Dodge RAM 1999 3500 Truck 2WD 5.9L, RAM 1999 2WD 5.9L VIN Z 2, RAM 1999 3500 Truck 2WD V8 5.9L.html Workshop Manual

dodge :: Dodge Truck RAM 3500 Truck 2WD V8-

5.9L VIN Z LDC (1999)

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> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antitheft Relay > Component Information > Diagrams > Diagram Information and Instructions

Antitheft Relay: Diagram Information and Instructions

Introduction

General Information (Part 1 Of 2)

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RAM 3500 Truck 2WD V8-5.9L VIN Z LDC (1999)

General Information (Part 2 Of 2)

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

Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placednear the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition.

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RAM 3500 Truck 2WD V8-5.9L VIN Z LDC (1999)

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

It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a shortpiece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only.

Circuit Function

Circuit Identification Code Chart

All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to theCircuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models.

Circuit Information

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RAM 3500 Truck 2WD V8-5.9L VIN Z LDC (1999)

Wire Code Identification

Wire Color Code Chart

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RAM 3500 Truck 2WD V8-5.9L VIN Z LDC (1999)

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

Connector Information

CAUTION:

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

IDENTIFICATION

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

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

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

- Connectors located on the body harness are C300 series numbers.

- Jumper harness connectors are C400 series numbers.

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

Component Identification

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

Connector Identification

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

Electrostatic Discharge (ESD) Sensitive Devices

Electrostatic Discharge Symbol

(ESD)

All Electrostatic Discharge sensitive components are solid state and a symbol is used to indicate this. When handling any component with thissymbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into thecomponent. If it is not known whether the part is ESD sensitive, assume that it is.

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

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

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RAM 3500 Truck 2WD V8-5.9L VIN Z LDC (1999)

Fasteners

Shock Tower To Spring Minimum Clearance Area

CAUTION:

NO

At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place ofan original plastic clip. Also, holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into thestrut tower.

Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of thespring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog.

Fuses

CAUTION:

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

Notes, Cautions and Warnings

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

NOTES

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

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

WARNINGS

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

WARNING:

- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.

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

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

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

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RAM 3500 Truck 2WD V8-5.9L VIN Z LDC (1999)

- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.

- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS.

­TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S),TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.

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

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

Positive Temperature Coefficient

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

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

Positive Temperature Coefficient Symbol

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

Section Identification

Wiring Diagram Section Identification

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

Symbols

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RAM 3500 Truck 2WD V8-5.9L VIN Z LDC (1999)

Symbols

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RAM 3500 Truck 2WD V8-5.9L VIN Z LDC (1999)

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

Take-Outs

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

How to Find System & Component Diagrams

Group Index

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

Group Index Diagrams By Sheet Number

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

Connector and Terminal Replacement

six inches

1/2 inch

1. Disconnect battery.2. Disconnect the connector (that is to be repaired) from its mating half/component.3. Cut off the existing wire connector directly behind the insulator. Remove of tape from the harness.4. Stagger cut all wires on the harness side at intervals.5. Remove of insulation from each wire on the harness side. 1 inch

Stagger Cutting Wires (Typical)

6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.

1 inch

7. Remove of insulation from each wire.8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.

Wire Repair

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RAM 3500 Truck 2WD V8-5.9L VIN Z LDC (1999)

9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).

10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2).11. Twist the wires together (Example 3).12. Solder the connection together using rosin core solder only. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of bothDo not use acid core solder.

ends of the tubing.

1-1/2 inches 2 inches

14. Repeat steps 8 through 13 for each wire.15. Re-tape the wire harness starting behind the connector and past the repair.16. Re-connect the repaired connector.17. Connect the battery and test all affected systems.

Connector Replacement

1. Disconnect the battery.2. Disconnect the connector (that is to be repaired) from its mating half/component.

Connector Locking Wedge

3. Remove the connector locking wedge, if required.

Terminal Removal

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RAM 3500 Truck 2WD V8-5.9L VIN Z LDC (1999)

Terminal Removal Using Special Tool

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

terminal from the connector.

