Dodge Magnum 1995 4x4 Pickup V8 5.2L Workshop Manual

dodge :: Dodge Truck 2500 4x4 Pickup V8-318

5.2L Magnum (1995)

> Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Light Relay > Component Information > Locations

ABS Light Relay: Locations

> Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Light Relay > Component Information > Locations > Page 7

2500 4x4 Pickup V8-318 5.2L Magnum (1995)

Power Distribution Center (Part 1 Of 2)

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> Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Light Relay > Component Information > Locations > Page 8

Warning Lamp Relay

> Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Locations

Related Images

> Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Locations > Page 12

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> Relays and Modules > Relays and Modules - Brakes and Traction Control > Brake Fluid Pump Relay > Component Information > Locations

Power Distribution Center (Part 1 Of 2)

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Brake Fluid Pump Relay > Component Information > Locations > Page 16

Brake Fluid Pump Relay: Description and Operation

(PDC)

When the ABS control module grounds the ABS pump relay on circuit B116, the relay contacts close connecting circuit A1O from the PowerDistribution Center and circuit B12O. Circuit A1O connects to fuse 5 in the PDC. Circuit A2O from the fuse 14 in the fuse block splices to feedthe coil side of the ABS warning low lamp relay.

From the ABS pump relay, circuit B12O splices to supply voltage to the ABS pump motor and all solenoids in the front brake anti-lock valve. CircuitB12O also supplies power to the solenoids in the rear antilock valve. Additionally, circuit B120 provides an input to cavity 34 of the ABS module. Theinput tells the module that voltage has been supplied to the pump motor.

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

Electronic Brake Control Module: LocationsABS Control Module

(RWAL)

The Rear Wheel Anti-Lock control module is located behind the instrument panel, to the right of the steering column, and near the intermittentwiper module.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > ABS Control Module > Page 21

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> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Rear Wheel Anti-Lock Control Module Connector

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Rear Wheel Anti-Lock Control Module Connector > Page 24

Electronic Brake Control Module: Diagrams4 Wheel ABS System

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> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Rear Wheel

Anti-Lock Control Module Connector > Page 25

2500 4x4 Pickup V8-318 5.2L Magnum (1995)

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> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > With Four Wheel Antilock Brakes

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

(CAB)

The Controller - Antilock Brake is mounted under the hood, separately from the valve body, and has microprocessor circuits that:-

Monitor the brake switch input to tell whether or not to prepare for possible antilock braking.

- Monitor the wheel speed sensor inputs to determine when a wheel is tending to lock up.

­Operate the integral control unit assembly during antilock braking based on comparing the speed sensors to information programmed inmemory.

- Detect ABS system related problems and take diagnostic action.

OPERATION

The CAB will disable antilock control and set a soft ignition latched trouble code if it detects one of the following conditions with itself:-

(71) RAM Read/Write

- (72) ROM Checksum

- (73) Watchdog

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > With Four Wheel Antilock Brakes > Page 28

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

Anti-Lock Electronic Control Module

PURPOSE

All phases of anti-lock mode brake operation are monitored and controlled by the Controller Antilock Brake module (CAB).

OPERATION

The module operates independently from other electrical circuits in the vehicle.
CAB input/output circuits include the system hydraulic valve, indicator lamps, and the speed sensor.

Speed sensor inputs are continuously monitored and interpreted by the module. The module determines wheel speed and rate of deceleration fromthese inputs and activates the appropriate solenoid in the hydraulic valve when necessary.

The module performs system diagnostic checks and contains a self test program. -

The program is activated when the ignition switch is turned to the ON position.

- In this mode, the module checks indicator light operation, the system electrical circuits and the pressure limiting valve solenoids.

The brake warning and anti-lock indicator lamps are illuminated for approximately two seconds during the system self test cycle.

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

Electronic Brake Control Module: Service and RepairWith Four Wheel Antilock System

Fig. 25 Main Harness Connector

The ABS module is located in the engine compartment attached to the forward side of the front brake anti-lock valve.NOTE:

1. Disconnect upper harness connector from module.2. Lift connector locking handle to release main harness connector for module. Rotate handle upward to clear connector.3. Lift connector up and out of retaining lugs on module.4. Remove module mounting screws then the module.5. Reverse procedure to install, installing harness main connector as follows:

a. Connecting main harness connector to module.b. Seat connector in module retaining lugs and start connector into module.c. Rotate connector locking handle downward into position to seat and retain connector.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > With Four Wheel Antilock System > Page 31

Electronic Brake Control Module: Service and RepairWith Rear Wheel Antilock System

1. Remove knee bolster; then, using a suitable long-shank screwdriver, remove electronic control module lower mounting screws.2. Remove module upper mounting screw, then lower module and bracket assembly from underside of instrument panel.3. Disconnect electrical harness from module; then, if necessary, separate module from bracket so that a new module may be installed.4. Reverse procedure to install.

