Dodge RAM 1996 3500 Van V8 5.2L Workshop Manual

dodge :: Dodge Truck RAM 3500 Van V8-318 5.2L
Magnum (1996)

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Audio Control Relay > Component Information > Description and Operation

Audio Control Relay: Description and Operation
CIRCUIT OPERATION

The radio speaker relay and filter choke supplies voltage to the amplifier circuits in the speakers. The radio supplies power to the coil side of the relay on circuit X60. Circuit Z1 provides ground for the coil side of the relay

Circuit F31 from fuse 2 in the fuse block supplies power to the contact side of the relay. Circuit A3 from fuse 14 in the Power Distribution Center(PDC) connects to the fuse block bus bar that feeds circuit F31 through fuse 2. Circuits A3 and F31 are HOT at all times.

When the radio supplies power for the coil side of the relay the contacts close and connect circuits F31 and X13. Circuit X13 supplies voltage tothe amplifier circuits in the speakers. Circuit X15 provides ground for the amplifier circuit of the speakers.

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Description and Operation

Keyless Entry Module: Description and Operation

POWER LOCK/REMOTE KEYLESS ENTRY MODULE

The power lock/remote keyless entry module is mounted on the dash panel beneath the instrument panel, above the heater-A/C air distribution ductand between the two defroster outlets. This module contains the remote keyless entry receiver, program logic, and functions as a smart relay for thepower door lock, remote keyless entry and illuminated entry systems.

The remote keyless entry receiver has a memory function to retain the vehicle access code of at least one, but no more than two, transmitters. Thereceiver is designed to retain the transmitter codes in memory, even if the battery is disconnected.

The module receives inputs from the ignition switch, power door lock switches, and the side/rear cargo door jamb switches. It also receives input fromthe remote keyless entry transmitter. In response to those inputs, it is programmed to control outputs to the lock motor and courtesy lamp circuits. Thepower lock/remote keyless entry module cannot be repaired and, if faulty, must be replaced.

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > System Tests

Keyless Entry Module: Service and RepairSystem Tests

POWER LOCK/REMOTE KEYLESS ENTRY MODULE

(1) Check the circuit breaker in the fuseblock module. If OK, go to Step 2. If not OK, replace the faulty circuit breaker.
(2) Check for battery voltage at the circuit breaker. If OK, go to Step 3. If not OK, repair the open circuit to the power distribution center as required.
(3) Access the power lock/remote keyless entry module connectors as described in this group.
(4) Unplug the connectors from the module. Check the connectors and the receptacles in the module for loose corroded, or damaged terminals and

pins. If OK, go to Step 5. If not OK, repair as required.

(5) Probe the ground circuit cavity of the black module connector and check for continuity to a good ground. There should be continuity. If OK, go to

Step 6. If not OK, repair the circuit to ground as required.

(6) Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the black module connector. If OK go to Step 7. If

not OK, repair the open circuit to the fuseblock module as required.

(7) Probe the door lock switch output (lock) circuit cavity of the black module connector and check for battery voltage as you actuate either, or both,

lock switch(es) to the Lock position. If OK, go to Step 8. If not OK, repair the open circuit to the lock switch(es) as required.

(8) Probe the door lock switch output (unlock) circuit cavity of the black module connector and check for battery voltage as you actuate either, or

both, lock switch(es) to the Unlock position. If OK, go to Step 9. If not OK. repair the open circuit to the lock switch(es) as required.

(9) Check for continuity between the doorjamb switch sense circuit cavity of the black module connector and a good ground with both the side and the

rear cargo doors closed. There should be no continuity until the side or rear cargo doors are opened. Check both the side and rear doors. If OK, goto Step 10. If not OK, repair the open circuit to the door jamb switch(es) or replace the faulty door jamb switch(es) as required.

(10) Check for battery voltage at the fused ignition switch output circuit cavity of the blue module connector with the ignition switch in the On position.

If OK, turn the ignition switch to the Off position and go to Step 11. If not OK, repair the open circuit to the fuseblock module as required.

(11) Plug the module connectors back into the module. Backprobe the door latch switch sense circuit cavity of the black module connector and check

for continuity to a good ground. There should be no continuity. Press and release the Unlock button of the keyless entry transmitter. There shouldnow he continuity for about 30 seconds. If OK, go to Step 12. If not OK, replace the faulty module.

