Battery group DODGE RAM 1500 1998 2.G User Guide

NOTE: If a new module has been installed, the com-
pass will have to be calibrated and the variance set.
Refer to Compass Variation Adjustment and Com-
pass Calibration in the Standard Procedures sec-
tion of this group for the procedures.
ELECTRONIC VEHICLE INFO
CENTER
DESCRIPTION
The Electronic Vehicle Information Center (EVIC)
is a module located in the overhead console on some
models. The EVIC module features a large Vacuum
Fluorescent Display (VFD) screen for displaying
information, and back-lit push button switches
labeled C/T (compass/temperature), RESET, STEP,
and MENU.
The EVIC module contains a central processing
unit and interfaces with other electronic modules in
the vehicle over the Programmable Communications
Interface (PCI) J1850 data bus circuit. The PCI data
bus circuit allows the sharing of sensor information.
This helps to reduce wire harness complexity, reduce
internal controller hardware, and reduce component
sensor current loads. At the same time, this system
provides increased reliability, enhanced diagnostics,
and allows the addition of many new feature capabil-
ities.The EVIC ªMenuº push button provides the vehicle
operator with a user interface, which allows the
selection of several optional customer programmable
electronic features to suit individual preferences.
Refer toELECTRONIC VEHICLE INFORMA-
TION CENTER PROGRAMMINGin the Standard
Procedures section of this group for more information
on the customer programmable feature options.
If the vehicle is equipped with the optional univer-
sal transmitter transceiver, the EVIC will also dis-
play messages and an icon indicating when the
universal transmitter transceiver is being trained,
which of the three transmitter buttons is transmit-
ting, and when the transceiver is cleared.
Data input for all EVIC functions, including VFD
dimming level, is received through the J1850 PCI
data bus circuit. The EVIC module uses its internal
programming and all of its data inputs to calculate
and display the requested data. If the data displayed
is incorrect, perform the self-diagnostic tests as
described in this group. If these tests prove inconclu-
sive, the use of a DRB IIItscan tool and the proper
Diagnostic Procedures manual are recommended for
further testing of the EVIC module and the J1850
PCI data bus circuit.
The EVIC module cannot be repaired, and is avail-
able for service only as a unit. If any part is faulty or
damaged, the complete EVIC module must be
replaced.
OPERATION
The Electronic Vehicle Information Center is wired
to both constant 12v and ignition switched sources of
battery current so that some of its features remain
operational at any time, while others may only oper-
ate with the ignition switch in the On position. When
the ignition switch is turned to the On position, the
EVIC module display will return to the last function
being displayed before the ignition was turned to the
Off position.
The compass/temperature display is the normal
EVIC display. With the ignition switch in the On
position, momentarily depressing and releasing the
C/T (compass/temperature) push button switch will
cause the EVIC to return to the compass/tempera-
ture display mode from any other mode. While in the
compass/temperature display mode, momentarily
depressing and releasing the Step push button will
step through the available trip computer display
options.
The EVIC trip computer features several functions
that can be reset. The functions that can be reset
are: average fuel economy, trip odometer and elapsed
time. With the ignition switch in the On position and
with one of the functions of the trip computer that
can be reset currently displayed, depressing the
Fig. 5 OVERHEAD CONSOLE MODULE REMOVAL
1 - COMPASS MINI-TRIP COMPUTER MODULE
2 - OVERHEAD CONSOLE
DRMESSAGE SYSTEMS 8M - 7
COMPASS/MINI-TRIP COMPUTER (Continued)

(2) Install the screws holding the EVIC module in
the overhead console.
(3) Connect the EVIC module electrical connector.
(4) Install the overhead console on the headlin-
er(Refer to 8 - ELECTRICAL/OVERHEAD CON-
SOLE - INSTALLATION).
(5) Connect the battery negative cable.
(6) Check EVIC module function.
NOTE: If a new EVIC module has been installed, the
compass will have to be calibrated and the variance
set. Refer to Compass Variation Adjustment and
Compass Calibration in the Standard Procedures
section of this group for the procedures.
AMBIENT TEMP SENSOR
DESCRIPTION
Ambient air temperature is monitored by the over-
head console. The ambient temperature messages are
received from the Front Control Module (FCM) over
the Programmable Communications Interface (PCI)
J1850 data bus circuit. The FCM receives a hard
wired input from the ambient temperature sensor
(Fig. 7). The ambient temperature sensor is a vari-
able resistor mounted to the underside of the hood,
in the engine compartment.
