Dodge Durango 1999 5.9L VIN Z Workshop Manual

dodge :: Dodge Truck Durango 4WD V8-5.9L VIN
Z LDC (1999)

> Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations

8w-11-002

> Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 7

Power Door Lock Relay: Diagrams

Relay And Fuse Box

Driver Unlock Relay

> Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 8

Power Door Lock Relay: Service Precautions

WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG SYSTEMS BEFOREATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE.FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLEPERSONAL INJURY

.

> Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 9

Power Door Lock Relay: Description and Operation
SYSTEM DESCRIPTION

(ISO)

The driver unlock relay is a International Standards Organization micro-relay The terminal designations and functions are the same as aconventional ISO relay However, the micro-relay terminal orientation (or footprint) is different, current capacity is lower, and the relay casedimensions are smaller than those of the conventional ISO relay.

The driver unlock relay is a electromechanical device that switches battery current to the left front door power lock motor when the RemoteKeyless Entry (RKE) receiver within the high-line Central Timer Module (CTM) grounds the relay coil. Test the Driver Unlock Relay.

The driver unlock relay is located in the relay and fuse block attached to the back of the junction block, under the left side of the instrument panelin the passenger compartment. The driver unlock relay cannot be repaired and, if faulty or damaged, it must be replaced.

> Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 10

Power Door Lock Relay: Service and Repair

REMOVAL

1. Disconnect and isolate the battery negative cable.2. Remove the steering column opening cover and knee blocker from the instrument panel. Refer to Steering Column Opening Cover and Knee
Blocker/Service and Repair for the procedures.

Relay And Fuse Block

3. Reach through the outboard side of the steering column opening in the instrument panel to access the relay and fuse block on the back of the
junction block.

4. Unplug the driver unlock relay from the relay and fuse block.5. Install the driver unlock relay by aligning the relay terminals with the cavities in the relay and fuse block and pushing the relay firmly into place.6. Connect the battery negative cable.7. Test the relay operation.8. Reverse the remaining removal procedures to complete the installation.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications

Electronic Brake Control Module: Specifications

REAR WHEEL ANTILOCK (RWAL) BRAKES:

Mounting Screws ................................................................................................................................................................................. 6 Nm (53 inch lbs.)

FOUR WHEEL ANTILOCK BRAKES:

CAB Screws ........................................................................................................................................................................ 4 - 4.7 Nm (36 - 42 inch lbs.)

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > EBC 2

Antilock Brake Controller (EBC) 2

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > EBC 2 > Page 17

Antilock Brake Controller (EBC) 325

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Connector Plug C1

Connector Pin Identification

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Connector Plug C1 > Page 20

Connector Pin Identification

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Controller Antilock Brake (CAB)

Electronic Brake Control Module: Description and OperationController Antilock Brake (CAB)

The controller antilock brake module is used to monitor wheel speeds and modulates (control) hydraulic pressure in each brake channel. The modulatedhydraulic pressure is used to prevent wheel lock up during braking. The CAB also provides a vehicle speed signal (VSS) to the powertrain controlmodule.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Controller Antilock Brake (CAB) > Page 23

Electronic Brake Control Module: Description and OperationWith Four Wheel Antilock Brakes

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 electrical circuits. CAB voltage source is through the ignition switch in the RUNposition.

The CAB contains dual microprocessors. A logic block in each microprocessor receives identical sensor signals. These signals are processed andcompared simultaneously.

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

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

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

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Controller Antilock Brake (CAB) > Page 24

Electronic Brake Control Module: Description and OperationWith Rear Wheel Antilock Brakes

RWAL CAB

(CAB)

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

Perform self-test diagnostics.

- Monitor the RWAL brake system for proper operation.

- Control the RWAL valve solenoids.

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

SYSTEM SELF-TEST

When the ignition switch is turned-on the microprocessor RAM and ROM are tested. If an error occurs during the test, a DTC will be set into theRAM memory. However it is possible the DTC will not be stored in memory if the error has occurred in the RAM module were the DTC's are stored.Also it is possible a DTC may not be stored if the error has occurred in the ROM which signals the RAM to store the DTC.