(12) Backprobe the door lock driver circuit cavity of the black module connector and check for battery voltage as the lock switch is moved to the Lock

position. Repeat the test pressing the Lock button of the transmitter. If OK, go to Step 13. If not OK, replace the faulty module.

(13) Still backprobing the door Lock driver circuit cavity of the black module connector, open the side or rear cargo door. Move the lock switch to the

Lock position or press the Lock button of the transmitter. Now close all of the doors. Within five seconds of the side or rear door(s) closing, thereshould be battery voltage on the door lock driver circuit. If OK, go to Step 14. If not OK, replace the faulty module.

(14) Backprobe the door unlock driver circuit cavity of the black module connector and check for battery voltage as the lock switch is moved to the

Unlock position. Repeat the test pressing the Unlock button of the transmitter. If OK, repair the open circuit to the lock motor(s) as required. If notOK. replace the faulty module.

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > System Tests > Page 12

Keyless Entry Module: Service and RepairRemote Keyless Entry Module Replacement

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > System Tests

> Page 13

RAM 3500 Van V8-318 5.2L Magnum (1996)

POWER LOCK/REMOTE KEYLESS ENTRY MODULE

(1) Disconnect the battery negative cable.
(2) Remove the six screws fastening the instrument cluster hood and bezel assembly. Pull the bezel off of the upper retaining clips.
(4) Remove the radio ground strap screw.
(5) Pull the radio out from the instrument panel far enough to disconnect the wiring and antenna lead.
(6) Remove the radio.
(7) Working through the radio opening, remove the two screws securing the power lock/RKE module to the dash panel.
(8) Unplug the two wiring connectors and remove the module.
(9) Reverse the removal procedures to install.

> Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Description and Operation

Keyless Entry Module: Description and Operation

POWER LOCK/REMOTE KEYLESS ENTRY MODULE

The power lock/remote keyless entry module is mounted on the dash panel beneath the instrument panel, above the heater-A/C air distribution ductand between the two defroster outlets. This module contains the remote keyless entry receiver, program logic, and functions as a smart relay for thepower door lock, remote keyless entry and illuminated entry systems.

The remote keyless entry receiver has a memory function to retain the vehicle access code of at least one, but no more than two, transmitters. Thereceiver is designed to retain the transmitter codes in memory, even if the battery is disconnected.

The module receives inputs from the ignition switch, power door lock switches, and the side/rear cargo door jamb switches. It also receives input fromthe remote keyless entry transmitter. In response to those inputs, it is programmed to control outputs to the lock motor and courtesy lamp circuits. Thepower lock/remote keyless entry module cannot be repaired and, if faulty, must be replaced.

> Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > System Tests

Keyless Entry Module: Service and RepairSystem Tests

POWER LOCK/REMOTE KEYLESS ENTRY MODULE

(1) Check the circuit breaker in the fuseblock module. If OK, go to Step 2. If not OK, replace the faulty circuit breaker.
(2) Check for battery voltage at the circuit breaker. If OK, go to Step 3. If not OK, repair the open circuit to the power distribution center as required.
(3) Access the power lock/remote keyless entry module connectors as described in this group.
(4) Unplug the connectors from the module. Check the connectors and the receptacles in the module for loose corroded, or damaged terminals and

pins. If OK, go to Step 5. If not OK, repair as required.

(5) Probe the ground circuit cavity of the black module connector and check for continuity to a good ground. There should be continuity. If OK, go to

Step 6. If not OK, repair the circuit to ground as required.

(6) Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the black module connector. If OK go to Step 7. If

not OK, repair the open circuit to the fuseblock module as required.

(7) Probe the door lock switch output (lock) circuit cavity of the black module connector and check for battery voltage as you actuate either, or both,

lock switch(es) to the Lock position. If OK, go to Step 8. If not OK, repair the open circuit to the lock switch(es) as required.

(8) Probe the door lock switch output (unlock) circuit cavity of the black module connector and check for battery voltage as you actuate either, or

both, lock switch(es) to the Unlock position. If OK, go to Step 9. If not OK. repair the open circuit to the lock switch(es) as required.