5. Reset the terminal locking tang, if it has one.6. Insert the removed wire in the same cavity on the repair connector.7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities.8. Insert the connector locking wedge into the repaired connector, if required.9. Connect the connector to its mating half/component.

10. Connect the battery and test all affected systems.

Diode Replacement

Diode Identification

Do not use acid core solder.

1. Disconnect the battery.2. Locate the diode in the harness and remove the protective covering.3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.5. Install the new diode in the harness, making sure current flow is correct.6. Solder the connection together using rosin core solder only. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements.8. Re-connect the battery and test affected systems.

Terminal Replacement

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

Connnector Locking Wedge Tab (Typical)

3. Remove the connector locking wedge, if required.

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RAM 3500 Truck 2WD V8-5.9L VIN Z LDC (1999)

Terminal Removal

Terminal Removal Using Special Tool

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

terminal from the connector.

6 inches

1 inch

1 inch

5. Cut the wire from the back of the connector.6. Remove of insulation from the wire on the harness side.7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired.8. Cut the repair wire to the proper length and remove of insulation.9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.

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RAM 3500 Truck 2WD V8-5.9L VIN Z LDC (1999)

Wire Repair

Do not use acid core solder.

10. Spread the strands of the wire apart on each part of the exposed wires (Example 1).11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2).12. Twist the wires together (Example 3).13. Solder the connection together using rosin core solder only. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.

1-1/2 inches 2 inches

15. Insert the repaired wire into the connector.16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component.17. Re-tape the wire harness starting behind the connector and past the repair.18. Connect the battery and test all affected systems.

Terminal/Connector Repair-Molex Connectors

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

Molex Connector Repair

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

Using Special Tool 6742

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RAM 3500 Truck 2WD V8-5.9L VIN Z LDC (1999)

6742

4. Using special tool , release the locking fingers on the terminal.5. Pull on the wire to remove it from the connector.6. Repair or replace the connector or terminal, as necessary.

Terminal/Connector Repair-Thomas and Betts Connectors

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

Thomas And Betts Connector Lock Release Tabs

3. Push in the two lock tabs on the side of the connector.

Removing Wire Terminal

6934
6934

4. Insert the probe end of Special Tool into the back of the connector cavity.5. Grasp the wire and Special Tool and slowly remove the wire and terminal from the connector.6. Repair or replace the terminal.7. Install the wire and terminal in the connector. Fully seat the terminal in the connector.

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RAM 3500 Truck 2WD V8-5.9L VIN Z LDC (1999)

Single Lock Tab

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

Wiring Repair

Wire Repair

When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securelyin place to prevent damage to the insulation.

1. Disconnect the battery negative cable.

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

3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.

4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).

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

6. Twist the wires together (Example 3).

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

8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.

9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.

10. Connect the battery and test all affected systems.

Special Tools

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RAM 3500 Truck 2WD V8-5.9L VIN Z LDC (1999)

Probing Tool Package 6807

Terminal Pick 6680

Terminal Removing Tool 6932

Terminal Removing Tool 6934

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Antitheft Relay: 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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RAM 3500 Truck 2WD V8-5.9L VIN Z LDC (1999)

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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RAM 3500 Truck 2WD V8-5.9L VIN Z LDC (1999)

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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Antitheft Relay: Connector Views

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RAM 3500 Truck 2WD V8-5.9L VIN Z LDC (1999)

Power Distribution Center (PDC)

Security Relay

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Radio/Stereo Noise Filter Relay > Component Information > Description and Operation

Radio/Stereo Noise Filter Relay: Description and Operation
FILTER, CHOKE, AND SPEAKER RELAY

DESCRIPTION

Models equipped with the Infinity premium speaker package have a filter, choke, and speaker relay unit. The filter, choke, and speaker relay unit ismounted to the lower instrument panel center brace, inboard of the Central Timer Module (CTM) and directly above the 16-way data linkconnector. The filter, choke, and speaker relay unit can be accessed for service without instrument panel disassembly or removal.

