Egr DODGE RAM 1500 1998 2.G Workshop Manual

INTEGRATED POWER MODULE C6 - BLACK 15 WAY
CAV CIRCUIT FUNCTION
1- -
2 A400 14TN/RD FUSED B(+)
3- -
4 K342 16BR/WT ASD RELAY OUTPUT
5- -
6- -
7- -
8- -
9- -
10 A961 14RD (DIESEL) FUEL HEATER RELAY OUTPUT
10 C123 16LB/WT (NGC) CONDENSER FAN RELAY OUTPUT
11 A960 14RD (DIESEL) FUSED B(+)
11 A16 16RD/BR (NGC) FUSED B(+)
12 F982 14PK/YL FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
13 - -
14 T16 18YL/OR TRANSMISSION CONTROL RELAY OUTPUT
15 - -
INTEGRATED POWER MODULE C7 - GRAY 26 WAY
CAV CIRCUIT FUNCTION
1 T750 14YL/GY STARTER MOTOR RELAY OUTPUT
2 W3 16BR/WT WIPER RELAY LOW SPEED OUTPUT
3 F983 20PK/YL FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
4 A930 18RD FUSED B(+)
5- -
6 L43 18WT/DB LEFT LOW BEAM OUTPUT
7 L34 18WT/GY RIGHT HIGH BEAM OUTPUT
8- -
9 A109 16OR/RD (GAS) FUEL PUMP RELAY OUTPUT
10 - -
11 K51 20BR/WT (GAS) ASD RELAY CONTROL
13 - -
14 - -
15 L33 18WT/LG LEFT HIGH BEAM OUTPUT
16 - -
16 A72 18RD/OR ADJUSTABLE PEDAL RELAY OUTPUT
17 - -
17 C15 16DB/WT REAR WINDOW DEFOGGER RELAY OUTPUT
18 - -
19 K31 20BR FUEL PUMP RELAY CONTROL
20 - -
20 L89 18WT/YL (FOG LAMPS) FOG LAMP RELAY OUTPUT
21 T751 16YL FUSED IGNITION SWITCH OUTPUT (START)
22 L44 18WT/TN RIGHT LOW BEAM OUTPUT
23 T41 20YL/DB (EXCEPT NGC) TRS T41 SENSE
23 T752 20DG/OR (NGC) STARTER RELAY CONTROL
24 A944 20RD FUSED B(+)
26 - -
8W - 80 - 76 8W-80 CONNECTOR PIN-OUTSDR

POWERTRAIN CONTROL MODULE C2 (NGC) - ORANGE 38 WAY
CAV CIRCUIT FUNCTION
1 K10 18DB/OR COIL CONTROL NO. 6
2 K16 18DB/YL COIL CONTROL NO. 5
3 K15 18DB/GY COIL CONTROL NO. 4
4 K58 18BR/VT INJECTOR CONTROL NO. 6
5 K38 18BR/OR INJECTOR CONTROL NO. 5
6 K447 18TN/YL (5.7L) ETC MOTOR (+)
7 K18 18DB/OR COIL CONTROL NO. 3
8 K35 18DB/VT (5.7L LIGHT DUTY) EGR SOLENOID CONTROL
9 K17 18DB/TN COIL CONTROL NO. 2
10 K19 18DB/DG COIL CONTROL NO. 1
11 K14 18BR/TN INJECTOR CONTROL NO. 4
12 K13 18BR/LB INJECTOR CONTROL NO. 3
13 K12 18BR/DB INJECTOR CONTROL NO. 2
14 K11 18BR/YL INJECTOR CONTROL NO. 1
15 K922 18BR/DB (5.7L) THROTTLE POSITION SENSOR GROUND
16 - -
17 K199 18BR/VT O2 2/1 HEATER CONTROL
18 K99 18BR/LG O2 1/1 HEATER CONTROL
19 K20 18BR/GY GEN FIELD CONTROL
20 K2 18VT/OR ECT SIGNAL
21 K22 18BR/OR TP NO. 1 SIGNAL
22 K34 18DB/LG (5.7L LIGHT DUTY) EGR SENSOR SIGNAL
23 K1 18VT/BR MAP SIGNAL
24 K942 18BR/LG (EXCEPT 4.7L) KNOCK SENSOR NO. 1 RETURN
25 K42 18DB/YL (EXCEPT 4.7L) KNOCK SENSOR NO. 1 SIGNAL
26 - -
27 K900 18DB/DG SENSOR GROUND
28 K122 18BR/DG (5.7L) TP NO. 2 SIGNAL
28 K961 18BR/VT (EXCEPT 5.7L) IAC RETURN
29 F855 18PK/YL 5 VOLT SUPPLY
30 K21 18DB/LG IAT SIGNAL
31 K41 18DB/LB O2 1/1 SIGNAL
32 K904 18DB/DG O2 RETURN (DOWN)
33 K43 18DB/LG O2 2/1 SIGNAL
34 K44 20DB/GY CMP SIGNAL
35 K24 20BR/LB CKP SIGNAL
36 K242 18BR/WT (EXCEPT 4.7L) KNOCK SENSOR NO. 2 SIGNAL
37 K924 18WT/BR (EXCEPT 4.7L) KNOCK SENSOR NO. 2 RETURN
38 K448 18TN/OR (5.7L) ETC MOTOR (-)
38 K61 18VT/GY (EXCEPT 5.7L) IAC MOTOR CONTROL
DR8W-80 CONNECTOR PIN-OUTS 8W - 80 - 89