(9) Check for continuity between the doorjamb switch sense circuit cavity of the black module connector and a good ground with both the side and the

rear cargo doors closed. There should be no continuity until the side or rear cargo doors are opened. Check both the side and rear doors. If OK, goto Step 10. If not OK, repair the open circuit to the door jamb switch(es) or replace the faulty door jamb switch(es) as required.

(10) Check for battery voltage at the fused ignition switch output circuit cavity of the blue module connector with the ignition switch in the On position.

If OK, turn the ignition switch to the Off position and go to Step 11. If not OK, repair the open circuit to the fuseblock module as required.

(11) Plug the module connectors back into the module. Backprobe the door latch switch sense circuit cavity of the black module connector and check

for continuity to a good ground. There should be no continuity. Press and release the Unlock button of the keyless entry transmitter. There shouldnow he continuity for about 30 seconds. If OK, go to Step 12. If not OK, replace the faulty module.

(12) Backprobe the door lock driver circuit cavity of the black module connector and check for battery voltage as the lock switch is moved to the Lock

position. Repeat the test pressing the Lock button of the transmitter. If OK, go to Step 13. If not OK, replace the faulty module.

(13) Still backprobing the door Lock driver circuit cavity of the black module connector, open the side or rear cargo door. Move the lock switch to the

Lock position or press the Lock button of the transmitter. Now close all of the doors. Within five seconds of the side or rear door(s) closing, thereshould be battery voltage on the door lock driver circuit. If OK, go to Step 14. If not OK, replace the faulty module.

(14) Backprobe the door unlock driver circuit cavity of the black module connector and check for battery voltage as the lock switch is moved to the

Unlock position. Repeat the test pressing the Unlock button of the transmitter. If OK, repair the open circuit to the lock motor(s) as required. If notOK. replace the faulty module.

> Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > System Tests > Page 20

Keyless Entry Module: Service and RepairRemote Keyless Entry Module Replacement

> Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > System Tests > Page 21

RAM 3500 Van V8-318 5.2L Magnum (1996)

POWER LOCK/REMOTE KEYLESS ENTRY MODULE

(1) Disconnect the battery negative cable.
(2) Remove the six screws fastening the instrument cluster hood and bezel assembly. Pull the bezel off of the upper retaining clips.
(4) Remove the radio ground strap screw.
(5) Pull the radio out from the instrument panel far enough to disconnect the wiring and antenna lead.
(6) Remove the radio.
(7) Working through the radio opening, remove the two screws securing the power lock/RKE module to the dash panel.
(8) Unplug the two wiring connectors and remove the module.
(9) Reverse the removal procedures to install.

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

Power Distribution (Part 1 Of 3)

> Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Locations > Page 26

ABS Main Relay: Description and Operation
CIRCUIT OPERATION

(CAB) (ABS)

When the Controller Anti-Lock Brakes grounds the Anti-lock Brakes power relay on circuit B116, the relay contacts close andconnect circuit A10 from fuse 7 in the Power Distribution Center (PDC) and circuit B120. Circuit A20 from fuse 5 in the fuse block splices to feedthe coil side of the ABS power relay

From the ABS power relay circuit B120 splices to power the pump motor and all the solenoids in the front hydraulic valve. Circuit B120 alsosupplies power to the solenoids in the rear hydraulic valve. Additionally circuit B120 provides an input to cavity 34 of the CAB. The input tells theCAB that power has been supplied to the pump motor.

> 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

(CAB)

The front anti-lock valve and ABS Controller Anti-Lock Brake module are each serviced as an assembly. Neither the valve nor the moduleshould be replaced unless it has been determined that a valve or module fault has occurred.

1. remove rear anti-lock valve and combination valve as described under On models equipped with an inline power booster, Rear Anti-Lock

.Valve

2. disconnect lines from combination valve, then remove rear anti-lock valve as describedOn models equipped with a transverse power booster,

under .Rear Anti-Lock Valve

3. remove driver's side headlamp trim bezels to access headlamp support panel, then disconnect and remove horns and access coverOn all models,

plate from radiator support panel.

4. Remove brake line between combination valve and front brake anti-lock valve, then disconnect both brake lines from front brake anti-lock valve.5. Remove front anti-lock valve protective cover, then the nuts securing valve to mounting plate. These nuts may be accessed through holes in
radiator support panel.

6. Disconnect wiring harness from front anti-lock valve, then the upper harness wire and main harness connector from ABS electronic control
module.

