fig. 16).
8W - 01 - 14 8W-01 WIRING DIAGRAM INFORMATION BR/BE
WIRE (Continued)
(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).
Fig. 15 CRIMPING TOOL
1 - CRIMPING TOOL
CAUTION: DO NOT USE ACID CORE SOLDER.
Fig. 17 HEAT SHRINK TUBE
1 - SEALANT
2 - HEAT SHRINK TUBE
Fig. 16 SOLDER SPLICE
1 - SOLDER
2 - SPLICE BAND
3 - SOLDERING IRON
BR/BE 8W-02 COMPONENT INDEX 8W - 02 - 1
8W-02 COMPONENT INDEX
Component Page
4WD Switch ..........................8W-31
A/C Compressor Clutch Relay ............8W-42
A/C Compressor Clutch .................8W-42
A/C- Heater Control ....................8W-42
A/C Heater Temperature Select ...........8W-42
A/C High Pressure Switch ...............8W-42
A/C Low Pressure Switch................8W-42
Accelerator Pedal Position Sensor .........8W-30
Aftermarket Center High Mounted Stop
Lamp .............................8W-51
Aftermarket Trailer Tow Connector ........8W-54
Airbag Control Module..................8W-43
Ambient Temperature Sensor ............8W-49
Ash Receiver Lamp ....................8W-44
Automatic Day/Night Mirror .............8W-49
Automatic Shut Down Relay .............8W-30
Auxiliary Battery ......................8W-20
Back-Up Lamp Switch ..................8W-51
Back-Up Lamp ........................8W-51
Battery Temperature Sensor .............8W-30
Battery .............................8W-20
Blend Door Actuator ...................8W-42
Blower Motor Relay ....................8W-42
Blower Motor Resistor Block .............8W-42
Blower Motor .........................8W-42
Brake Lamp Switch ....................8W-51
Brake Pressure Switch ...............8W-34, 35
Bypass Jumper .......................8W-21
Camshaft Position Sensor ...............8W-30
Capacitor .........................8W-10, 30
Cargo Lamps ........................ 8W-44
Center High Mounted Stop Lamps ........8W-51
Center Identification Lamp ..............8W-50
Central Timer Module ..................8W-45
Cigar Lighter .........................8W-41
Circuit Breakers ......................8W-12
Clockspring ..................8W-33, 41, 43, 47
Clutch Pedal Position Switch .............8W-21
Combination Flasher ...................8W-52
Controller Antilock Brake ............8W-34, 35
Crankshaft Position Sensor ..............8W-30
Cummins Bus ........................8W-18
Cup Holder Lamp .....................8W-44
Data Link Connector ...................8W-18
Daytime Running Lamp Module ..........8W-50
Dome Lamp ..........................8W-44
Driver Airbag .........................8W-43
Driver Cylinder Lock Switch .............8W-39
Driver Door Ajar Switch ................8W-45
Driver Door Lock Motor .................8W-61
Driver Door Window/Lock Switch ......8W-60, 61
Driver Heated Seat Cushion .............8W-63
Component Page
Driver Heated Seat Switch ..............8W-63
Driver Lumbar Motor ..................8W-63
Driver Power Seat Front Vertical Motor ....8W-63
Driver Power Seat Horizontal Motor .......8W-63
Driver Power Seat Rear Vertical Motor .....8W-63
Driver Power Seat Switch ...............8W-63
Driver Power Window Motor .............8W-60
Electric Brake Provision ................8W-54
Engine Control Module .................8W-30
Engine Coolant Temperature Sensor .......8W-30
Engine Oil Pressure Sensor ..............8W-30
Engine Starter Motor Relay ..............8W-21
Engine Starter Motor...................8W-21
EVAP/Purge Solenoid ...................8W-30
Fender Lamp .........................8W-51
Fog Lamp Relay .......................8W-50
Fog Lamp ............................8W-50
Fuel Heater Relay .....................8W-30
Fuel Heater ........................8W-30-36
Fuel Injection Pump ...................8W-30
Fuel Injectors .........................8W-30
Fuel Pump Module ....................8W-30
Fuel Pump Relay ......................8W-30
Fuel Tank Module .....................8W-30
Fuel Transfer Pump ....................8W-30
Fuses (JB) ...........................8W-12
Fuses (PDC) ..........................8W-10
Fusible Link .......................8W-20, 30
Grounds .............................8W-15
Generator............................8W-20
Glove Box Lamp And Switch .............8W-44
Headlamp Beam Select Switch ...........8W-50
Headlamp Switch ......................8W-50
Headlamp ...........................8W-50
Heated Mirror Relay ...................8W-62
Heated Mirror Switch ..................8W-62
Heated Seat Relay .....................8W-12
High Note Horn .......................8W-41
