Dodge WipersWashers 3500 2005, WipersWashers 2500 2005, WipersWashers 1500 2005 Service Manual

DR/DH WIPERS/WASHERS 8R - 1

WIPERS/WASHERS

TABLE OF CONTENTS

page page

WIPERS/WASHERS - ELECTRICAL

DIAGNOSTICS ........................... 1

WIPERS/WASHERS - ELECTRICAL DIAGNOSTICS

TABLE OF CONTENTS

WIPERS/WASHERS - ELECTRICAL

DIAGNOSTICS

DIAGNOSIS AND TESTING

FCM-WASHER FLUID LEVEL SENSOR

CIRCUIT FAILURE ......................2

FCM-WASHER PUMP OUTPUT CIRCUIT

LOW ................................6

FCM-WASHER PUMP OUTPUT CIRCUIT

OPEN ...............................9

FCM-WIPER ON-OFF RELAY OUTPUT

CIRCUIT HIGH ........................13

FCM-WIPER ON-OFF RELAY OUTPUT

CIRCUIT OPEN .......................16

FCM-WIPER ON-OFF RELAY OUTPUT

CIRCUIT LOW ........................19

WIPERS/WASHERS - SERVICE INFORMATION .. 45

page page

FCM-WIPER PARK SWITCH INPUT

PERFORMANCE ......................22

FCM-WIPER SPEED RELAY OUTPUT

CIRCUIT HIGH ........................26

FCM-WIPER SPEED RELAY OUTPUT

CIRCUIT LOW ........................29

FCM-WIPER SPEED RELAY OUTPUT

CIRCUIT OPEN .......................32

MIC-WASH-BEAM INPUT CIRCUIT

SHORTED ...........................35

MIC-WIPER SWITCH INPUT CIRCUIT OPEN . 38 MIC-WIPER SWITCH INPUT CIRCUIT

SHORTED ...........................41

SCHEMATICS AND DIAGRAMS ............44

WIPERS/WASHERS - ELECTRICAL DIAGNOSTICS

DIAGNOSIS AND TESTING

8R - 2 WIPERS/WASHERS - ELECTRICAL DIAGNOSTICS DR/DH

FCM-WASHER FLUID LEVEL SENSOR CIRCUIT FAILURE

DR/DH WIPERS/WASHERS - ELECTRICAL DIAGNOSTICS 8R - 3

FCM-WASHER FLUID LEVEL SENSOR CIRCUIT FAILURE (CONTINUED)

For the Wiper Washer system circuit diagram (Refer to 8 - ELECTRICAL/WIPERS/WASHERS - SCHEMATICS AND DIAGRAMS).

For a complete wiring diagram Refer to Section 8W.

• When Monitored:

Continuous with the ignition on.

• Set Condition:

The FCM detects the Washer Fluid Level Switch circuit voltage is below 0.05 volts or above 5.0 volts.

Possible Causes

WASHER FLUID LEVEL SWITCH WASHER FLUID LEVEL SENSOR SIGNAL CIRCUIT OPEN WASHER FLUID LEVEL SWITCH GROUND CIRCUIT OPEN WASHER FLUID LEVEL SWITCH SIGNAL CIRCUIT SHORT TO GROUND FRONT CONTROL MODULE

Diagnostic Test

WASHER FLUID LEVEL SWITCH

Turn the ignition off. Disconnect the Washer Fluid Level Switch harness

connector. Connect a jumper wire between cavity 1 and cavity

2. With the DRBIIIT, in Sensors, read the Washer

Fluid Level Switch Volts.

Does the DRBIIIT read below 1 volt?

Yes >>

No >>

Replace the Washer Fluid Level Switch in accordance with the Service Information.

Perform BODY VERIFICATION TEST VER 1.

Go To 2

8R - 4 WIPERS/WASHERS - ELECTRICAL DIAGNOSTICS DR/DH

FCM-WASHER FLUID LEVEL SENSOR CIRCUIT FAILURE (CONTINUED)

WASHER FLUID LEVEL SWITCH SIGNAL CIRCUIT OPEN

Turn the ignition off. Disconnect the FCM harness connector. Disconnect the Washer Fluid Level Switch harness connector. Measure the resistance of the Washer Fluid Level Switch Signal cir-

cuit.

Is the resistance above 5.0 ohms?