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

Blower Motor Relay: Locations

Fig 39 Blower Motor Relay Removal/Installation

The relay is located in the passenger compartment on the stop lamp switch bracket. The stop lamp switch bracket is secured to the inboard side of thepedal support bracket under the driver side of the instrument panel. The relay case includes a molded-in plastic slot that snaps over the blade-type relaymount on the stop lamp switch bracket.

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

Blower Motor Relay: Description and Operation

Fig 39 Blower Motor Relay Removal/Installation

Blower Motor Relay

OPERATION

The blower motor relay is a International Standards Organization (ISO)-type relay. The relay is a electromechanical device that switches batterycurrent from a fuse in the fuse block module to the blower motor, whenever the ignition switch is in the On position. This arrangement reduces theamount of battery current that must flow through the ignition switch.

The relay is energized when the relay coil is provided a voltage signal by the ignition switch. When the relay is de-energized, the blower motorreceives no battery feed.

The relay is located in the passenger compartment on the stop lamp switch bracket. The stop lamp switch bracket is secured to the inboard side ofthe pedal support bracket under the driver side of the instrument panel. The relay case includes a molded-in plastic slot that snaps over theblade-type relay mount on the stop lamp switch bracket. The relay cannot be repaired and, if faulty or damaged, it must be replaced.

CIRCUIT OPERATION

Circuit C1 from fuse 2 in the Fuse Block supplies voltage to the contact side of the blower motor relay

(PDC)

When the ignition switch is in the RUN position it connects Circuit A2 from fuse 2 in the Power Distribution Center to Circuit A22. CircuitA22 connects to the coil side of the blower motor relay
Circuit C1 connects to Circuit C11 through the blower motor relay contacts and supplies voltage to the blower motor.

Circuit Z3 provides the ground path for the blower motor relay.

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

Blower Motor Relay: Testing and Inspection

Blower Motor Relay

Fig 39 Blower Motor Relay Removal/Installation

RELAY TEST

Remove the blower motor relay from its wire harness connector as described to perform the following tests:

1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK.
go to Step 2. If not OK, replace the faulty relay

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 procedure. If not OK, replace the faulty relay.

RELAY CIRCUIT TEST

1. The relay common feed terminal cavity (30) is connected to battery voltage and should be hot at all times. If OK go to Step 2. If not OK, repair the
open circuit to the fuse block module as required.

2. The relay normally closed terminal cavity (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to

Step 3.

3. The relay normally open terminal cavity (87) is connected to the blower motor. When the relay is energized, terminal 87 is connected to terminal

30 and provides full battery current to the blower motor. There should be continuity between this cavity and the blower motor relay output circuitcavity of the blower motor wire harness connector at all times. If OK, go to Step 4. If not OK, repair the open circuit to the blower motor asrequired.

4. The coil battery terminal cavity (86) is connected to the electromagnet in the relay. It is energized when the ignition switch is in the On position.
Check for battery voltage at the cavity for relay terminal 86 with the ignition switch in the On position. If OK, go to Step 5. If not OK, repair theopen circuit to the ignition switch through the Power Distribution Center (PDC) as required.

5. The coil ground terminal cavity (85) is connected to ground. This terminal supplies the ground for the relay electromagnetic coil. There should be
continuity between the cavity for relay terminal 85 and a good ground at all times. If not OK, repair the open circuit as required.

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

Blower Motor Relay: Service and Repair

Fig 39 Blower Motor Relay Removal/Installation

NOTE:

The blower motor relay and wire harness connector are snap-fit onto a blade-type retainer located on the stop lamp switch mounting bracket.The stop lamp switch mounting bracket is secured with two screws to the inboard side of the brake pedal support bracket, under the driver side of theinstrument panel. To remove the relay:

1. Disconnect and isolate the battery negative cable.2. Reach under the knee blocker on the driver side of the instrument panel between the throttle and brake pedals, and unsnap the relay from the blade
on the stop lamp switch bracket.