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Battery Temperature Sensor BK Below Battery Tray 22, 25, 26, 28
Blend Door Actuator (Single Zone) BK Behind Right Side of Instrument
PanelN/S
Blower Motor BK Behind Right Side of Instrument
PanelN/S
Blower Motor Resistor Block BK Behind Right Side of Instrument
PanelN/S
Brake Lamp Switch BK Top of Brake Pedal Arm 30, 35, 38
Brake Transmission Shift Interlock
SolenoidBK Near Steering Column 31, 35, 38
C102 Near Integrated Power Module 25
C106 BK Left Rear Engine 7
C107 (5.7L) BK Left Rear Engine 7
C112 (Diesel) BK Near T/O for Water In Fuel Sensor N/S
C113 BK Left Side Engine 10
C114 BK Left side Engine 10
C115 (Diesel) BK Left Side Engine 10
C130 BK Left Rear of Engine 4, 8, 21
C131 Right Rear Engine Compartment 4, 8, 21
C200 GY Under Instrument Panel 39
C201 WT Near Left Instrument Panel
Speaker35, 38
C202 BK Left Rear Side of Engine
Compartment27
C206 BK Right Instrument Panel 35, 39, 48
C207 Rear Engine Compartment 22
C216 BK Middle Left Frame 22, 25, 50
C217 BK Middle Left Frame 22, 25, 50
C218 WT Left Side of Instrument Panel 22, 24, 40, 44, 46
C219 GY Left Side of Instrument Panel 22, 24, 31, 35, 38, 40,
44
C220 WT Left Side of Instrument Panel 35, 38, 40, 44, 46
C250 Seft Side Instrument Panel 35
C301 WT Right Kick Panel 40, 42, 45, 47
C302 BK Left Front Door 40, 42, 45, 47
C304 WT Left Side of Instrument Panel 41, 44, 46
C305 BK At Left Front Door 41, 44, 46
C306 WT Middle Front of Door 43, 46
C308 WT Under Instrument Panel 39, 40, 45, 47
C309 WT Left Side of Instrument Panel 35, 38, 40, 44, 46
C311 BK Left Rear of Frame 44, 46
C312 WT Under Seat 47
C313 DK GY At Driver Seat N/S
C314 DK GY At Driver Seat N/S
8W - 91 - 2 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONDR
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Data Link Connector - Engine
(Diesel)BK Near T/O for Water In Fuel Sensor N/S
Dome Lamp BK Center of Headliner N/S
Door Ajar Switch-Driver (Base) BK Left Front Door 41
Door Ajar Switch-Left Rear (Base) BK Left Rear Door 43
Door Ajar Switch-Right Rear (Base) BK Right Rear Door 43
Door Lock Motor/Ajar Switch-Driver
(Except Base)BK Left Front Door 41
Door Lock Motor/Ajar Switch-Left
Rear (Except Base)BK Left Rear Door 43
Door Lock Motor/Ajar Switch-
PassengerBK Right Front Door 42
Door Lock Motor/Ajar Switch-Right
Rear (Except Base)BK Right Rear Door 43
Door Lock Switch-Passenger BL In Right Front Door 42
Driver Airbag Squib BK In Steering Column N/S
Driver Blend Door Actuator (Dual
Zone)BK Right Side of HVAC N/S
Driver Door Module C1 BL In Left Front Door 41
Driver Door Module C2 BL In Left Front Door 41
EGR Solenoid Right Front Engine 9
Electric Brake Provision Rear of Engine 22, 24
Engine Control Module C1 BK Left Engine 10
Engine Control Module C2 BK Left Engine 10
Engine Coolant Temperature
SensorBK Near Generator 6
Engine Oil Pressure Switch BK Lower Left Side of Engine 6, 9
Evap/Purge Solenoid BK Left Fender Side Shield 23, 25
Evaporator Temperature Sensor BK Right Side of HVAC N/S
Fog Lamp-Left WT Left Front Facia N/S