The filter, choke, and speaker relay unit should be checked if there is no sound output noted from the speakers. The filter, choke, and speaker relayunit cannot be repaired or adjusted and, if faulty or damaged, the unit must be replaced.

OPERATION

The filter, choke, and speaker relay unit is used to control the supply of fused battery current to the front door speaker-mounted dual amplifiers.The speaker relay is energized by a fused output from the radio receiver whenever the radio is turned on. 12 volt

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Radio/Stereo Noise Filter Relay > Component Information > Description and Operation > Page 32

Radio/Stereo Noise Filter Relay: Testing and Inspection

The filter, choke and speaker relay is used to switch power to the individual speaker amplifiers used with the Infinity premium speaker package. Thechoke and relay are serviced only as a unit. If all of the speakers lack bass or low frequency response, the filter, choke and speaker relay unit should beconsidered suspect. However, before replacement make the following checks of the filter, choke and speaker relay circuits.

1. Check the fused B(+) fuse in the junction block. If OK, go to Step 2.If not OK, replace the faulty fuse.2. Check for battery voltage at the fused B(+) fuse in the junction block. If OK, go to Step 3. If not OK, repair the open fused B(+) circuit to the
battery as required.

3. Disconnect the instrument panel wire harness connector from the filter, choke and speaker relay unit. Check for battery voltage at the fused B(+)
circuit cavity of the instrument panel wire harness connector for the filter, choke and speaker relay unit. If OK, go to Step 4. If not OK, repair theopen fused B(+) circuit to the junction block fuse as required.

4. Probe the ground circuit cavity of the instrument panel wire harness connector for the filter, choke and speaker relay unit. Check for continuity to a
good ground. There should be continuity. If OK, go to Step 5. If not OK, repair the open ground circuit to ground as required.

5. Turn the ignition switch to the On position and turn the radio on. Check for battery voltage at the radio output circuit cavity of the12 volt
instrument panel wire harness connector for the filter, choke and speaker relay unit. If OK, go to Step 6. If not OK, repair the open radio output circuit to the radio as required.12 volt

6. Turn the radio and ignition switches to the Off position. Reconnect the instrument panel wire harness connector to the filter, choke and speaker

zero volts

relay unit. Check for battery voltage at the amplified speaker (+) circuit cavity of the instrument panel wire harness connector for the filter, chokeand speaker relay unit. There should be . Turn the ignition and radio switches to the On position. There should now be battery voltage. IfOK, repair the open amplified speaker (+) circuits to the speaker-mounted amplifiers as required. If not OK, replace the faulty filter, choke andspeaker relay unit.

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Radio/Stereo Noise Filter Relay > Component Information > Description and Operation > Page 33

Radio/Stereo Noise Filter Relay: Service and Repair

1. Disconnect and isolate the battery negative cable.REMOVAL

Filter, Choke And Speaker Relay Remove/Install

2. Reach under the driver side of the instrument panel near the 16-way data link connector and inboard of the ash receiver to access the filter, choke
and speaker relay.

3. Disconnect the instrument panel wire harness connector from the filter, choke and speaker relay wire harness connector.4. Remove the two screws that secure the filter, choke, and speaker relay mounting bracket to the instrument panel center brace.5. Remove the filter, choke, and speaker relay unit from under the instrument panel.

screws to .2.7 Nm (24 in lbs)

3. Reconnect the instrument panel wire harness connector to the filter, choke and speaker relay wire harness connector.4. Reconnect the battery negative cable.

INSTALLATION

1. Position the filter, choke, and speaker relay unit under the instrument panel.2. Install and tighten the two screws that secure the filter, choke, and speaker relay mounting bracket to the instrument panel center brace. Tighten the

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

Electronic Brake Control Module: Specifications

WITH RWAL ANTILOCK BRAKES:

Mounting Screws .............................................................................................................................................................. 2.5 - 3.5 Nm (22 - 31 inch lbs.)