3. Lower the relay from under the instrument panel far enough to unplug the relay from the wire harness connector.4. To install the relay, align the terminals with the cavities in the relay wire harness connector and push the relay firmly into place.5. Reverse the remaining removal procedures to complete the installation.6. Test the relay operation.

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

Pinout

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

Pinout

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

Compressor Clutch Relay: Description and Operation

Compressor Clutch Relay

The compressor clutch relay is a International Standards Organization (ISO) micro-relay The terminal designations and functions are the same as aconventional ISO relay However, the micro-relay terminal orientation (footprint) is different, the current capacity is lower and the relay case dimensionsare smaller than on the conventional ISO relay.

The compressor clutch relay is a electromechanical device that switches current to the compressor clutch coil when the Powertrain Control Module(PCM) grounds the coil side of the relay The PCM responds to inputs from the heater-A/C mode control switch, the low pressure cycling clutch switch,and the high pressure cut-off switch.

The compressor clutch relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the PDC label for relay identificationand location.

> Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 45

Compressor Clutch Relay: Testing and Inspection

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. Remove therelay 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. If not OK, replace the faulty relay.

RELAY CIRCUIT TEST

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

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

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 > Locations > Page 46

Compressor Clutch Relay: Service and Repair

Fig 24 Power Distribution Center

(PDC)

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

> Relays and Modules > Relays and Modules - Instrument Panel > ABS Light Relay > Component Information > Locations

ABS Light Relay: Locations

> Relays and Modules > Relays and Modules - Instrument Panel > ABS Light Relay > Component Information > Locations > Page 51

2500 4x4 Pickup V8-318 5.2L Magnum (1995)

Power Distribution Center (Part 1 Of 2)

Related Images

> Relays and Modules > Relays and Modules - Instrument Panel > ABS Light Relay > Component Information > Locations > Page 52

Warning Lamp Relay

> Relays and Modules > Relays and Modules - Instrument Panel > Key Reminder Relay > Component Information > Locations

Key Reminder Relay: Locations

Fuse Block (Part 1 Of 2)

> Relays and Modules > Relays and Modules - Instrument Panel > Key Reminder Relay > Component Information > Locations > Page 56

2500 4x4 Pickup V8-318 5.2L Magnum (1995)

Fuse Block (Part 2 Of 2)

> Relays and Modules > Relays and Modules - Instrument Panel > Key Reminder Relay > Component Information > Locations > Page 57

Key Reminder Relay: Description and Operation

The time delay relay is used to allow a time-ON function for the ignition switch lamp. Power for the relay is provided on the M1 circuit from the IODfuse (fuse 17) in the fuse block.

Circuit M2 provides ground for the time delay relay through the right and left door jamb switches and the headlamp switch. When a door is OPENED, orthe headlamp switch is moved to the dome/cargo lamp ON position, a ground path is provided for the relay on circuit M2. This energizes the relay,causing the contacts to close.

When the relay contacts close, power is provided through the relay to circuit M50. The M50 circuit supplies current to the ignition switch lamp. CircuitZ3 provides ground for the lamp.

> Relays and Modules > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Description and Operation

Speedometer Module: Description and Operation

The Speedometer and Odometer receive a signal from the Vehicle Speed Sensor (VSS) on circuit G7. Circuit G7 is spliced and also connects to thePowertrain Control Module (PCM).
Circuit F14 from the fuse block provides voltage for the tachometer. Circuit Z11 provides ground for the tachometer.

> Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Technical Service Bulletins > Lighting - Service Manual Revisions

Fog/Driving Lamp Relay: Technical Service BulletinsLighting - Service Manual Revisions

NUMBER: 08-55-94C
GROUP: Electrical
DATE: Oct. 14, 1994
REVISIONS ARE HIGHLIGHTED WITH ASTERISKS

Models:1995 Ram Truck - Publication No. 81-370-5108
DESCRIPTION OF CHANGES
Reading Lamp/Dome Lamp Circuit Revised.

> Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Technical Service Bulletins > Lighting - Service

Manual Revisions > Page 66

2500 4x4 Pickup V8-318 5.2L Magnum (1995)

> Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Technical Service Bulletins > Lighting - Service

Manual Revisions > Page 67

2500 4x4 Pickup V8-318 5.2L Magnum (1995)

8W-49-3
Fog Lamp Relay 1 & 2 Revised.

> Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Technical Service Bulletins > Lighting - Service

Manual Revisions > Page 68

2500 4x4 Pickup V8-318 5.2L Magnum (1995)

8W-50-3

8W-50-6

> Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations

Power Distribution Center (Part 1 Of 2)

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >

Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 182395 > Jun > 95 > PCM - Cold Start Sag/Hesitation or Backfire/Pop

Powertrain Control Module: Customer InterestPCM - Cold Start Sag/Hesitation or Backfire/Pop

NO: 18-23-95
GROUP: Vehicle Performance
DATE: Jun. 30, 1995

SUBJECT: Cold Start Sag/Hesitation and/or Exhaust Backfire or Pop

MODELS: 1994 - 1995

(AB) Ram Van/Wagon
1994 - 1995 (AN) Dakota
1994 - 1995 (BR) Ram Truck

:NOTE

THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.9L ENGINE.

SYMPTOM/CONDITION:^

Driving away after a cold start up, a sag/hesitation may be experienced. At idle, a slight engine surge/rough idle may also be felt. The condition maypersist for up to one minute and be most prevalent on cold starts at ambient of 60-80 degrees F.

^

An exhaust backfire or popping noise in the exhaust system may occur during a closed throttle deceleration before the engine has reached normaloperating temperatures.

^ The vehicle may exhibit one or both of these conditions.

DIAGNOSIS:Using the Mopar Diagnostic System (MDS) or Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify that allengine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repairbefore proceeding with the repair procedure in this bulletin.

COLD START SAG/HESITATION:1.

Allow engine to cool down at least eight (8) hours, preferably overnight.

2.

Following cold start drive away, make frequent stops and medium accelerations checking for sags and hesitations. If sags or hesitations result,perform the repair procedure.

While vehicle is still cold, start engine and accelerate in first gear until engine speed reaches 3000 RPM.

2. Remove foot from accelerator pedal. Decelerate the vehicle and allow the vehicle to come to a stop.

3. If a backfire or popping sound comes from the exhaust system during deceleration, perform the repair procedure.

PARTS REQUIRED:1

4798341 POM, 3.9L Man. Trans AN Body 1994 MY
1 4798342 POM, 3.9L Auto Trans. AN Body 1994 MY
1 4798343 POM, 3.9L Auto Trans. AB Body 1994 MY
1 4798344 POM, 3.9L Man. Trans. BR Body 1994 MY
1 4798345 PCM, 3.9L Auto Trans. BR Body 1994 MY
1 4275086 Label - Authorized Modification
1 4669020 Label - Authorized Software Update

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine

Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 182395 > Jun > 95 > PCM - Cold Start Sag/

Hesitation or Backfire/Pop > Page 82

2500 4x4 Pickup V8-318 5.2L Magnum (1995)

EXHAUST BACKFIRE OR POPPING NOISE:1.

EQUIPMENT NEEDED:1

CH6OOO Scan Tool (DRB III)
1 CH7035 General Purpose Interface Bus Cable (GPIB)
1 CH7015 Engine Cable

REPAIR PROCEDURE:

This bulletin includes the replacement of the Powertrain Control Module (PCM) for 1994 model year vehicles, and the flashing of 1995 model yearvehicles with revised software.

MODULE REPLACEMENT:This section of the bulletin involves the replacement of the powertrain control module with one of the above powertrain control modules.

1. Record all radio station presets.

2. Disconnect negative cable at battery and isolate.

3. Remove 60 way electrical connector from POM (one bolt). POM is located in the right rear side of the engine compartment.

4. Remove the three PCM mounting bolts and remove PCM.

5. Install new PCM and torque bolts to 9 in. lbs. (1 Nm) torque.

6. Connect 60 way electrical connector to POM. Torque bolt to 35 in. lbs. (4 Nm).

7. Connect negative cable to battery.

8. Program radio station presets and clock.

9. Proceed to module reprogramming.

1995 MODULE REPROGRAMMING:This section of the bulletin involves reprogramming the PCM with new software and installation of appropriate labels.

: NOTE

THE MOPAR DIAGNOSTIC SYSTEM IS REQUIRED TO PERFORM THE FOLLOWING REPAIR. THE SYSTEM MUST BE OPERATINGWITH RELEASE 16 OR LATER INSTALLED. (TIL CD 1083 OR LATER)

This repair involves selectively erasing and reprogramming the Powertrain Control Module with new software (calibration change).