Fog Lamp-Right WT Right Front Facia N/S
Fuel Control Actuator (Diesel) BK Left Rear Engine N/S
Fuel Heater (Diesel) BK Left Side Engine 10
Fuel Injector No. 1 BK At Fuel Injector 6
Fuel Injector No. 2 BK At Fuel Injector 3
Fuel Injector No. 3 BK At Fuel Injector 6
Fuel Injector No. 4 BK At Fuel Injector 3
Fuel Injector No. 5 BK At Fuel Injector 6
Fuel Injector No. 6 BK At Fuel Injector 3
Fuel Injector No. 7 BK At Fuel Injector 6
Fuel Injector No. 8 BK At Fuel Injector 3
Fuel Pump Module LT GY At Fuel Tank 50
Fuel Pump Motor (Diesel) BK Left Side Engine 10
Generator BK Front of Engine 6, 9, 10
8W - 91 - 4 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONDR
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Glove Box Lamp and Switch BK At Glove Box 35, 39
Governor Pressure Sensor BK Left Rear of Transmission N/S
Hands Free Module Right Instrument Panel 39
Headlamp Switch BK Left Side of Instrument Panel 32, 35, 38
Headlamp-Left BL At Headlamp 23, 28, 29
Headlamp-Right BL At Headlamp 1, 21, 26
Heated Seat Cushion - Driver BL Under Driver Seat N/S
Heated Seat Cushion - Passenger BL Under Passenger Seat N/S
Heated Seat Switch-Driver RD Center of Instrument Panel 33, 35, 36
Heated Seat Switch-Passenger BL Center of Instrument Panel 33, 35, 36
Horn Switch WT In Steering Wheel N/S
Horn-High Note BK Left Front Fender 23, 28, 29
Horn-Low Note BK Left Front Fender 23, 29
Idle Air Control Motor BK On Throttle Body 6
Ignition Coil GY Left Rear of Engine N/S
Ignition Switch BK Steering Column 31
Inlet Air Temperature/Pressure
SensorBK Right Side Engine 10
Input Speed Sensor BK At Transmission 15, 16
Instrument Cluster C1 GY Rear of Instrument Cluster 35
Instrument Cluster C2 GY Rear of Instrument Cluster 35
Instrument Cluster C3 WT Rear of Instrument Cluster 35
Intake Air Heater Relay Right Engine Compartment 2
Intake Air Temperature/Manifold
Absolute Pressure Sensor (Diesel)BK Left rear Engine N/S
Intake Air Temperature Sensor BK On Intake Manifold 5
Integrated Power Module C1 BK Left Front Fender 26, 28
Integrated Power Module C2 WT Left Front Fender 26, 28
Integrated Power Module C3 GR Left Front Fender 26, 28
Integrated Power Module C4 WT Left Front Fender 26, 28
Integrated Power Module C5 BK Left Front Fender 26, 28
Integrated Power Module C6 BK Left Front Fender 25, 26, 28
Integrated Power Module C7 GY Left Front Fender 26, 28
Integrated Power Module FCM BK In IPM N/S
Knock Sensor BK Left Rear of Engine 5, 7, 9
License Lamp-Left BK At Rear Bumper 50, 51
License Lamp-Right BK At Rear Bumper 50, 51
Lift Pump Motor BK Near T/O for WIF Sensor N/S
Line Pressure Sensor BK Right Rear of Transmission 15, 18
Lumbar Motor-Driver DK GY At Driver Seat N/S
Lumbar Motor-Passenger BK At Passenger Seat N/S
Manifold Absolute Pressure Sensor GY Left Front of Intake Manifold 6
Mode Door Actuator 1 BK Right Side of HVAC N/S
DR8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 5
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

SPLICE
NUMBERLOCATION FIG.