Horn Relay ..........................8W-41
Horn Switch ..........................8W-41
Idle Air Control Motor ..................8W-30
Ignition Coils .........................8W-30
Ignition Switch .......................8W-10
Instrument Cluster ....................8W-40
Intake Air Heater Relays ................8W-30
Intake Air Heater .....................8W-30
Intake Air Temperature Sensor ...........8W-30
Intermittent Wiper Switch ...............8W-53
Joint Connectors .......8W-10, 12, 15, 30, 34, 35,
40, 44, 45, 51, 53, 54, 70
Junction Block ........................8W-12
Leak Detection Pump ..................8W-30
8W - 02 - 2 8W-02 COMPONENT INDEX BR/BE
Component Page
License Lamp .........................8W-51
Low Note Horn .......................8W-41
Manifold Absolute Pressure Sensor ........8W-30
Outboard Clearance Lamps ..............8W-50
Outboard Headlamps ...................8W-50
Outboard Identification Lamps ...........8W-50
Output Speed Sensor ...................8W-31
Overdrive Switch ......................8W-31
Overhead Console .....................8W-49
Oxygen Sensors .......................8W-30
Oxygen Sensor Downstream Relay ........8W-30
Park Brake Switch ..................8W-40, 50
Park/Neutral Position Switch ..........8W-30, 51
Park/Turn Signal Lamp .................8W-52
Passenger Airbag On/Off Switch ..........8W-43
Passenger Airbag ......................8W-43
Passenger Cylinder Lock Switch ..........8W-39
Passenger Door Ajar Switch ..............8W-45
Passenger Door Lock Motor ..............8W-61
Passenger Door Window/Lock Switch ....8W-60, 61
Passenger Heated Seat Cushion ..........8W-63
Passenger Heated Seat Switch ...........8W-63
Passenger Lumbar Motor................8W-63
Passenger Power Seat Front Vertical
Motor .............................8W-63
Passenger Power Seat Horizontal Motor ....8W-63
Passenger Power Seat Rear Vertical Motor . . 8W-63
Passenger Power Seat Switch ............8W-63
Passenger Power Window Motor ..........8W-60
Power Distribution Center...............8W-10
Power Mirror Switch ...................8W-62
Component Page
Power Mirror .........................8W-62
Power Outlet .........................8W-41
Powertrain Control Module ..............8W-30
PTO Switch ..........................8W-30
Quad High Beam Relay .................8W-50
Radio Choke Relay.....................8W-47
Radio ...............................8W-47
Rear Wheel Speed Sensor ............8W-34, 35
Remote Radio Switch ...................8W-47
Splices ..............................8W-70
Seat Belt Switch ......................8W-40
Seat Heat Interface Module ..............8W-63
Security Relay ........................8W-39
Speakers ............................8W-47
Speed Control Servo ...................8W-33
Speed Control Switches .................8W-33
Tail/Stop/Turn Signal Lamp ..............8W-51
Tailgate Lamps .......................8W-51
Throttle Position Sensor ................8W-30
Trailer Tow Connector ..................8W-54
Trailer Tow Relay ......................8W-54
Transmission Control Relay ..............8W-31
Transmission Solenoid Assembly ..........8W-31
Turn Signal/Hazard Switch ..............8W-52
Underhood Lamp ......................8W-44
Visor/Vanity Lamps ....................8W-44
Washer Fluid Level Switch ..............8W-40
Water In Fuel Sensor ...................8W-30
Wheel Speed Sensor....................8W-35
Windshield Washer Pump ...............8W-53
Wiper Motor Relay .....................8W-53
BR/BE 8W-10 POWER DISTRIBUTION 8W - 10 - 1
8W-10 POWER DISTRIBUTION
Component Page
A/C Compressor Clutch ................8W-10-27
A/C Compressor Clutch Relay .........8W-10-9, 27
Aftermarket Center High Mounted Stop
Lamp ...........................8W-10-13
Aftermarket Trailer Tow Connector .......8W-10-21
Automatic Shut Down Relay ..........8W-10-14, 20
Auxiliary Battery .....................8W-10-8
Battery .............................8W-10-8
Blower Motor .......................8W-10-23
Blower Motor Relay .................8W-10-8, 23
Brake Lamp Switch .................8W-10-8, 13
Capacitor ..........................8W-10-16
Center High Mounted Stop Lamp No. 1 ....8W-10-13
Center High Mounted Stop Lamp No. 2 ....8W-10-13
Central Timer Module ..............8W-10-22, 26
Circuit Breaker 2 ....................8W-10-10
Clockspring .........................8W-10-26
Combination Flasher ..................8W-10-13
Controller Antilock Brake ..............8W-10-23