1. Connect the MDS (Mopar Diagnostic System) and DRBIII (Scan Tool) to the vehicle and power them up.

2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRBIII MAIN MENU Screen.

3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU.

4. Use the arrow keys and select CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU.

5. Use the arrow keys and select PROGRAM CONTROLLER PART on the MDS, then press NEXT MENU.

6. Follow the steps presented on the MDS and DRBIII which will allow the DRBIII to obtain the current part number of the controller.

7.

The MDS will display the part number of the controller on the vehicle and the appropriate replacement part number, then press NEXT MENU tobegin programming.

If the controller on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the partnumber of the controller on the vehicle and compare it to the part number displayed. If the part numbers match and the controller update has beenverified, proceed to Step 9.

8. The MDS and DRBIII will prompt for any operator action needed during the remainder of the programming process.

: NOTE

THE FOLLOWING STEPS ARE REQUIRED BY LAW.

Chrysler Authorized Software Update Label

9.

Type the necessary information on the "Authorized Software Update Label" and attach it to the PCM and cover the label with a clear plasticsticker.

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine

Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 182395 > Jun > 95 > PCM - Cold Start Sag/

Hesitation or Backfire/Pop > Page 83

2500 4x4 Pickup V8-318 5.2L Magnum (1995)

Chrysler Authorized Modification Label

10. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label.

POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Module. Powertrain Control Reprogram

Labor Operation No: 08-19-42-97 (1995 BR) 0.5 Hrs.

Replace Module. Powertrain Control and Reprogram 08-19-42-98 (1994 BR)

0.7 Hrs.

FAILURE CODE: FM - Flash Module

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >

Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 182395 > Jun > 95 > PCM - Cold Start Sag/Hesitation or Backfire/Pop

Powertrain Control Module: All Technical Service BulletinsPCM - Cold Start Sag/Hesitation or Backfire/Pop

NO: 18-23-95
GROUP: Vehicle Performance
DATE: Jun. 30, 1995

SUBJECT: Cold Start Sag/Hesitation and/or Exhaust Backfire or Pop

MODELS: 1994 - 1995

(AB) Ram Van/Wagon
1994 - 1995 (AN) Dakota
1994 - 1995 (BR) Ram Truck

:NOTE

THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.9L ENGINE.

SYMPTOM/CONDITION:^

Driving away after a cold start up, a sag/hesitation may be experienced. At idle, a slight engine surge/rough idle may also be felt. The condition maypersist for up to one minute and be most prevalent on cold starts at ambient of 60-80 degrees F.

^

An exhaust backfire or popping noise in the exhaust system may occur during a closed throttle deceleration before the engine has reached normaloperating temperatures.

^ The vehicle may exhibit one or both of these conditions.

DIAGNOSIS:Using the Mopar Diagnostic System (MDS) or Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify that allengine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repairbefore proceeding with the repair procedure in this bulletin.

COLD START SAG/HESITATION:1.

Allow engine to cool down at least eight (8) hours, preferably overnight.

2.

Following cold start drive away, make frequent stops and medium accelerations checking for sags and hesitations. If sags or hesitations result,perform the repair procedure.

While vehicle is still cold, start engine and accelerate in first gear until engine speed reaches 3000 RPM.

2. Remove foot from accelerator pedal. Decelerate the vehicle and allow the vehicle to come to a stop.

3. If a backfire or popping sound comes from the exhaust system during deceleration, perform the repair procedure.

PARTS REQUIRED:1

4798341 POM, 3.9L Man. Trans AN Body 1994 MY
1 4798342 POM, 3.9L Auto Trans. AN Body 1994 MY
1 4798343 POM, 3.9L Auto Trans. AB Body 1994 MY
1 4798344 POM, 3.9L Man. Trans. BR Body 1994 MY
1 4798345 PCM, 3.9L Auto Trans. BR Body 1994 MY
1 4275086 Label - Authorized Modification
1 4669020 Label - Authorized Software Update

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine

Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 182395 > Jun > 95 > PCM -

Cold Start Sag/Hesitation or Backfire/Pop > Page 89

2500 4x4 Pickup V8-318 5.2L Magnum (1995)

EXHAUST BACKFIRE OR POPPING NOISE:1.