S176 Left Side Engine Near T/O for Fuel Control Actuator N/S
S187 Rear of Engine 7
S191 Near Integrated Power Module 23
S203 Right Side Engine Compartment 23
S204 Left Side of Instrument Panel 35
S205 Left Side of Instrument Panel 35
S206 At Steering Column N/S
S207 At Steering Column N/S
S209 Center of Instrument Panel 35
S210 Center of Instrument Panel 35, 38
S212 Left Side of Instrument Panel 31, 38
S214 Left Side of Instrument Panel 31, 38
S216 Center of Instrument Panel 35, 36
S217 Left Side of Instrument Panel N/S
S218 Left Side of Instrument Panel N/S
S219 Center of Instrument Panel N/S
S220 Center of Instrument Panel N/S
S221 Center of Instrument Panel 35, 39
S222 Center of Instrument Panel 35
S224 Right Side of HVAC N/S
S225 Center of Instrument Panel 35
S226 Right Side of HVAC N/S
S228 At Steering Column N/S
S230 Right Instrument Panel 35
S231 Left Instrument Panel 38
S232 Right Engine Compartment 23
S240 Steering Column 31, 38
S241 Center Instrument Panel 35, 36
S243 Right Engine Compartment 23
S245 Left Instrument Panel 35
S300 Left Kick Panel 40, 44, 46
S301 Center of Headliner N/S
S302 Center of Headliner N/S
S303 Middle of Roof 48
S304 Center of Headliner N/S
S305 Middle of Roof 48
S306 Left Side of Frame N/S
S307 Center of Headliner N/S
S308 Left Rear Chassis 50, 51
S309 Center Rear of Chassis 51
S311 Left Front of Body 44, 46
DR8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 11
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

Fig. 28 INTEGRATED POWER MODULE AND FAN
8W - 91 - 38 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONDR
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

8W-97 POWER DISTRIBUTION
TABLE OF CONTENTS
page page
POWER DISTRIBUTION
DESCRIPTION..........................1
OPERATION............................1
SPECIAL TOOLS
POWER DISTRIBUTION SYSTEMS.........2
CIGAR LIGHTER OUTLET
DESCRIPTION..........................2
OPERATION............................2
DIAGNOSIS AND TESTING - CIGAR LIGHTER
OUTLET.............................2
INTEGRATED POWER MODULE
DESCRIPTION..........................3
OPERATION............................3
REMOVAL.............................3
INSTALLATION..........................4
FRONT CONTROL MODULE
DESCRIPTION..........................5OPERATION............................5
DIAGNOSIS AND TESTING - FRONT
CONTROL MODULE....................5
REMOVAL.............................6
INSTALLATION..........................6
IOD FUSE
DESCRIPTION..........................6
OPERATION............................6
REMOVAL.............................7
INSTALLATION..........................7
POWER OUTLET
DESCRIPTION..........................7
OPERATION............................7
DIAGNOSIS AND TESTING - POWER
OUTLET.............................7
REMOVAL.............................8
INSTALLATION..........................8
POWER DISTRIBUTION
DESCRIPTION
This group covers the various standard and
optional power distribution components used on this
model. The power distribution system for this vehicle
consists of the following components:
²Integrated Power Module (IPM)
²Front Control Module (FCM)
²Power Distribution Center (PDC)
²Power Outlets
²Cigar Lighter Outlets
²Relays
Refer to Wiring Diagrams for complete circuit sche-
matics.