For more information on the front control module,
refer toFront Control Modulein the Electronic
Control Modules section of this manual. For complete
circuit diagrams, refer toWiring. The ambient tem-
perature sensor cannot be adjusted or repaired and,
if faulty or damaged, it must be replaced.
OPERATION
The ambient temperature sensor is a variable
resistor that operates on a five-volt reference signal
sent to it by the Front Control Module. The resis-
tance in the sensor changes as temperature changes,
changing the temperature sensor signal circuit volt-
age to the Front Control Module. Based upon the
resistance in the sensor, the Front Control Modulesenses a specific voltage on the temperature sensor
signal circuit, which it is programmed to correspond
to a specific temperature. The Front Control Module
then sends the proper ambient temperature mes-
sages to the EVIC, CMTC over the PCI J1850 data
bus.
The temperature function is supported by the
ambient temperature sensor, a wiring circuit, the
Front Control Module, the Programmable Communi-
cations Interface (PCI) data bus, and a portion of the
Electronics module. If any portion of the ambient
temperature sensor circuit fails, the Front Control
Module will self-diagnose the circuit.
For complete circuit diagrams, refer toWiring.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - AMBIENT
TEMPERATURE SENSOR
(1) Turn the ignition switch to the Off position.
Disconnect and isolate the battery negative cable.
Disconnect the ambient temperature sensor wire har-
ness connector.
(2) Measure the resistance of the ambient temper-
ature sensor. At 24É C (75É F), the sensor resistance
should be approximately 10.3 kilohms. At 30É C (86É
F), the sensor resistance should be approximately
7.57 kilohms. The sensor resistance should decrease
as the temperature rises. If OK, refer toDiagnosis
and Testing - Ambient Temperature Sensor Cir-
cuitin this group. If not OK, replace the faulty
ambient temperature sensor.
NOTE: The ambient temperature sensor is a very
sensitive device. When testing, be certain the tem-
perature sensor has had time to stabilize (room
temperature) before attempting to read the sensor
resistance. Failure to let the ambient temperature
sensor temperature stabilize could result in a mis-
leading test.
DIAGNOSIS AND TESTING - AMBIENT
TEMPERATURE SENSOR CIRCUIT
(1) Turn the ignition switch to the Off position.
Disconnect and isolate the battery negative cable.
Disconnect the ambient temperature sensor wire har-
ness connector and the Front Control Module wire
harness connector.
(2) Connect a jumper wire between the two termi-
nals of the ambient temperature sensor wire harness
connector.
(3) Check for continuity between the sensor return
circuit and the ambient temperature sensor signal
circuit cavities of the Front Control Module wire har-
Fig. 7 Ambient Temperature Sensor - Typical
8M - 10 MESSAGE SYSTEMSDR
ELECTRONIC VEHICLE INFO CENTER (Continued)

ness connector. There should be continuity. If OK, go
to Step 4. If not OK, repair the open sensor return or
signal circuit as required.
(4) Remove the jumper wire from the ambient tem-
perature sensor wire harness connector. Check for
continuity between the sensor return circuit cavity of
the Front Control Module wire harness connector
and a good ground. There should be no continuity. If
OK, go to Step 5. If not OK, repair the shorted sen-
sor return circuit as required.
(5) Check for continuity between the ambient tem-
perature sensor signal circuit cavity of the Front
Control Module wire harness connector and a good
ground. There should be no continuity. If OK, refer to
Diagnosis and Testing - Overhead Consolein
this group. If not OK, repair the shorted ambient
temperature sensor signal circuit as required.
REMOVAL
(1) Open the hood.
(2) Disconnect and isolate the battery negative
cable.
(3) Working on the underside of the hood, remove
screw holding sensor to hood panel.
(4) Disconnect the sensor electrical connector and
remove sensor from vehicle.
INSTALLATION
(1) Connect the sensor electrical connector.
(2) Working on the underside of the hood, install
screw holding sensor to hood panel.
(3) Connect the battery negative cable.
(4) Close the hood.