7. Lift main harness connector up and out of module retaining lugs, then remove front anti-lock valve, ABS electronic control module and bracket as
an assembly by moving assembly upward and toward lefthand side.

8. If necessary to replace front anti-lock valve only, separate valve from bracket.9. Reverse procedure to install, noting the following:

Torque 16-21 12-17

a. front anti-lock valve stud nuts to ft. lbs. and hydraulic line fittings to ft. lbs.b. Bleed brake system as described under .Antilock Brake System/Service and Repair

> 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

On models with A/C,

1. Disconnect battery ground cable.2. remove glove compartment.3. remove module attaching screws from righthand side of dash panel.On all models,

Fig. 98 CAB Module Replacement

4. Disconnect electrical connector from module, then remove the module.5. Reverse procedure to install. attaching screws to inch lbs.Torque 21

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

Power Distribution (Part 1 Of 3)

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

Audible Warning Device Control Module: Description and Operation
CIRCUIT OPERATION

The buzzer module sounds an audible warning tone. The tone sounds for seat belt warning and when the ignition key is in the ignition switch whilethe drivers door is OPEN. The tone also sounds when the ignition key is in the ON position while the drivers side seat belt is not buckled.

Fuses 15 and 17 in the fuse block protect the buzzer module. Fuse 15 powers circuit F32 which connects to the module. Circuit A12 from fuse 6 inthe Power Distribution Center (PDC) supplies power to the fuse block for fuse 15 and circuit F32.

Circuit G5 from fuse 17 also provides voltage to the combination buzzer when the ignition switch is in the START or RUN position. The ignitionswitch connects circuit A1 from fuse 15 in the PDC to circuit A21. Circuit A21 connects to the fuse block and powers circuit G5 through fuse 17.

When the parking lamps or headlamps are ON, the headlamp switch connects circuit G16 from the drivers side door jamb switch to circuit G26.Circuit G26 connects to the buzzer module and the key-in switch. Circuit G16 from the drivers side door switch also connects to the key-in switch.

Circuit G13 from the buzzer module powers the seat belt warning lamp in the message center. Circuit Z1 at the message center provides ground forthe lamp.
Circuit G1O from the buzzer connects to the seat belt switch. When the seat belt switch CLOSES. circuit Z1 provides ground.
Circuit Z1 also grounds the combined buzzer module.

> Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Description and Operation > Page 40

Audible Warning Device Control Module: Testing and Inspection

Circuit G5 splices to supply current to the lamps in the message center.

> 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 44

RAM 3500 Van V8-318 5.2L Magnum (1996)

Fuse Block (Part 2 Of 2)

> Relays and Modules > Relays and Modules - Instrument Panel > Key Reminder Relay > Component Information > Locations > Page 45

Key Reminder Relay: Description and Operation
CIRCUIT OPERATION

The time delay relay is used to allow a time-ON function for the ignition switch lamp and the headlamp switch lamp. Power for the relay isprovided on the M11 circuit from the interior lamp defeat switch.

Circuit M2 provides ground for the time delay relay through the door ajar switches, headlamp switch and the power door lock module. When adoor is opened, or the headlamp switch is moved to the dome lamp position a ground path is provided for the relay on circuit M2. This energizesthe relay, causing the contacts to close.

When the relay contacts close, power is provided through the relay to circuit M50. Circuit M50 supplies current to the ignition switch key-in halolamp and the headlamp switch lamp. Circuit Z1 provides ground for the lamps. Circuit Z1 also provides ground for the cigar lighter lamp, andglove box lamp.

> Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Description and Operation

Daytime Running Lamp Control Unit: Description and Operation
CIRCUIT OPERATION - CANADA

On Canadian vehicles, the low-beam headlamps operate when the ignition switch is in the RUN position and the headlamp switch is OFF.

(PDC)

When the ignition switch is in the START or RUN position, circuit A1 from fuse 15 in the Power Distribution Center connects to circuitA21. Circuit A21 powers circuit F18 through fuse 19 in the fuse block. Circuit F18 feeds the Daytime Running Module module.(DRL)

Circuit L20 from the headlamp switch connects to DRL module. Circuit L20 is HOT at all times.

The DRL module receives the vehicle speed sensor input from circuit G7. Circuit G34 from the DRL module provides power for the high beamindicator lamp in the instrument cluster.