WITH 4-WHEEL ANTILOCK BRAKES:

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

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

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Control Modules, PDC, and Relays > Page 40

Electronic Brake Control Module: LocationsEBC 2

Controller Antilock Brakes (CAB) EBC 2

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Control Modules, PDC, and Relays > Page 41

Electronic Brake Control Module: LocationsEBC 325

Controller Antilock Brakes (CAB) EBC 32 5

EBC-325

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

Electronic Brake Control Module: DiagramsConnector Plug C1

Connector Pin Identification

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Connector Plug C1 > Page 44

Electronic Brake Control Module: DiagramsConnector Plug C2

Connector Pin Identification

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

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

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

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Controller Antilock Brake (CAB) > Page 47

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

CAB/HCU

The CAB is mounted on the top of the hydraulic control unit.

The CAB operates the ABS system and is separate from other vehicle electrical circuits. CAB voltage source is through the ignition switch in the RUNposition.

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

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

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

NOTE:

If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programmed into the new CAB. For axle type referto Transmission and Drivetrain. For tire revolutions per mile refer to Steering and Suspension.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Controller Antilock Brake (CAB) > Page 48

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

RWAL CAB

(CAB)

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

Perform self-test diagnostics.

- Monitor the RWAL brake system for proper operation.

- Control the RWAL valve solenoids.

NOTE:

If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programmed into the new CAB. For axle type referto Transmission and Drivetrain. For tire revolutions per mile refer to Steering and Suspension.

SYSTEM SELF-TEST

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

CAB INPUTS

Rear Wheel Speed Sensor

- Brake Lamp Switch

- Brake Warning Lamp Switch

- Reset Switch

- 4WD Switch (If equipped)

CAB OUTPUTS

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

RWAL Valve

- ABS Warning Lamp

- Brake Warning Lamp

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

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Antilock Control Assembly Replacement

Electronic Brake Control Module: Service and RepairAntilock Control Assembly Replacement

NOTE:

If the antilock control assembly needs to be replaced, the rear axle type and tire revolutions per mile must be programmed into the new CAB.For axle type refer to Transmission and Drivetrain. For tire revolutions per mile refer to Steering and Suspension.

REMOVAL

1. Disconnect battery negative cable.2. Push the harness connector locks to release the locks, then remove the connectors from the CAB.

Brake Lines

3. Disconnect brake lines from HCU.4. Remove the two mounting bolts on either side of the assembly which attach the assembly to the mounting bracket.5. Tilt the assembly upward were the brake lines attach and remove the assembly from the mounting bracket.

INSTALLATION

12 Nm (102 inch lbs.)

19 - 23 Nm (170 - 200 inch lbs.)

1. Install the assembly into the mounting bracket.2. Install the mounting bolts and tighten to .3. Connect the CAB harnesses.4. Connect the brake lines to the HCU. Tighten brake line fittings to .5. Connect battery.6. Bleed brake system.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Antilock Control Assembly Replacement > Page 51

Electronic Brake Control Module: Service and RepairController Antilock Brake (CAB) Replacement

Four Wheel Antilock Brake System

NOTE:

If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programmed into the new CAB. For axle type referto Transmission and Drivetrain. For tire revolutions per mile refer to Steering and Suspension.

REMOVAL

1. Disconnect battery negative cable.

Harness Connector Locks

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

Pump Motor Connector

3. Disconnect the pump motor connector.

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

Control Assembly Replacement > Page 52

RAM 3500 Truck 2WD V8-5.9L VIN Z LDC (1999)

Controller Mounting Screws

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

INSTALLATION

1. Place the CAB onto the HCU.

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

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

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

Rear Wheel Antilock Brake System

REMOVAL

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

Control Assembly Replacement > Page 53

RAM 3500 Truck 2WD V8-5.9L VIN Z LDC (1999)

NOTE:

If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programmed into the new CAB. For axle type referto Transmission and Drivetrain. For tire revolutions per mile refer to Steering and Suspension.