UNIVERSAL TRANSMITTER
DESCRIPTION
Some DR models are equipped with a universal
transmitter transceiver. The universal transmitter is
integral to the Electronic Vehicle Information Center
(EVIC) and the Compass Mini-Trip Computer
(CMTC), which is located in the overhead console.
The only visible component of the universal transmit-
ter are the three transmitter push buttons centered
between the modules push buttons located just rear-
ward of the display screen in the overhead console.
The three universal transmitter push buttons are
identified with one, two or three light indicators so
that they be easily identified.
Each of the three universal transmitter push but-
tons control an independent radio transmitter chan-
nel. Each of these three channels can be trained to
transmit a different radio frequency signal for the
remote operation of garage door openers, motorized
gate openers, home or office lighting, security sys-tems or just about any other device that can be
equipped with a radio receiver in the 286 to 399
MegaHertz (MHz) frequency range for remote opera-
tion. The universal transmitter is capable of operat-
ing systems using either rolling code or non-rolling
code technology.
The electronics module displays messages and a
small house-shaped icon with one, two or three dots
corresponding to the three transmitter buttons to
indicate the status of the universal transmitter. The
EVIC messages are:
²Clearing Channels- Indicates that all of the
transmitter codes stored in the universal transmitter
have been successfully cleared.
²Channel ªXº Training- Indicates that the uni-
versal transmitter is in its transmitter learning
mode.
²Channel ªXº Trained- Indicates that the uni-
versal transmitter has successfully acquired a new
transmitter code.
²Channel ªXº Transmitting- Indicates that a
trained universal transmitter button has been
depressed and that the universal transmitter is
transmitting.
The universal transmitter cannot be repaired, and
is available for service only as a unit with the EVIC
or CMTC modules. If any part of the universal trans-
mitter is faulty or damaged, the complete EVIC or
CMTC module must be replaced.
OPERATION
The universal transmitter operates on a non-
switched source of battery current so the unit will
remain functional, regardless of the ignition switch
position. For more information on the features, pro-
gramming procedures and operation of the universal
transmitter, see the owner's manual in the vehicle
glove box.
DIAGNOSIS AND TESTING - UNIVERSAL
TRANSMITTER
If the Universal Transmitter is inoperative, but the
Electronic Vehicle Information Center (EVIC) is oper-
ating normally, see the owner's manual in the vehicle
glove box for instructions on training the Transmit-
ter. Retrain the Transmitter with a known good
transmitter as instructed in the owner's manual and
test the Transmitter operation again. If the unit is
still inoperative, test the universal transmitter with
Radio Frequency Detector special tool. If both the
Transmitter and the EVIC module are inoperative,
refer toElectronic Vehicle Information Center
Diagnosis and Testingin this group for further
diagnosis. For complete circuit diagrams, refer to
Wiring Diagrams. (Fig. 8) as described below:
DRMESSAGE SYSTEMS 8M - 11
AMBIENT TEMP SENSOR (Continued)

DRIVER SEAT SWITCH
DESCRIPTION
The power seat on this model can be adjusted in
eight different directions, up, down, front up, front
down, rear up, rear down, rearward and forward.
The power seat switch (Fig. 1) on this model has an
additional switch knob for adjusting the power lum-
bar support. The power seat switch is located on the
outboard side of the seat cushion on the seat cushion
side shield. Refer to the owner's manual in the vehi-
cle glove box for more information on the power seat
switch functions and the seat adjusting procedures.
The individual switches in the power seat switch
assembly cannot be repaired. If one switch is dam-
aged or faulty, the entire power seat switch assembly
must be replaced.
OPERATION
When a power switch control knob or knobs are
actuated, a battery feed and a ground path are
applied through the switch contacts to the power seat
track or recliner adjuster motor. The selected
adjuster motor operates to move the seat track or
recliner through its drive unit in the selected direc-
tion until the switch is released, or until the travel
limit of the adjuster is reached. When the switch ismoved in the opposite direction, the battery feed and
ground path to the motor are reversed through the
switch contacts. This causes the adjuster motor to
run in the opposite direction.
No power seat switch should be held applied in any
direction after the adjuster has reached its travel
limit. The power seat adjuster motors each contain a
self-resetting circuit breaker to protect them from
overload. However, consecutive or frequent resetting
of the circuit breaker must not be allowed to con-
tinue, or the motor may be damaged.