Yes >>

No >>

WASHER FLUID LEVEL SWITCH GROUND CIRCUIT OPEN

Turn the ignition off. Disconnect the FCM harness connector. Disconnect the Washer Fluid Level Switch harness connector. Measure the resistance of the Washer Fluid Level Switch Ground cir-

cuit.

Is the resistance above 5.0 ohms?

Yes >>

No >>

Repair the Washer Fluid Level Sensor Signal circuit for an open.

Perform BODY VERIFICATION TEST - VER 1. Go To 3

Repair the Washer Fluid Level Switch Ground circuit for an open.

Perform BODY VERIFICATION TEST - VER 1. Go To 4

DR/DH WIPERS/WASHERS - ELECTRICAL DIAGNOSTICS 8R - 5

FCM-WASHER FLUID LEVEL SENSOR CIRCUIT FAILURE (CONTINUED)

WASHER FLUID LEVEL SWITCH SIGNAL CIRCUIT SHORT TO GROUND

Turn the ignition off. Disconnect the FCM harness connector. Disconnect the Washer Fluid Level Switch harness connector. Measure the resistance between ground and the Washer Fluid Level

Switch Signal circuit.

Is the resistance below 5.0 ohms?

Yes >>

No >>

Repair the Washer Fluid Level Switch Signal circuit for a short to ground.

Perform BODY VERIFICATION TEST - VER 1. Replace the Front Control Module (FCM) in accordance

with the Service Information. Perform BODY VERIFICATION TEST - VER 1.

8R - 6 WIPERS/WASHERS - ELECTRICAL DIAGNOSTICS DR/DH

FCM-WASHER PUMP OUTPUT CIRCUIT LOW

DR/DH WIPERS/WASHERS - ELECTRICAL DIAGNOSTICS 8R - 7

FCM-WASHER PUMP OUTPUT CIRCUIT LOW (CONTINUED)

For the Wiper Washer system circuit diagram (Refer to 8 - ELECTRICAL/WIPERS/WASHERS - SCHEMATICS AND DIAGRAMS).

For a complete wiring diagram Refer to Section 8W.

• When Monitored:

With the igntion on.

• Set Condition:

The FCM detects less than 0.05 volts on the Washer Pump Motor Control circuit.

Possible Causes

WASHER PUMP MOTOR-FRONT WASHER PUMP MOTOR CONTROL CIRCUIT SHORT TO GROUND FRONT CONTROL MODULE POWER DISTRIBUTION CENTER

INTERMITTENT CONDITION

Turn the ignition on. With the DRBIIIT, clear all FCM DTC’s. Actuate the Wiper Washers. With the DRBIIIT, read the DTC information.

Does the DRBIIIT read: Washer Pump Output Circuit Low?

Yes >> No >>

Go To 2 The condition that caused the symptom

is currently not present. Inspect the related wiring for a possible intermittent condition. Look for any chafed, pierced, pinched, or partially broken wires.

Perform BODY VERIFICATION TEST VER 1.

8R - 8 WIPERS/WASHERS - ELECTRICAL DIAGNOSTICS DR/DH

FCM-WASHER PUMP OUTPUT CIRCUIT LOW (CONTINUED)

WASHER PUMP MOTOR - FRONT

Turn the ignition off. Disconnect the Washer Pump Motor - Front harness connector. Turn the ignition on. With the DRBIIIT, read DTCs.

Does the DRBIIIT display: Washer Pump Output Circuit Open?

Yes >>

No >>

WASHER PUMP MOTOR CONTROL CIRCUIT SHORT TO GROUND

Turn the ignition off. Disconnect the Integrated Power Module C3 harness connector. Disconnect the Washer Pump Motor harness connector. Measure the resistance between ground and the Washer Pump Motor

Control circuit.

Is the resistance below 5.0 ohms?

Yes >>

No >>

Replace the Washer Pump Motor - Front in accordance with the Service Information.

Perform BODY VERIFICATION TEST - VER 1. Go To 3

Repair the Washer Pump Motor Control circuit for a short to ground.

Perform BODY VERIFICATION TEST - VER 1. Go To 4

POWER DISTRIBUTION CENTER

Turn the ignition off. Disconnect the FCM from the IPM. Disconnect the IPM C3 harness connector. Measure the resistance between ground and the IPM Washer Pump Motor Control circuit terminal pin.

Is the resistance below 5.0 ohms?

Yes >>

No >>

Replace the Power Distribution Center (PDC) in accordance with the Service Information. Perform BODY VERIFICATION TEST - VER 1.