CAB Harness Connections

1. Pull up on the CAB harness connector lock release and remove the connector from the controller.2. Remove the RWAL valve harness connector from the controller.

CAB Mounting Screws

3. Remove the controller mounting screws, and remove the controller from the mounting bracket.

INSTALLATION

2.5 - 3.5 Nm (22 - 31 inch lbs.)

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

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

Blower Motor Relay: Component Locations

8w-10-2

The blower motor relay is located in the PDC in the engine compartment.

> Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Component Locations > Page 59

Blower Motor Relay: Connector Locations

> Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Component Locations > Page 60

RAM 3500 Truck 2WD V8-5.9L VIN Z LDC (1999)

Power Distribution Center (PDC)

Blower Motor Relay

> Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 61

Blower Motor Relay: Description and Operation
SYSTEM OPERATION

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

The blower motor relay control circuit is protected by a fuse located in the junction block. When the relay is de-energized, the blower motorreceives no battery current. See Blower Motor Relay in the Diagnosis and Testing for more information.

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

> Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 62

Blower Motor Relay: Testing and Inspection
Relay Test

Blower Motor Relay

The blower motor relay is located in the Power Distribution Center (PDC). Remove the blower motor relay from the PDC to perform the followingtests:1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK,

go to Step 2. If not OK, replace the faulty relay.

75 5 ohms

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

Relay Circuit Test

1. The relay common feed terminal cavity (30) is connected to fused battery feed directly from a fuse in the Power Distribution Center (PDC), and
should be hot at all times. Check for battery voltage at the PDC cavity for relay terminal 30. If OK, go to Step 2. If not OK, repair the open circuitto the PDC fuse as required.

2. The relay normally closed terminal cavity (87A) is not used for this application. Go to Step 3.3. The relay normally open terminal cavity (87) is connected to the blower motor. When the relay is energized, terminal 87 is connected to terminal

30 and provides full battery current to the blower motor feed circuit. There should be continuity between the PDC cavity for terminal 87 and the blower motor relay output circuit cavity of the blower motor wire harness connector at all times. If OK, go to Step 4. If not OK, repair the opencircuit to the blower motor as required.

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

switch output is directed from a fuse in the junction block to the relay electromagnetic coil to energize the relay There should be battery voltage atthe PDC 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 thejunction block fuse 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 PDC 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 63

Blower Motor Relay: Service and Repair
REMOVAL AND INSTALLATION

1. Disconnect and isolate the battery negative cable.

Power Distribution Center

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

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

Compressor Clutch Relay: Component Locations

> Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Component Locations > Page 68

RAM 3500 Truck 2WD V8-5.9L VIN Z LDC (1999)

8w-10-2

Power Distribution Center

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

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

Compressor Clutch Relay: Connector Locations

> Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Component Locations > Page 70

RAM 3500 Truck 2WD V8-5.9L VIN Z LDC (1999)

Power Distribution Center (PDC)

A/C Compressor Clutch Relay

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

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

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

The compressor clutch relay is a electromechanical device that switches battery current to the compressor clutch coil when the Powertrain ControlModule (PCM) grounds the coil side of the relay. The PCM responds to inputs from the heater-A/C mode control switch, the low pressure cyclingclutch switch, and the high pressure cut-off switch. See Compressor Clutch Relay in the Diagnosis and Testing for more information.

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

> Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Description and Operation > A/C Compressor Clutch Relay Description > Page 73

Compressor Clutch Relay: Description and OperationA/C Compressor Clutch Relay-PCM Output
AIR CONDITIONING (A/C) CLUTCH RELAY - PCM OUTPUT

Power Distribution Center (PDC)

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

The powertrain control module (PCM) activates the A/C compressor through the A/C clutch relay. The PCM regulates A/C compressor operationby switching the ground circuit for the A/C clutch relay on and off.

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

15seconds 125 C (257 F)

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