DIAGNOSIS AND TESTING - DRIVER SEAT
SWITCH
For circuit descriptions and diagrams, refer to Wir-
ing.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the power seat switch from the power
seat.
(3) Use an ohmmeter to test the continuity of the
power seat switches in each position. See the Power
Seat Switch Continuity chart (Fig. 2). If OK, refer to
Power Seat Track Diagnosis and Testing in this
group. If not OK, replace the faulty power seat
switch.
DRIVER POWER SEAT SWITCH TEST TABLE
DRIVER SWITCH
POSITIONCONTINUITY BETWEEN
OFF B-N, B-J, B-M
B-E, B-L, B-K
VERTICAL UP A-E, A-M, B-N, B-J
VERTICAL DOWN A-J, A-N, B-M, B-E
Fig. 1 DR Power Seat Switch
1 - POWER SEAT SWITCH ASSEMBLY
2 - FRONT SEAT CUSHION ADJUSTMENT BUTTON
3 - COMPLETE SEAT ADJUSTMENT BUTTON
4 - REAR SEAT CUSHION ADJUSTMENT BUTTON
5 - LUMBAR ADJUSTMENT BUTTON
Fig. 2 Testing Driver Power Seat Switch
8N - 14 POWER SEATSDR

DIAGNOSIS AND TESTING - PASSENGER SEAT
SWITCH
For circuit descriptions and diagrams, refer to Wir-
ing.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the power seat switch from the power
seat.
(3) Use an ohmmeter to test the continuity of the
power seat switches in each position. See the Power
Seat Switch Continuity chart (Fig. 4). If OK, refer to
Power Seat Track Diagnosis and Testing in this
group. If not OK, replace the faulty power seat
switch.
PASSENGER SEAT SWITCH TEST TABLE
PASSENGER SWITCH
POSITIONCONTINUITY BETWEEN
OFF B-N, B-J, B-M
B-E, B-L, B-K
VERTICAL DOWN A-E, A-M, B-N, B-E
VERTICAL UP A-J, A-N, B-M, B-E
HORIZONTAL
FORWARDA-L, B-K
HORIZONTAL
REARWARDA-K, B-L
FRONT TILT DOWN A-M, B-N
FRONT TILT UP A-N, B-M
REAR TILT DOWN A-E, B-J
REAR TILT UP A-J, B-E
LUMBAR OFF O-P, O-R, P-R
LUMPAR UP (DEFLATE) O-P, Q-R
LUMBAR DOWN
(INFLATE)O-R, P-Q
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the seat cushion side shield from the
seat. Refer to the Body section of the service manual
for the procedure.
(3) Pull the switch bezel or side shield unit out
from the seat far enough to access the switch wire
harness connector. Gently pry the locking tabs of the
switch away from the wire harness connector and
carefully unplug the connector from the power seat
switch module.
(4) Remove the screws that secure the power seat
switch.
INSTALLATION
(1) Position the power seat switch on the seat
cushion bezel and install the screws that secure the
power seat switch to seat cushion side bezel.
(2) Connect the electrical connector.
(3) Install the seat cushion switch bezel on the
seat. Refer to the Body section of the service manual
for the procedure.
(4) If equipped, install the screw that secures the
recliner lever to the recliner mechanism release shaft
on the outboard side of the front seat.
(5) Connect the battery negative cable.
POWER SEAT TRACK
DESCRIPTION
The eight-way power seat option includes a power
seat track assembly located under each front seat
(Fig. 5). The power seat track assembly replaces the
standard manually operated seat tracks. The lower
half of the power seat track is secured at the front
with two bolts to the floor panel seat cross member,
and at the rear with two bolts to the floor panel.
Four nuts secure the bottom of the seat cushion
frame to the upper half of the power seat track unit.
The power seat track assembly cannot be repaired,
and is serviced only as a complete assembly. If any
component in this assembly is faulty or damaged, the
entire power seat track must be replaced.
OPERATION
The power seat track unit includes three reversible
electric motors that are secured to the upper half of
the track unit. Each motor moves the seat adjuster
through a combination of worm-drive gearboxes and
screw-type drive units.