The power distribution system also incorporates
various types of circuit control and protection fea-
tures, including:
²Automatic resetting circuit breakers
²Blade-type fuses
²Cartridge fuses
²Relays
Following are general descriptions of the major
components in the power distribution system. See the
owner's manual in the vehicle glove box for more
information on the features and use of all of the
power distribution system components.
OPERATION
The power distribution system for this vehicle is
designed to provide safe, reliable, and centralized dis-
tribution points for the electrical current required to
operate all of the many standard and optional facto-
ry-installed electrical and electronic powertrain,
chassis, safety, security, comfort and convenience sys-
tems. At the same time, the power distribution sys-
tem was designed to provide ready access to these
electrical distribution points for the vehicle techni-
cian to use when conducting diagnosis and repair of
faulty circuits. The power distribution system can
also prove useful for the sourcing of additional elec-
trical circuits that may be required to provide the
electrical current needed to operate many accessories
that the vehicle owner may choose to have installed
in the aftermarket.
DR8W-97 POWER DISTRIBUTION 8W - 97 - 1

SPECIAL TOOLS
POWER DISTRIBUTION SYSTEMS
CIGAR LIGHTER OUTLET
DESCRIPTION
On models equipped a cigar lighter outlet is
installed to the left of the center stack area in the
lower instrument panel. The cigar lighter outlet is
secured by a snap fit within the bezel.
The cigar lighter outlet, plastic cap and the knob
and heating element unit are available for service
replacement. These components cannot be repaired
and, if faulty or damaged, they must be replaced.
OPERATION
The cigar lighter consists of two major components:
a knob and heating element unit, and the cigar
lighter base or outlet shell. The receptacle shell is
connected to ground, and an insulated contact in the
bottom of the shell is connected to battery current.
The cigar lighter receives battery voltage from a fuse
in the junction block when the ignition switch is in
the Accessory or Run positions.
The cigar lighter knob and heating element are
encased within a spring-loaded housing, which also
features a sliding protective heat shield. When the
knob and heating element are inserted in the outlet
shell, the heating element resistor coil is grounded
through its housing to the outlet shell. If the cigar
lighter knob is pushed inward, the heat shield slides
up toward the knob exposing the heating element,
and the heating element extends from the housing
toward the insulated contact in the bottom of the
outlet shell.
Two small spring-clip retainers are located on
either side of the insulated contact inside the bottom
of the outlet shell. These clips engage and hold the
heating element against the insulated contact longenough for the resistor coil to heat up. When the
heating element is engaged with the contact, battery
current can flow through the resistor coil to ground,
causing the resistor coil to heat.
When the resistor coil becomes sufficiently heated,
excess heat radiates from the heating element caus-
ing the spring-clips to expand. Once the spring-clips
expand far enough to release the heating element,
the spring-loaded housing forces the knob and heat-
ing element to pop back outward to their relaxed
position. When the cigar lighter knob and element
are pulled out of the outlet shell, the protective heat
shield slides downward on the housing so that the
heating element is recessed and shielded around its
circumference for safety.
DIAGNOSIS AND TESTING - CIGAR LIGHTER
OUTLET
For complete circuit diagrams, refer toWiring
Diagrams.
(1) Check the fused B(+) fuse in the integrated
power module. If OK, go to Step 2. If not OK, repair
the shorted circuit or component as required and
replace the faulty fuse.
(2) Turn the ignition switch to the Run position.