Replace the Front Control Module (FCM) in accordance with the Service Information. Perform BODY VERIFICATION TEST - VER 1.

DR/DH WIPERS/WASHERS - ELECTRICAL DIAGNOSTICS 8R - 9

FCM-WASHER PUMP OUTPUT CIRCUIT OPEN

8R - 10 WIPERS/WASHERS - ELECTRICAL DIAGNOSTICS DR/DH

FCM-WASHER PUMP OUTPUT CIRCUIT OPEN (CONTINUED)

For the Wiper Washer system circuit diagram (Refer to 8 - ELECTRICAL/WIPERS/WASHERS - SCHEMATICS AND DIAGRAMS).

For a complete wiring diagram Refer to Section 8W.

• When Monitored:

With the igntion on.

• Set Condition:

The FCM detects more than 5.0 volts on the Washer Pump Motor Control circuit.

Possible Causes

WASHER PUMP MOTOR-FRONT WASHER PUMP MOTOR GROUND CIRCUIT OPEN WASHER PUMP MOTOR CONTROL CIRCUIT OPEN POWER DISTRIBUTION CENTER FRONT CONTROL MODULE

INTERMITTENT CONDITION

Turn the ignition on. With the DRBIIIT, clear all FCM DTC’s. Actuate the Wiper Washers. With the DRBIIIT, read the DTC information.

Does the DRBIIIT read: Washer Pump Output Circuit Open?

Yes >> No >>

Go To 2 The condition that caused the symptom

is currently not present. Inspect the related wiring for a possible intermittent condition. Look for any chafed, pierced, pinched, or partially broken wires.

Perform BODY VERIFICATION TEST VER 1.

DR/DH WIPERS/WASHERS - ELECTRICAL DIAGNOSTICS 8R - 11

FCM-WASHER PUMP OUTPUT CIRCUIT OPEN (CONTINUED)

WASHER PUMP MOTOR - FRONT

Turn the ignition off. Disconnect the Washer Pump Motor harness connector. Connect a jumper wire between cavity 1 and cavity 2. Turn the ignition on. With the DRBIIIT, read DTCs.

Does the DRBIIIT display: Washer Pump Output Circuit Low?

Yes >>

No >>

WASHER PUMP MOTOR GROUND CIRCUIT OPEN

Turn the ignition off. Disconnect the Washer Pump Motor harness connector. Measure the resistance between ground and the Washer Pump Motor

Ground circuit.

Is the resistance above 5.0 ohms?

Yes >>

No >>

Replace the Washer Pump Motor - Front in accordance with the Service Information. Perform BODY VERIFICATION TEST - VER 1.

Go To 3

Repair the Washer Pump Motor Ground circuit for an open.

Perform BODY VERIFICATION TEST - VER 1. Go To 4

WASHER PUMP MOTOR CONTROL CIRCUIT OPEN

Turn the ignition off. Disconnect the Washer Pump Motor harness connector. Disconnect the IPM C3 harness connector. Measure the resistance of the Washer Pump Motor Control circuit.

Is the resistance above 5.0 ohms?

Yes >>

No >>

Repair the Washer Pump Motor Control circuit for an open.

Perform BODY VERIFICATION TEST - VER 1. Go To 5

8R - 12 WIPERS/WASHERS - ELECTRICAL DIAGNOSTICS DR/DH

FCM-WASHER PUMP OUTPUT CIRCUIT OPEN (CONTINUED)

POWER DISTRIBUTION CENTER

Turn the ignition off. Disconnect the FCM from the IPM. Disconnect the IPM C3 harness connector. Measure the internal resistance of the IPM Washer Pump Motor Control circuit.

Is the resistance above 5.0 ohms?

Yes >>

No >>

Replace the Power Distribution Center (PDC) in accordance with the Service Information. Perform BODY VERIFICATION TEST - VER 1.

Replace the Front Control Module (FCM) in accordance with the Service Information. Perform BODY VERIFICATION TEST - VER 1.

DR/DH WIPERS/WASHERS - ELECTRICAL DIAGNOSTICS 8R - 13

FCM-WIPER ON-OFF RELAY OUTPUT CIRCUIT HIGH

8R - 14 WIPERS/WASHERS - ELECTRICAL DIAGNOSTICS DR/DH

FCM-WIPER ON-OFF RELAY OUTPUT CIRCUIT HIGH (CONTINUED)

For the Wiper Washer system circuit diagram (Refer to 8 - ELECTRICAL/WIPERS/WASHERS - SCHEMATICS AND DIAGRAMS).