The front and rear of the seat are operated by two
separate vertical adjustment motors. These motors
can be operated independently of each other, tilting
the entire seat assembly forward or rearward; or,
Fig. 4 Testing Passenger Power Seat Switch
8N - 16 POWER SEATSDR
PASSENGER SEAT SWITCH (Continued)

they can be operated in unison by selecting the
proper power seat switch functions, which will raise
or lower the entire seat assembly. The third motor is
the horizontal adjustment motor, which moves the
seat track in the forward and rearward directions.
DIAGNOSIS AND TESTING - POWER SEAT
TRACK
For complete power seat circuit descriptions and
diagrams, refer to Wiring Diagrams.
Operate the power seat switch to move all three
seat motors in each direction. The seat should move
in each of the selected directions. If the power seat
track fails to operate in only one direction, move the
seat track a short distance in the opposite direction
and test again to be certain that the track is not at
its travel limit. If the power seat track still fails to
operate in only one direction, refer to Diagnosis and
Testing of the Power Seat Switch in this section. If
the power seat track fails to operate in more than
one direction, proceed as follows:
(1) Check the power seat fuse in the power distri-
bution center. If OK, go to Step 2. If not OK, replace
the faulty fuse.
(2) Remove the power seat switch from the seat.
Check for battery voltage at the fused B(+) circuit
cavity of the power seat switch wire harness connec-
tor. If OK, go to Step 3. If not OK, repair the open
circuit to the power distribution center as required.(3) Check for continuity between the ground cir-
cuit cavity of the power seat switch wire harness con-
nector and a good ground. There should be
continuity. If OK, go to Step 4. If not OK, repair the
open circuit to ground as required.
(4) Test the power seat switch as described in this
group. If the switch tests OK, check the wire harness
between the power seat switch and the motor for
shorts or opens. If the circuits check OK, replace the
faulty power seat track (adjuster) assembly. If the
circuits are not OK, repair the wire harness as
required.
REMOVAL
(1) Remove the appropriate seat from the vehicle.
(Refer to 23 - BODY/SEATS/SEAT - REMOVAL).
(2) Remove the power seat switch from the seat.
Refer to the procedure in this section of the service
manual.
(3) Remove four seat track mounting nuts from
cushion pan.
(4) Disconnect the power seat electrical and
remove the seat track from the seat cushion.
(5) Remove the necessary components that must
be transferred to the replacement seat track (seat
belt buckles, wire harness, etc.).
INSTALLATION
(1) Install the necessary components that must be
transferred to the replacement seat track (seat belt
buckles, wire harness, etc.).
(2) Position the seat track and install the retaining
nuts on the seat cushion pan studs. Torque the bolts
to 25 N´m.
(3) Route and connect the power seat electrical on
the seat track and cushion pan.
(4) Install the power seat switch on the seat. Refer
to the procedure in this section of the service man-
ual.
(5) Install the seat in the vehicle (Refer to 23 -
BODY/SEATS/SEAT - INSTALLATION).
(6) Connect the negative battery cable.
LUMBAR CONTROL SWITCH
DESCRIPTION
The power lumbar seat option includes an electri-
cally operated lumbar support mechanism. A single
two-way momentary power lumbar switch is integral
with the power seat switches. The power lumbar
switch is secured to the back of the seat cushion side
shield with screws, and the switch paddle protrudes
through a hole to the outside of the shield. The
switch paddle is located in a shallow depression
molded into the outer surface of the seat cushion side
Fig. 5 DR Driver Power Seat Track
1 - POWER SEAT TRACK ASSEMBLY
2 - SEAT TRACK WIRE HARNESS
3 - SEAT BELT BUCKLE ASSEMBLIES
DRPOWER SEATS 8N - 17
POWER SEAT TRACK (Continued)

shield that helps to shroud it from unintentional
actuation when entering or leaving the vehicle.
The power lumbar switches cannot be adjusted or
repaired and, if faulty or damaged, the seat switch
assembly must be replaced.
OPERATION
When the power lumbar switch paddle is actuated,
a battery feed and a ground path are applied through
the switch contacts to the power lumbar adjuster
motor. The motor operates to move the lumbar
adjuster through its drive unit in the selected direc-
tion until the switch is released, or until the travel
limit of the adjuster is reached. When the switch is
moved in the opposite direction, the battery feed and
ground path to the motor are reversed through the
switch contacts. This causes the motor to run in the
opposite direction.