CAB INPUTS

The CAB continuously monitors the speed of the differential ring gear by monitoring signals generated by the rear wheel speed sensor. The CABdetermines a wheel locking tendency when it recognizes the ring gear decelerating too rapidly. The CAB monitors the following inputs to determinewhen a wheel locking 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

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Four Wheel Antilock Brake System

Electronic Brake Control Module: Service and RepairFour Wheel Antilock Brake System

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

REMOVAL

1. Disconnect battery negative cable.

Harness Connector Locks

2. Push the harness connector locks to release the locks, then remove the connectors from the CAB.

Pump Motor Connector

3. Disconnect the pump motor connector.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Four Wheel

Antilock Brake System > Page 27

Durango 4WD V8-5.9L VIN Z LDC (1999)

Controller Mounting Screws

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

INSTALLATION

1. Place the CAB onto the HCU.

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

4 - 4.7 Nm (36 - 42 inch 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 - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Four Wheel Antilock Brake System > Page 28

Electronic Brake Control Module: Service and RepairRear Wheel Antilock Brake System

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

REMOVAL

RWAL Controller

1. Push the CAB harness connector lock to release the lock and remove the connector from the controller.2. Remove the RWAL valve harness connector from the controller.3. Remove the controller mounting screws and remove the controller from the mounting bracket.

INSTALLATION

6 Nm (53 inch lbs.)

1. Position the controller on the bracket.2. Install the mounting screws and tighten to .3. Install the RWAL valve harness connector into the controller.4. Install the CAB harness connector into the controller and push down on the connector lock.

> Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Component Locations

Blower Motor Relay: Component Locations

Power Distribution Center

The blower motor relay is located in the PDC in the engine compartment.The high speed blower motor relay is located in the relay and fuse block, which is attached to the back of the junction block, under the left side of theinstrument panel in the passenger compartment.

> Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Component Locations > Page 34

Blower Motor Relay: Connector Locations

> Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Component Locations > Page 35

Durango 4WD V8-5.9L VIN Z LDC (1999)

Power Distribution Center

Blower Motor Relay

> Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 36

Blower Motor Relay: Description and Operation
SYSTEM DESCRIPTION

The blower motor relay is an International Standards Organization (ISO)-type relay. The relay is an electromechanical device that switches batterycurrent from a fuse in the Power Distribution Center (PDC) directly to the blower motor. The relay is energized when the relay coil is provided avoltage signal by the ignition switch. This arrangement reduces the amount of battery current that must flow through the ignition switch.

The blower motor relay control circuit is protected by a fuse located in the junction block. When the relay is de-energized, the blower motorreceives no battery current.

The blower motor relay is located in the PDC in the engine compartment. Refer to the PDC label for blower motor relay identification andlocation.
The blower motor relay cannot be repaired and, if faulty or damaged, it must be replaced.

High Speed Blower Motor Relay

The front blower motor electrical circuit uses a high speed blower motor relay. The high speed blower motor relay is an International StandardsOrganization (ISO)-type relay. The relay is an electromechanical device that switches the blower motor to ground, bypassing the remainder of theblower motor feed circuit.

The high speed blower motor relay is energized when the relay coil is provided a ground signal by the blower motor switch, and a battery feedfrom the ignition switch. When the relay is de-energized, the front blower motor ground feed is routed through the front blower motor switch andthe blower motor resistor.

The high speed blower motor relay is located in the relay and fuse block, which is attached to the back of the junction block, under the left side ofthe instrument panel in the passenger compartment. The high speed blower motor relay cannot be repaired and, if faulty or damaged, it must bereplaced.

> Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 37

Blower Motor Relay: Testing and Inspection

Relay Test

Blower Motor Relay

The high speed blower motor relay is located in the relay and fuse block, which is attached to the back of the junction block, under the left side of theinstrument panel in the passenger compartment. Remove the high speed blower motor relay from the relay and fuse block as described to perform thefollowing 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 . If OK, go to Step 3. If not OK, replace the faulty relay.75 5 ohms

3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A
and 30. If OK, see Relay Circuit Test in the Diagnosis and Testing. If not OK, replace the faulty relay.

Relay Circuit Test

1. The relay common feed terminal cavity (30) is connected to the ground side of the blower motor. There should be continuity between the ground
circuit cavity of the blower motor wire harness connector and the relay and fuse block cavity for relay terminal 30 at all times. If OK, go to Step 2.If not OK, repair the open circuit to the blower motor as required.

2. The relay normally closed terminal cavity (87A) is not used for this application. Go to Step 3.

3. The relay normally open terminal cavity (87) is connected to ground. When the relay is energized, terminal 87 is connected to terminal 30 and
provides a direct path to ground for the blower motor. There should be continuity between the relay and fuse block cavity for terminal 87 andground at all times. If OK, go to Step 4. If not OK, repair the open circuit to ground as required.

4. The coil battery terminal cavity (86) is connected to the ignition switch. When the ignition switch is placed in the On position, fused ignition

switch output is directed from a fuse in the junction block to the relay electromagnetic coil to energize the relay There should be battery voltage atthe relay and fuse block cavity for relay terminal 86 with the ignition switch in the On position. If OK, go to Step 5. If not OK, repair the opencircuit to the junction block fuse as required.