For a complete wiring diagram Refer to Section 8W.

• When Monitored:

• Set Condition:

Possible Causes

WIPER ON/OFF RELAY FRONT CONTROL MODULE POWER DISTRIBUTION CENTER

INTERMITTENT CONDITION

Turn the ignition on. With the DRBIIIT, clear all FCM DTC’s. Turn the Wipers ON than OFF. With the DRBIIIT, read the DTC information.

Does the DRBIIIT read: Wiper ON-OFF Relay Output Circuit High?

Yes >> No >>

Go To 2 The condition that caused the symptom

is currently not present. Inspect the related wiring for a possible intermittent condition. Look for any chafed, pierced, pinched, or partially broken wires.

Perform BODY VERIFICATION TEST VER 1.

DR/DH WIPERS/WASHERS - ELECTRICAL DIAGNOSTICS 8R - 15

FCM-WIPER ON-OFF RELAY OUTPUT CIRCUIT HIGH (CONTINUED)

WIPER ON/OFF RELAY

Turn the ignition off. Remove the Wiper On/Off Relay from the IPM. Turn the ignition on. Activate the Wiper Switch to all speed positions. With the DRBIIIT, read DTCs.

Does the DRBIIIT display: Wiper On/Off Relay Output Circuit High?

Yes >>

No >>

POWER DISTRIBUTION CENTER

Turn the ignition off. Remove the Wiper On/Off Relay from the IPM. Remove the FCM from the IPM. Measure the voltage between the Wiper On/Off Relay Control circuit

and ground in the IPM.

Is there any voltage present?

Yes >>

No >>

Replace the Wiper On/Off Relay in accordance with the Service Information.

Perform BODY VERIFICATION TEST - VER 1. Go To 3

Replace the Power Distribution Center (PDC) in accordance with the Service Information.

Perform BODY VERIFICATION TEST - VER 1. Replace the Front Control Module (FCM) in accordance

with the Service Information. Perform BODY VERIFICATION TEST - VER 1.

8R - 16 WIPERS/WASHERS - ELECTRICAL DIAGNOSTICS DR/DH

FCM-WIPER ON-OFF RELAY OUTPUT CIRCUIT OPEN

DR/DH WIPERS/WASHERS - ELECTRICAL DIAGNOSTICS 8R - 17

FCM-WIPER ON-OFF RELAY OUTPUT CIRCUIT OPEN (CONTINUED)

For the Wiper Washer system circuit diagram (Refer to 8 - ELECTRICAL/WIPERS/WASHERS - SCHEMATICS AND DIAGRAMS).

For a complete wiring diagram Refer to Section 8W.

• When Monitored:

With the ignition on

• Set Condition:

The FCM detects an open condition on the BUS

Possible Causes

WIPER ON/OFF RELAY FRONT CONTROL MODULE POWER DISTRIBUTION CENTER

INTERMITTENT CONDITION

Turn the ignition on. With the DRBIIIT, clear all FCM DTC’s. Turn the Wipers ON then OFF. With the DRBIIIT, read the DTC information.

Does the DRBIIIT read: Wiper ON-OFF Relay Output Circuit Open?

Yes >> No >>

Go To 2 The condition that caused the symptom

is currently not present. Inspect the related wiring for a possible intermittent condition. Look for any chafed, pierced, pinched, or partially broken wires.

Perform BODY VERIFICATION TEST VER 1.

8R - 18 WIPERS/WASHERS - ELECTRICAL DIAGNOSTICS DR/DH

FCM-WIPER ON-OFF RELAY OUTPUT CIRCUIT OPEN (CONTINUED)

WIPER ON/OFF RELAY

Turn the ignition off. Install a substitute relay in place of the Wiper On/Off Relay. Turn the ignition on. With the DRBIIIT, read DTCs.

Does the DRBIIIT display: Wiper On/Off Relay Output Circuit Open?

Yes >> No >>

POWER DISTRIBUTION CENTER

Turn the ignition off. Remove the Wiper On/Off Relay from the IPM. Remove the FCM from the IPM. Measure the resistance of the Wiper On/Off Control circuit in the IPM.

Is the resistance above 5.0 ohms?

Yes >>

No >>

Go To 3 Replace the Wiper On/Off Relay in accordance with the

Service Information. Perform BODY VERIFICATION TEST - VER 1.