The power lumbar switch should not be held
applied in either direction after the adjuster has
reached its travel limit. The power lumbar adjuster
motor contains a self-resetting circuit breaker to pro-
tect it from overload. However, consecutive or fre-
quent resetting of the circuit breaker must not be
allowed to continue, or the motor may be damaged.
REMOVAL
The power lumbar switch is integral with the other
power seat switches. Refer to the appropriate driver
or passenger power front seat switch removal and/or
installation procedure.
LUMBAR MOTOR
DESCRIPTION
The power lumbar seat option includes an electri-
cally operated lumbar support mechanism. The only
visible evidence of this option is the separate power
lumbar switch control paddle that is located on the
outboard seat cushion switch bezel, next to the other
power seat switch control knobs. The power lumbar
adjuster and motor are concealed beneath the seat
back trim cover and padding, where they are secured
to a molded plastic back panel and to the seat back
frame.
The power lumbar adjuster cannot be repaired, and
is serviced only as a unit with the seat back frame. If
the power lumbar adjuster or the seat back frame
are damaged or faulty, the entire seat back frame
unit must be replaced (Refer to 23 - BODY/SEATS/
SEAT BACK - REMOVAL).
OPERATION
The power lumbar adjuster mechanism includes a
reversible electric motor that is secured to theinboard side of the seat back panel and is connected
to a worm-drive gearbox. The motor and gearbox
operate the lumbar adjuster mechanism in the center
of the seat back driving a nut up or down a fixed
drive screw. The action of this nut extends or con-
tracts the plastic lumbar support band. The more
this band is contracted, the more outward pressure is
applied against the center of the seat back padding,
providing additional lumbar support.
DIAGNOSIS AND TESTING - LUMBAR MOTOR
Actuate the power lumbar switch to move the
power lumbar adjuster in each direction. The power
lumbar adjuster should move in both directions. It
should be noted that the power lumber adjuster nor-
mally operates very quietly and exhibits little visible
movement. If the power lumbar adjuster fails to oper-
ate in only one direction, move the adjuster a short
distance in the opposite direction and test again to be
certain that the adjuster is not at its travel limit. If
the power lumbar adjuster fails to operate in only
one direction, Test the appropriate power seat switch
as described in this group. If the power lumbar
adjuster fails to operate in either direction, perform
the following tests. For complete circuit diagrams,
refer toWiring.
(1) Check the power seat circuit breaker. If OK, go
to Step 2. If not OK, replace the faulty power seat
circuit breaker.
(2) Check for battery voltage at the power seat cir-
cuit breaker. If OK, go to Step 3. If not OK, repair
the open fused B(+) circuit to the fuse in the Inte-
grated Power Module as required.
(3) Remove the outboard seat cushion side shield
from the seat. Disconnect the seat wire harness con-
nector from the power lumbar switch connector
receptacle. Check for battery voltage at the fused
B(+) circuit cavity of the power seat wire harness
connector for the power lumbar switch. If OK, go to
Step 4. If not OK, repair the open fused B(+) circuit
to the power seat as required.
(4) Check for continuity between the ground cir-
cuit cavity of the power seat wire harness connector
for the power lumbar switch and 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) Test the power lumbar switch. . If the switch
tests OK, test the circuits of the power seat wire har-
ness between the power lumbar adjuster motor and
the power lumbar switch for shorts or opens. If the
circuits check OK, replace the faulty seat back frame
assembly. If the circuits are not OK, repair the power
seat wire harness as required.
8N - 18 POWER SEATSDR
LUMBAR CONTROL SWITCH (Continued)

DESCRIPTION - CIRCUIT FUNCTIONS
All circuits in the diagrams use an alpha/numeric
code to identify the wire and it's function. To identify
which circuit code applies to a system, refer to the
Circuit Identification Code Chart. This chart shows
the main circuits only and does not show the second-
ary codes that may apply to some models.