Circuit L4 powers the low beams of the headlamps. When the headlamp switch is OFF, the DRL module powers the low beams on circuit L4.When the headlamps are ON, the multi-function switch powers the low beams on circuit L4.

Circuit L3 feeds the high beams of the headlamps. When the operator flashes the headlamps with the stalk of the multi-function switch, the DRLmodule senses voltage on circuit L3. When it senses voltage on circuit L3, the DRL module stops supplying power to the low beams on circuit L4.
Circuit Z1 provides ground for the DRL module.

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

Power Distribution (Part 1 Of 3)

> Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Description and Operation

Interior Lighting Module: Description and Operation
CIRCUIT OPERATION

The door lock module controls the remote keyless entry and illuminated entry systems. When the module receives input from the transmitter, itoperates the door locks and provides ground for courtesy lamps on circuit M2.

Also, circuit G70 from right and rear door jamb switches connect to the door lock module. When the doors open, the switches CLOSE and supplyground for circuit G70. The door lock module then provides ground for the courtesy lamps on circuit M2.

> Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Description and Operation

Power Distribution Relay: Description and Operation
Van Conversion Relay

CIRCUIT OPERATION

Circuit A12 from the van conversion relay is powered when the ignition switch is in the ACCESSORY or RUN positions. The relay provides apower source for aftermarket accessories.

When the ignition switch is in the ACCESSORY or RUN positions it connects circuit A1 from fuse 15 in the Power Distribution Center (PDC)with circuit A31. Circuit A31 connects to the fuse block and powers circuit L5 through fuse 12. Circuit L5 splices to the coil side of the vanconversion relay. Circuit Z1 provides ground for the coil side of the relay.

When battery voltage is present on circuit L5, the relay contacts close and connect circuit A12 to circuit A18 from the fuse in cavities 9 and 10 inthe fuse block.

> Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams

Relay Box: Diagrams

> Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Page 63

RAM 3500 Van V8-318 5.2L Magnum (1996)

Power Distribution (Part 1 Of 3)

> Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Page 64

RAM 3500 Van V8-318 5.2L Magnum (1996)

Power Distribution (Part 2 Of 3)

Power Distribution (Part 3 Of 3)

> 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 > PCM - Cruise Control System Check

Powertrain Control Module: Technical Service BulletinsPCM - Cruise Control System Check

NO: 08-01-96
GROUP: Electrical
DATE: Jan. 19, 1996
SUBJECT: Speed Control Light Flickers and/or Servo Clicks
MODELS: 1996 (BR) Ram Truck

1996 (AN) Dakota1996 (AB) Ram Van/wagon1996 (XJ) Cherokee

SYMPTOM/CONDITION:

The speed control indicator light, located on the speed control switch module, may flicker and/or a click may be heard from the speed control servo whenthe ignition key is turned to the RUN/START position and/or when the key is turned from RUN/START to OFF.
DISCUSSION:

The speed control indicator light is operated by the Powertrain Control Module (PCM). When the PCM is first powered-up by positioning the ignitionkey to the RUN/START position, the PCM performs a systems check. During the system check, the PCM momentarily provides power for the speedcontrol indicator light, causing the light to illuminate. Also, the speed control servo is supplied with battery voltage at the same time. When the servoreceives power, a click may also be noticed. This is due to the dump solenoid being energized momentarily. The PCM performs an additional systemscheck when the ignition switch is turned from RUN to OFF. The flickering of the light or the sound of the dump solenoid clicking will not have anyadverse effects on the electrical system within the vehicle.

Please inform your customers that the flickering of the light and the click from the dump solenoid is due to a PCM systems check and is a normaloperation of the system.

: NOTE

Do not replace the clockspring or any other components directly or indirectly related to the speed control system for this condition.

POLICY: Information Only

> 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 > PCM - Cruise Control System Check > Page 71

Powertrain Control Module: Technical Service BulletinsPowertrain Control Module - Service Precaution

NO: 18-21-98
GROUP: Vehicle Performance
DATE: Jun. 5, 1998
SUBJECT:

Powertrain ControlModule (PCM)Service Caution
MODELS:

1996 - 1998 (AB) Ram Van
1996 - 1998 (AN) Dakota
1996 - 1998 (BR/BE) Ram Truck
1998 (DN) Durango
1997 - 1998 (TJ) Wrangler
1996-1998 (XJ) Cherokee
1996-1998 (ZJ) Grand Cherokee
1996 - 1998 (ZG) Grand Cherokee (European Market)

DISCUSSION:

Whenever any connector on the PCM is disconnected, the ignition switch must be in the "OFF" position for a minimum of 5 seconds before connectorremoval.