5. The coil ground terminal cavity (85) is connected to the high speed output circuit terminal of the blower motor switch. This terminal supplies the
ground for the relay electromagnetic coil. There should be continuity between the relay and fuse block cavity for relay terminal 85 and the highspeed output circuit terminal of the blower motor switch at all times. If not OK, repair the open circuit to the blower motor switch as required.

> Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 38

Blower Motor Relay: Service and Repair
REMOVAL AND INSTALLATION

1. Disconnect and isolate the battery negative cable.

Power Distribution Center

2. Remove the cover from the Power Distribution Center (PDC).3. Refer to the label on the PDC for blower motor relay identification and location.4. Unplug the blower motor relay from the PDC.5. Install the blower motor relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place.6. Install the PDC cover.7. Connect the battery negative cable.8. Test the relay operation.

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

Compressor Clutch Relay: Component Locations

Power Distribution Center

The compressor clutch relay is located in the Power Distribution Center (PDC) in the engine compartment.

> Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Component Locations > Page 43

Compressor Clutch Relay: Connector Locations

> Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Component Locations > Page 44

Durango 4WD V8-5.9L VIN Z LDC (1999)

Power Distribution Center

A/C Compressor Clutch Relay

> Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Description and Operation > A/C Compressor Clutch Relay Description

Compressor Clutch Relay: Description and OperationA/C Compressor Clutch Relay Description
SYSTEM DESCRIPTION

The compressor clutch relay is an International Standards Organization (ISO) micro-relay. The terminal designations and functions are the same asa 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.

The compressor clutch relay is an electromechanical device that switches battery current to the compressor clutch coil when the PowertrainControl Module (PCM) grounds the coil side of the relay. The PCM responds to inputs from the heater-A/C mode control switch, the electroniccycling clutch switch, the low pressure cut-off 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 relayidentification and location.
The compressor clutch relay cannot be repaired and, if faulty or damaged, it must be replaced.

> Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Description and Operation > A/C Compressor Clutch Relay Description > Page 47

Compressor Clutch Relay: Description and OperationA/C Compressor Clutch Relay-PCM Output

Power Distribution Center (PDC)

AIR CONDITIONING (A/C) CLUTCH RELAY-PCM OUTPUT

The A/C relay is located in the Power Distribution Center (PDC). The PDC is located in the engine compartment. Refer to label on PDC cover forrelay location.

The Powertrain Control Module (PCM) activates the A/C compressor through the A/C clutch relay. The PCM regulates A/C compressor operationby switching the ground circuit for the A/C clutch relay on and off.

When the PCM receives a request for A/C from A/C evaporator switch, it will adjust idle air control (IAC) motor position. This is done to increaseidle speed. The PCM will then activate the A/C clutch through the A/C clutch relay. The PCM adjusts idle air control (IAC) stepper motor positionto compensate for increased engine load from the A/C compressor.

By switching the ground path for the relay on and off, the PCM is able to cycle the A/C compressor clutch. This is based on changes in engineoperating conditions. If; during A/C operation, the PCM senses low idle speeds or a wide open throttle condition, it will de-energize the relay. Thisprevents A/C clutch engagement. The relay will remain de-energized until the idle speed increases or the wide open throttle condition exceeds or no longer exists. The PCM will also de-energize the relay if coolant temperature exceeds .15seconds 125C (257F)

> Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Description and Operation > Page 48

Compressor Clutch Relay: Testing and Inspection
Relay Test

Compressor Clutch Relay

The compressor clutch relay is located in the Power Distribution Center (PDC). 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 Relay Circuit Test in the Diagnosis and Testing. 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 (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 theopen circuit as required.

> Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Description and Operation > Page 49

Compressor Clutch Relay: Service and Repair
REMOVAL AND INSTALLATION

1. Disconnect and isolate the battery negative cable.

Power Distribution Center

2. Remove the cover from the Power Distribution Center (PDC).3. Refer to the label on the PDC 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.

> Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service Precautions

Control Module HVAC: Service Precautions

WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS / AIRBAG SYSTEMS BEFOREATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE.FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLEPERSONAL INJURY

.

> Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Specifications

Audible Warning Device Control Module: Specifications

CTM Mounting Bracket Screws (2) to Bracket on Outboard Side of Glove Box Opening20 in.lb
Bracket on Outboard Side of Glove Box Opening to Instrument Panel Screws (3) 20 in.lb

> Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Specifications > Page 57

Central Timer Module Remove/Install

> Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions

Audible Warning Device Control Module: Diagram Information and Instructions

Introduction

(Part 1 Of 2)

> Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information

and Instructions > Page 60

Durango 4WD V8-5.9L VIN Z LDC (1999)

(Part 2 Of 2)

Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagramsto diagnose and repair a Chrysler vehicle, 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 placednear the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition.

> Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information

and Instructions > Page 61

Durango 4WD V8-5.9L VIN Z LDC (1999)

Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a componentindicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component isshown 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 shortpiece 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 Function

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

> Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information

and Instructions > Page 62

Durango 4WD V8-5.9L VIN Z LDC (1999)

Wire Code Identification

Wire Color Code Chart

> Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information

and Instructions > Page 63

Durango 4WD V8-5.9L VIN Z LDC (1999)

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

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

In-line connectors are identified by a number, as follows:-

In-line connectors located on the engine compartment harness are C100 series numbers.

- Connectors located on the instrument panel harness are C200 series numbers.

- Connectors located on the body harness 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 connector.

Component Identification

Component connectors are identified by the component name instead of a number.

Connector Identification

Multiple connectors on a component use a C1, C2, etc. identifier.

Electrostatic Discharge (ESD) Sensitive Devices

Electrostatic Discharge Symbol

(ESD)

All Electrostatic Discharge sensitive components are solid state and a symbol is used to indicate this. When handling any component with thissymbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into thecomponent. 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.

> Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information

and Instructions > Page 64

Durango 4WD V8-5.9L VIN Z LDC (1999)

Fasteners

Shock Tower To Spring Minimum Clearance Area

CAUTION:

NO

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 ofan original plastic clip. Also, holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into thestrut 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 thespring. 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.

Fuses

CAUTION:

When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a ratingother than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.

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.

­SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK.A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL.

> Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information

and Instructions > Page 65

Durango 4WD V8-5.9L VIN Z LDC (1999)

- 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.

Positive Temperature Coefficient

Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the

junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids.

Positive Temperature Coefficient Symbol

A special symbol is used to identify these in the wiring diagrams.

Section Identification

Wiring Diagram 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 Shut Down 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.

Symbols

> Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information

and Instructions > Page 66

Durango 4WD V8-5.9L VIN Z LDC (1999)

Wiring Symbols

> Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information

and Instructions > Page 67

Durango 4WD V8-5.9L VIN Z LDC (1999)

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

Take-Outs

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

How to Find System & Component Diagrams

Group Index

When trying to find the diagram for a specific component or system, use the information or the under Alphabetic Index to Wiring Diagrams Electrical

Group Index Diagrams By Sheet Number

Whenever a reference exists to another sheet or figure, find the corresponding diagram using the , , or . The reference number for the subsequent diagram will match a listed group shown.Diagrams By Figure Number

Connector and Terminal Replacement

six inches

1/2 inch

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 of tape from the harness.4. Stagger cut all wires on the harness side at intervals.5. Remove of insulation from each wire on the harness side. 1 inch

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.

1 inch

7. Remove 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

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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. 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 bothDo not use acid core solder.

ends of the tubing.

1-1/2 inches 2 inches

14. Repeat steps 8 through 13 for each wire.15. Re-tape the wire harness starting behind the connector and 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.

Connector Locking Wedge

3. Remove the connector locking wedge, if required.

Terminal Removal

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Terminal Removal Using Special Tool

4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit . Pull on the wire to remove the6680

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

Diode Identification

Do not use acid core solder.

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. 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.

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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 . Pull on the wire to remove the6680

terminal from the connector.

6 inches

1 inch

1 inch

5. Cut the wire from the back of the connector.6. Remove 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 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.

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Wire Repair

Do not use acid core solder.

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. 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.

1-1/2 inches 2 inches

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 behind the connector and past the repair.18. Connect the battery and test all affected systems.

Terminal/Connector Repair-Molex Connectors

1. Disconnect the battery.2. Disconnect the connector from its mating half/component.

Molex Connector Repair

3. Insert the terminal releasing special tool into the terminal end of the connector.6742

Using Special Tool 6742

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6742

4. Using special tool , 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.

Removing Wire Terminal

6934
6934

4. Insert the probe end of Special Tool into the back of the connector cavity.5. Grasp the wire and Special Tool 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.

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Single Lock Tab

8. Push in the single lock tab on the side of the connector.

Wiring Repair

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 securelyin place to prevent damage to the insulation.

1. Disconnect the battery negative cable.

2. Remove of insulation from each end of the wire.1 inch

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

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Probing Tool Package 6807

Terminal Pick 6680

Terminal Removing Tool 6932

Terminal Removing Tool 6934

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Audible Warning Device 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 aproblem. 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 Problemssection.

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.

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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

6 to 8 Inches

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 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.