Replace the Power Distribution Center (PDC ) in accordance with the Service Information. Perform BODY VERIFICATION TEST - VER 1.

Replace the Front Control Module (FCM) in accordance with the Service Information. Perform BODY VERIFICATION TEST - VER 1.

DR/DH WIPERS/WASHERS - ELECTRICAL DIAGNOSTICS 8R - 19

FCM-WIPER ON-OFF RELAY OUTPUT CIRCUIT LOW

8R - 20 WIPERS/WASHERS - ELECTRICAL DIAGNOSTICS DR/DH

FCM-WIPER ON-OFF RELAY OUTPUT CIRCUIT LOW (CONTINUED)

For the Wiper Washer system circuit diagram (Refer to 8 - ELECTRICAL/WIPERS/WASHERS - SCHEMATICS AND DIAGRAMS).

For a complete wiring diagram Refer to Section 8W.

• When Monitored:

With the ignition on

• Set Condition:

When the FCM detects a low condition in the relay

Possible Causes

WIPER ON/OFF RELAY FRONT CONTROL MODULE POWER DISTRIBUTION CENTER

INTERMITTENT CONDITION

Turn the ignition on. With the DRBIIIT, clear all FCM DTC’s. Turn the Wipers ON then OFF. With the DRBIIIT, read the DTC information.

Does the DRBIIIT read: Wiper On-Off Relay Output Circuit Low?

Yes >> No >>

Go To 2 The condition that caused the symptom

is currently not present. Inspect the related wiring for a possible intermittent condition. Look for any chafed, pierced, pinched, or partially broken wires.

Perform BODY VERIFICATION TEST VER 1.

DR/DH WIPERS/WASHERS - ELECTRICAL DIAGNOSTICS 8R - 21

FCM-WIPER ON-OFF RELAY OUTPUT CIRCUIT LOW (CONTINUED)

WIPER ON/OFF RELAY

Turn the ignition off. Install a substitute relay in place of the Wiper On/Off Relay. Turn the ignition on. With the DRBIIIT, read DTCs.

Does the DRBIIIT display: Wiper On/Off Relay Output Circuit Low?

Yes >> No >>

POWER DISTRIBUTION CENTER

Turn the ignition off. Remove the Wiper On/Off Relay. Remove the FCM from the IPM. Measure the resistance between ground and the Wiper On/Off Relay Control circuit in the IPM.

Is the resistance below 5.0 ohms?

Yes >>

No >>

Go To 3 Replace the Wiper On/Off Relay in accordance with the

Service Information. Perform BODY VERIFICATION TEST - VER 1.

Replace the Power Distribution Center (PDC) in accordance with the Service Information. Perform BODY VERIFICATION TEST - VER 1.

Replace the Front Control Module (FCM) in accordance with the Service Information. Perform BODY VERIFICATION TEST - VER 1.

8R - 22 WIPERS/WASHERS - ELECTRICAL DIAGNOSTICS DR/DH

FCM-WIPER PARK SWITCH INPUT PERFORMANCE

DR/DH WIPERS/WASHERS - ELECTRICAL DIAGNOSTICS 8R - 23

FCM-WIPER PARK SWITCH INPUT PERFORMANCE (CONTINUED)

For the Wiper Washer system circuit diagram (Refer to 8 - ELECTRICAL/WIPERS/WASHERS - SCHEMATICS AND DIAGRAMS).

For a complete wiring diagram Refer to Section 8W.

• When Monitored:

With the ignition on

• Set Condition:

The FCM detects a performance condition on the BUS

Possible Causes

WIPER MOTOR PARK SWITCH GROUND CIRCUIT OPEN WIPER MOTOR WIPER PARK SWITCH SENSE CIRCUIT SHORT TO VOLTAGE WIPER PARK SWITCH SENSE CIRCUIT SHORT TO GROUND WIPER PARK SWITCH SENSE CIRCUIT OPEN POWER DISTRIBUTION CENTER FRONT CONTROL MODULE

INTERMITTENT CONDITION

Turn the ignition on. With the DRBIIIT, clear all FCM DTC’s. Turn the Wipers ON then OFF. With the DRBIIIT, read the DTC information.

Does the DRBIIIT read: Wiper Park Switch Input Performance?

Yes >> No >>

Go To 2 The condition that caused the symptom

is currently not present. Inspect the related wiring for a possible intermittent condition. Look for any chafed, pierced, pinched, or partially broken wires.

Perform BODY VERIFICATION TEST VER 1.

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