It has been found under certain key "ON" or momentary key "OFF" conditions, when the black connector is unplugged, the PCM may attempt to writeinformation to the EEPROM processor within the PCM. Sometimes this inadvertent write will set the target charging voltage to 0 (zero) volts. The resultwill prevent the charging system from charging the battery.
If this occurs, the only correction is PCM replacement.

POLICY: Information Only

> 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 > PCM - Cruise Control System Check > Page 72

Technical Service Bulletin # 080197

Discussion

NO: 08-01-97
GROUP: Electrical
EFFECTIVE DATE: Feb. 3, 1997

SUBJECT:JTEC Powertrain ControlModule Wiring HarnessConnector Repair Packages
MODELS:

1996 - 1997 (AB) Ram Van
1996 - 1997 (AN) Dakota
1996 - 1997 (BR) Ram Truck
1996 - 1997 (SR) Viper/Viper GTS
1997 (TJ) Wrangler
1996-1997 (XJ) Cherokee
1996-1997 (ZJ) Grand Cherokee
1996 - 1997 (ZG) Grand Cherokee (International Markets)

DISCUSSION:

The following Jeep/Truck Engine Controller (JTEC) Powertrain Control Module (PCM) electrical connector and terminal repair components areavailable to aid in powertrain electrical wiring repairs. These components allow repairs of individual wiring circuits without the need to replace the entireengine harness. If you have determined that a powertrain customer complaint could be related to a poor electrical connection, the PCM connectorsshould be inspected. The following diagnosis and inspection can be utilized to determine the condition of the PCM connectors and their terminals.

Diagnosis

Inspection of the connector begins with a thorough inspection of the insulator.

1. Record the radio station presets.

2. Disconnect and isolate the battery negative cable (both batteries should be disconnected if the vehicle is equipped with a 5.9L Cummins Diesel).

3. Disconnect the connector from the PCM.

> 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 > PCM - Cruise Control System Check > Page 73

RAM 3500 Van V8-318 5.2L Magnum (1996)

4. Inspect the connector lock tab on the side of the insulator (Figure 1) for damage and replace the insulator if damaged is identified.

5. Gently pull on the wires of the connector one at a time. The initial and final locks will need to be inspected if the wire pulls out of the insulator.

6. Push in the single lock tab on the side of the insulator (Figure 2).

> 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 > PCM - Cruise Control System Check > Page 74

RAM 3500 Van V8-318 5.2L Magnum (1996)

7. Then, insert the probe of special tool 6934 (Figure 3) into the back of the insulator cavity.

8.
Grasp the wire and tool 6934 and slowly remove the wire and terminal from the insulator (Figure 4). Then, remove the strain relief and wire seal(Figure 1).

9. Inspect the initial and final locks of the insulator (Figure 1) for damage. Replace the insulator if there are any signs of damage.

10. Inspect all wire terminals for corrosion. If corrosion is evident, replace the terminal ends and the insulator.

11.

To verify how secure the cavity of the terminal fits onto the PCM pins, insert and remove the wire end terminal onto the mating pin of the PGM.Then, rotate the terminal 90, 180, and 270 while inserting and removing the terminal from the pin. If any connection is loose, replace the wireend terminal.

12. Inspect and replace the PCM connector cover or connector plug if the locking tabs are damaged.

Perform the following Repair Procedure if damage or wear is identified in any component of the insulator or terminals (including corrosion on theterminal).

> 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 > PCM - Cruise Control System Check > Page 75

RAM 3500 Van V8-318 5.2L Magnum (1996)

PARTS REQUIRED:
REPAIR PROCEDURE:
This bulletin involves replacing either the insulator or terminals of the PCM connectors.
Insulator Replacement

NOTE:

THIS PROCEDURE ASSUMES THAT THE WIRE END TERMINALS WERE ALREADY REMOVED WHEN THE DIAGNOSIS WASPERFORMED.