Daytime Running Lamp Module .........8W-10-25
Electric Brake Provision .............8W-10-13, 21
Engine Control Module ................8W-10-12
Engine Starter Motor .................8W-10-23
Engine Starter Motor Relay ...........8W-10-8, 23
Fog Lamp Relay .....................8W-10-25
Fuel Heater ........................8W-10-20
Fuel Heater Relay ..................8W-10-8, 20
Fuel Injection Pump ..................8W-10-12
Fuel Injector No. 1 .................8W-10-15, 16
Fuel Injector No. 2 .................8W-10-15, 16
Fuel Injector No. 3 .................8W-10-15, 16
Fuel Injector No. 4 .................8W-10-15, 16
Fuel Injector No. 5 .................8W-10-15, 16
Fuel Injector No. 6 .................8W-10-15, 16
Fuel Injector No. 7 .................8W-10-15, 16
Fuel Injector No. 8 .................8W-10-15, 16
Fuel Injector No. 9 ...................8W-10-16
Fuel Injector No. 10 ...................8W-10-16
Fuel Pump Module ...................8W-10-11
Fuel Pump Relay ..................8W-10-11, 12
Fuse 1 (JB) .........................8W-10-10
Fuse 1 (PDC) ......................8W-10-8, 10
Fuse 2 (PDC) ...................8W-10-8, 10, 22
Fuse 3 (PDC) ...................8W-10-8, 11, 12
Fuse 4 (JB) .........................8W-10-10
Fuse 4 (PDC) ......................8W-10-8, 13
Fuse 5 (PDC) ......................8W-10-8, 13
Fuse 6 (PDC) ...................8W-10-8, 14, 20
Fuse 7 (PDC) ......................8W-10-8, 20
Fuse 8 (PDC) ......................8W-10-8, 21
Fuse 9 (PDC) ......................8W-10-8, 23
Fuse 10 (PDC) .....................8W-10-8, 22
Fuse 11 (PDC) .....................8W-10-8, 23
Fuse 12 (JB) ........................8W-10-10
Fuse 12 (PDC) ...................8W-10-8, 9, 23
Fuse 13 (JB) ........................8W-10-10
Component Page
Fuse 14 (JB) ........................8W-10-10
Fuse B (PDC) ...................8W-10-8, 9, 24
Fuse C (PDC) .....................8W-10-9, 24
Fuse E (PDC) .....................8W-10-9, 24
Fuse F (PDC) .....................8W-10-9, 24
Fuse G (PDC) .....................8W-10-9, 25
Fuse H (PDC) .....................8W-10-9, 26
Fuse I (PDC) ......................8W-10-9, 26
Fuse J (PDC) ......................8W-10-9, 27
Fuse K (PDC) .............8W-10-9, 14, 17, 18, 19
Fuse L (PDC) .....................8W-10-9, 27
Fuse Gen (PDC) ...................8W-10-8, 27
G201 .............................8W-10-22
Generator ........................8W-10-8, 27
Headlamp Beam Select Switch ...........8W-10-25
Headlamp Switch ..................8W-10-9, 24
High Note Horn .....................8W-10-26
Horn Relay .......................8W-10-9, 26
Ignition Coil ........................8W-10-15
Ignition Coil 4 Pack ...................8W-10-16
Ignition Coil 6 Pack ...................8W-10-16
Ignition Switch .................8W-10-8, 10, 22
Joint Connector No. 1 ..............8W-10-25, 26
Joint Connector No. 2 ........8W-10-8, 9, 11, 12, 14,
15, 16, 20, 21
Joint Connector No. 5 .................8W-10-22
Joint Connector No. 6 ............8W-10-13, 22, 26
Joint Connector No. 8 .................8W-10-22
Junction Block ..................8W-10-8, 10, 13
Left Fog Lamp ......................8W-10-25
Left Headlamp ......................8W-10-24
Left Outboard Headlamp ..........8W-10-9, 24, 25
Low Note Horn ......................8W-10-26
Oxygen Sensor 1/1 Left Bank Up . . . 8W-10-17, 18, 19
Oxygen Sensor 1/1 Upstream ............8W-10-17
Oxygen Sensor 1/2 Downstream ..........8W-10-17
Oxygen Sensor 1/2 Left Bank Down .......8W-10-19
Oxygen Sensor 1/2 Pre-Catalyst ..........8W-10-18
Oxygen Sensor 1/3 Post-Catalyst .........8W-10-18
Oxygen Sensor 2/1 Right Bank Up . . 8W-10-17, 18, 19
Oxygen Sensor 2/2 Right Bank Down ......8W-10-19
Oxygen Sensor Downstream Relay .....8W-10-18, 19
Power Distribution Center ....8W-10-8, 9, 10, 11, 12,
13, 14, 2, 20, 21, 22, 23, 24, 25, 26, 27
Power Outlet ......................8W-10-9, 27
Powertrain Control Module . . 8W-10-11, 12, 15, 16, 20
Quad High Beam Relay ................8W-10-24
Right Fog Lamp .....................8W-10-25
Right Headlamp .....................8W-10-24
Right Outboard Headlamp .........8W-10-9, 24, 25
Security Relay .....................8W-10-9, 25
Trailer Tow Connector .................8W-10-21
Trailer Tow Relay ....................8W-10-21
Transmission Control Relay ...........8W-10-9, 26
Transmission Solenoid Assembly .........8W-10-26
Turn Signal/Hazard Switch .............8W-10-13
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