EQUIPMENT NEEDED:1

CH6OOO Scan Tool (DRB III)
1 CH7035 General Purpose Interface Bus Cable (GPIB)
1 CH7015 Engine Cable

REPAIR PROCEDURE:

This bulletin includes the replacement of the Powertrain Control Module (PCM) for 1994 model year vehicles, and the flashing of 1995 model yearvehicles with revised software.

MODULE REPLACEMENT:This section of the bulletin involves the replacement of the powertrain control module with one of the above powertrain control modules.

1. Record all radio station presets.

2. Disconnect negative cable at battery and isolate.

3. Remove 60 way electrical connector from POM (one bolt). POM is located in the right rear side of the engine compartment.

4. Remove the three PCM mounting bolts and remove PCM.

5. Install new PCM and torque bolts to 9 in. lbs. (1 Nm) torque.

6. Connect 60 way electrical connector to POM. Torque bolt to 35 in. lbs. (4 Nm).

7. Connect negative cable to battery.

8. Program radio station presets and clock.

9. Proceed to module reprogramming.

1995 MODULE REPROGRAMMING:This section of the bulletin involves reprogramming the PCM with new software and installation of appropriate labels.

: NOTE

THE MOPAR DIAGNOSTIC SYSTEM IS REQUIRED TO PERFORM THE FOLLOWING REPAIR. THE SYSTEM MUST BE OPERATINGWITH RELEASE 16 OR LATER INSTALLED. (TIL CD 1083 OR LATER)

This repair involves selectively erasing and reprogramming the Powertrain Control Module with new software (calibration change).

1. Connect the MDS (Mopar Diagnostic System) and DRBIII (Scan Tool) to the vehicle and power them up.

2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRBIII MAIN MENU Screen.

3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU.

4. Use the arrow keys and select CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU.

5. Use the arrow keys and select PROGRAM CONTROLLER PART on the MDS, then press NEXT MENU.

6. Follow the steps presented on the MDS and DRBIII which will allow the DRBIII to obtain the current part number of the controller.

7.

The MDS will display the part number of the controller on the vehicle and the appropriate replacement part number, then press NEXT MENU tobegin programming.

If the controller on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the partnumber of the controller on the vehicle and compare it to the part number displayed. If the part numbers match and the controller update has beenverified, proceed to Step 9.

8. The MDS and DRBIII will prompt for any operator action needed during the remainder of the programming process.

: NOTE

THE FOLLOWING STEPS ARE REQUIRED BY LAW.

Chrysler Authorized Software Update Label

9.

Type the necessary information on the "Authorized Software Update Label" and attach it to the PCM and cover the label with a clear plasticsticker.

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Cold Start Sag/Hesitation or Backfire/Pop > Page 90

2500 4x4 Pickup V8-318 5.2L Magnum (1995)

Chrysler Authorized Modification Label

10. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label.

POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Module. Powertrain Control Reprogram

Labor Operation No: 08-19-42-97 (1995 BR) 0.5 Hrs.

Replace Module. Powertrain Control and Reprogram 08-19-42-98 (1994 BR)

0.7 Hrs.

FAILURE CODE: FM - Flash Module

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Technical Service Bulletins > Page 91

Powertrain Control Module: Locations

PCM Location

The Powertrain Control Module is located on the firewall at the right-hand rear corner of the engine compartment.(PCM)

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Diagrams > Diagram Information and Instructions

Powertrain Control Module: Diagram Information and Instructions

Circuit Function

Circuit Identification

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

Wire Color Code Chart

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

Connector Information

Connector Identification

Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placednext to the arrows to indicate the connector number.

For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and providesterminal numbering, circuit identification, wire colors, and functions.

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All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector LocationsIndex, which uses the connector identification number from the wiring diagrams to provide a figure number reference.

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.

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.

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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 TO BE ON.

­SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. AMANUAL 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), TAILPIPE, CATALYTIC CONVERTER, AND MUFFLER.

- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY.

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

Symbols

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2500 4x4 Pickup V8-318 5.2L Magnum (1995)

Symbol Identification

Various symbols are used throughout the Wiring Diagrams group. These symbols can be identified by referring to the Symbol Identification chart.

Take-Outs

The abbreviation is used in the component location group 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

How to Read Wiring Diagrams

Wire Color Code Identification

Wire Color Code Chart

Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shownas a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk willfollow the main wire color. If the tracer is non-standard, the main wire color will have a slash after it, followed by the tracer color.(/)

Connector and Terminal Replacement