1.
Utilizing the appropriate insulator (see Parts Required list), install the wire and terminal into the appropriate cavities of the insulator. Refer to theappropriate Service Manual, Group 8W-80, for proper terminal-to-cavity locations in the connector. Fully seat all terminals into the insulator.

2. Push in the two lock tabs on the side of the connector (Figure 5).

3. Install the connector into the proper cavity of the PCM.

> 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 > PCM - Cruise Control System Check > Page 76

RAM 3500 Van V8-318 5.2L Magnum (1996)

4. Connect the battery negative cable (both batteries should be connected if the vehicle is equipped with a 5.9L Cummins Diesel).

5. Reset the clock and reprogram the radio stations to the presets recorded in step 1 of the Diagnosis.

Wire End Terminal Replacement

NOTE:

THIS PROCEDURE ASSUMES THAT THE DAMAGED OR CORRODED WIRE END TERMINAL WAS ALREADY REMOVED WHEN THEDIAGNOSIS WAS PERFORMED.

1.
The wire of the terminal end that needs repaired will need to be cut and discarded. Measure approximately three inches down the wire from theend of the terminal and cut the wire.

2. Cut one of the wires with terminal ends from package P/N 04882087 in half. This action will allow for two repairs if necessary.

3. Remove approximately one inch of insulation from the wires that are being spliced together.

4. Place a piece of heat shrink tubing over one of the wires. Make sure the tubing will be long enough to cover and seal the entire repair.

5. Spread the strands of the wire apart on each part of the exposed wire (Example 1) (Figure 6).

6. Push the ends of the two wires together until the strands of wire are close to the insulation (Example 2) (Figure 6).

7. Twist the wires together (Example 3) (Figure 6).

8. Solder the connection together using rosin core type solder only. Do not use acid core solder.

9.
Center the heat shrink tubing over the joint and heat the tubing using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comesout of both ends of the tubing.

10. Secure the wires to the existing harness to prevent chafing or damage to the insulation.

11. Install the wire terminal end into the appropriate cavity of the insulator. Fully seat all terminals into the insulator.

12. Push in the single lock tab on the side of the connector (Figure 5).

13. Install the connector into the proper cavity of the PCM.

14. Connect the battery negative cable (both batteries should be connected if the vehicle is equipped with a 5.9L Cummins Diesel).

15. Reset the clock and reprogram the radio stations to the presets recorded in step 1 of the Diagnosis.

POLICY: Information Only

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Technical Service Bulletins > Page 77

Powertrain Control Module: Locations

Powertrain Control Module

The Powertrain Control Module is located under the hood; mounted to the cowling, near the wiper motor.(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.

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.

- 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.

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

Symbols

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Symbol Identification

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

Take-Outs

The abbreviation is used in the component location section 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

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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

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

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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

Terminal Removal Using Special Tool

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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.

Wire Repair

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RAM 3500 Van V8-318 5.2L Magnum (1996)

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

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.

Wiring Repair

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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

Probing Tool Package 6807

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Terminal Pick 6680

Terminal Removing Tool 6932

Terminal Removing Tool 6934

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Diagrams > Diagram Information and Instructions > Page 91

Powertrain Control Module: Diagnostic Aids

Intermittent and Poor Connections

Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause 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.

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Testing For Voltage Drop

Testing For Voltage Drop

1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery.2. Connect the other lead of the voltmeter to the other side of the switch or component.

3. Operate the item.4. The voltmeter will show the difference in voltage between the two points.

Troubleshooting Tools
TROUBLESHOOTING TOOLS

When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below.

- - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit.Jumper Wire

WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERYFEED AND GROUND.

- Voltmeter

- This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead tothe positive side of the circuit.

CAUTION:

Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a or greater impedance.10 megohm

- Ohmmeter

- This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean goodcontinuity or a shorted circuit.

CAUTION:

10 megohm

Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter witha or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicleelectrical system can cause damage to the equipment and provide false readings.

Probing Tool

- Probing Tools 6807

- These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package and insert itinto the terminal being tested. Use the other end of the tool to insert the meter probe.

Troubleshooting Wiring Problems

When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check fornon-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-onitems are not the cause of the problem.

1. Verify the problem.

2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams.

3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the
diagnosis will continue.

4. Isolate the problem area.

5. Repair the problem.

6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams.

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Powertrain Control Module