Check for battery voltage at the fused B(+) fuse in
the integrated power module. If OK, go to Step 3. If
not OK, repair the open or short as required.
(3) Remove the cigar lighter knob and element
from the cigar lighter outlet shell. Check for continu-
ity between the inside circumference of the cigar
lighter outlet shell and a good ground. there should
be continuity. If OK, go to Step 4. If not OK, go to
Step 5.
(4) Turn the ignition switch to the Run position.
Check for battery voltage at the insulated contact
located at the back of the cigar lighter outlet shell. If
OK, replace the faulty cigar lighter knob and ele-
ment. If not OK, go to Step 5.
(5) Turn the ignition switch to the Off position.
Disconnect and isolate the battery negative cable.
Check for continuity between the ground circuit cav-
ity of the cigar lighter wire harness connector and a
good ground. There should be continuity. If OK, go to
Step 6. If not OK, repair the open ground circuit to
ground as required.
(6) Connect the battery negative cable. Turn the
ignition switch to the Accessory or Run positions.
Check for battery voltage at the fused B(+) circuit
cavity of the cigar lighter wire harness connector. If
OK, replace the faulty cigar lighter outlet. If not OK,
repair the open fused B(+) circuit to the integrated
power module fuse as required.Terminal Pick Kit 6680
8W - 97 - 2 8W-97 POWER DISTRIBUTIONDR
POWER DISTRIBUTION (Continued)

INTEGRATED POWER MODULE
DESCRIPTION
The Integrated Power Module (IPM) (Fig. 1) is a
combination of the Power Distribution Center (PDC)
and the Front Control Module (FCM). The IPM is
located in the engine compartment, next to the bat-
tery on this model. The power distribution center
mates directly with the Front Control Module (FCM)
to form the Integrated Power Module Fuse and Relay
Center. The power distribution center (PDC) is a
printed circuit board based module that contains
fuses and relays, while the front control module con-
tains the electronics controlling the integrated power
module and other functions. This integrated power
module connects directly to the battery positive via a
stud located on top of the unit. The ground connec-
tion is via electrical connectors. The integrated power
module provides the primary means of voltage distri-
bution and protection for the entire vehicle.
The molded plastic integrated power module hous-
ing includes a base and cover. The integrated power
module cover is easily opened or removed for service
access by unscrewing the cover retaining nut and has
a fuse and relay layout map integral to the inside
surface of the cover. This integrated power module
housing base and cover are secured in place via bolts
to the left front fender support assembly.
Replaceable components of the integrated power
module assembly are broken down into the followingcomponents: the Power Distribution Center (PDC),
the integrated power module cover, the Front Control
Module (FCM) and the Integrated Power Module
Assembly which includes the power distribution cen-
ter, the cover and FCM.Refer to the Front Con-
trol Module in the Electronic Control Module
sectionof this service manual for information on the
front control module.
OPERATION
All of the current from the battery and the gener-
ator output enters the integrated power module via a
stud on the top of the module. The integrated power
module cover is removed to access the fuses or relays.
Internal connections of all of the power distribution
center circuits is accomplished by a combination of
bus bars and a printed circuit board. Refer to the
Wiring section of the service manual for complete
integrated power module circuit schematics.
REMOVAL
(1) Disconnect the negative and positive battery
cables.
(2) Unsnap cover and remove the B+ terminal nut
from the integrated power module B+ terminal.
Remove the B+ cable from the integrated power mod-
ule.
(3) Disconnect the gray connector from the inte-
grated power module.
Fig. 1 DR INTEGRATED POWER MODULE
1 - POWER DISTRIBUTION CENTER HOUSING
2 - FRONT CONTROL MODULE ELECTRICAL CONNECTOR
Fig. 2 DR INTEGRATED POWER MODULE
1 - COVER RETAINING BOLT
2 - INTEGRATED POWER MODULE RETAINING BOLT
3 - RETAINING SCREW
4 - INTEGRATED POWER MODULE COVER
DR8W-97 POWER DISTRIBUTION 8W - 97 - 3