CIRCUIT IDENTIFICATION CODE CHART
CIRCUIT FUNCTION
A BATTERY FEED
B BRAKE CONTROLS
C CLIMATE CONTROLS
D DIAGNOSTIC CIRCUITS
E DIMMING ILLUMINATION
CIRCUITS
F FUSED CIRCUITS
G MONITORING CIRCUITS
(GAUGES)
H OPEN
I NOT USED
J OPEN
K POWERTRAIN CONTROL
MODULE
L EXTERIOR LIGHTING
M INTERIOR LIGHTING
N NOT USED
O NOT USED
P POWER OPTION (BATTERY
FEED)
Q POWER OPTIONS (IGNITION
FEED)
R PASSIVE RESTRAINT
S SUSPENSION/STEERING
T TRANSMISSION/TRANSAXLE/
TRANSFER CASE
U OPEN
V SPEED CONTROL, WIPER/
WASHER
W OPEN
X AUDIO SYSTEMS
Y OPEN
Z GROUNDS
DESCRIPTION - SECTION IDENTIFICATION AND
INFORMATION
The wiring diagrams are grouped into individual
sections. If a component is most likely found in a par-
ticular group, it will be shown complete (all wires,
connectors, and pins) within that group. For exam-
ple, the Auto Shutdown Relay is most likely to be
found in Group 30, so it is shown there complete. It
can, however, be shown partially in another group if
it contains some associated wiring.
Splice diagrams in Section 8W-70 show the entire
splice and provide references to other sections the
splices serves. Section 8W-70 only contains splice dia-
grams that are not shown in their entirety some-
where else in the wiring diagrams.
Section 8W-80 shows each connector and the cir-
cuits involved with that connector. The connectors
are identified using the name/number on the dia-
gram pages.
WIRING SECTION CHART
GROUP TOPIC
8W-01 thru
8W-09General information and Diagram
Overview
8W-10 thru
8W-19Main Sources of Power and
Vehicle Grounding
8W-20 thru
8W-29Starting and Charging
8W-30 thru
8W-39Powertrain/Drivetrain Systems
8W-40 thru
8W-49Body Electrical items and A/C
8W-50 thru
8W-59Exterior Lighting, Wipers and
Trailer Tow
8W-60 thru
8W-69Power Accessories
8W-70 Splice Information
8W-80 Connector Pin Outs
8W-91 Connector, Ground and Splice
Locations
8W - 01 - 6 8W-01 WIRING DIAGRAM INFORMATIONDR
WIRING DIAGRAM INFORMATION (Continued)

(37) Rotate generator into position. Install upper
bolt and torque upper and lower bolts.
(38)
Install wire harness push-on clip below bracket.
(39) Install wire harness P-clip to top of bracket.
(40) Install fan support and torque to 32 N´m (24
ft. lbs.).
(41) Install cooling fan/drive refer to (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - INSTALLA-
TION).
(42) Install accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(43) Install exhaust manifold/turbocharger assem-
bly, using new gaskets. Start all bolts/spacers by
hand. Torque bolts to 43 N´m (32 ft. lbs.).
(44) Install exhaust manifold heat shield to
exhaust manifold studs. Install retaining nuts.Torque
to 15 N´m (11 ft. lbs.).
(45) Install exhaust bolt retention straps across
cylinders5&6.
(46) Connect turbocharger oil drain tube. Torque
clamp to 8 N´m (71 in. lbs.).
(47) Perform the turbocharger pre-lube procedure.
Refer to Group 11, Exhaust System and Turbo-
charger for the correct procedure.
(48) Connect the turbocharger oil supply line.
Torque to 24 N´m (18 ft. lbs.).
(49) Install air cleaner housing and duct.
(50) Connect air inlet temperature/pressure sensor.
(51) Raise vehicle on hoist.
(52) Install exhaust pipe to turbocharger elbow.
Torque bolts to 11 N´m (100 in. lbs.).
(53) Lower vehicle.
(54) Fill engine coolant (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(55) Start engine and check for leaks.
CYLINDER HEAD COVER(S)
REMOVAL
REMOVALÐCYLINDER HEAD COVER
(1) Disconnect both battery negative cables.
(2) Remove oil fill cap.
(3) Remove the breather cover.
(4) Disconnect the breather hose and breather
drain tube from the breather housing.
(5) Remove cylinder head cover bolts.
(6) Remove the cylinder head cover.
REMOVALÐROCKER HOUSING
(1) Remove cylinder head cover as outlined in this
section.
(2) Disconnect rocker housing injector harness con-
nectors.(3) Remove injector harness nuts from injectors.
(4) Remove rocker housing bolts.
(5) Remove rocker housing and gasket.
CLEANING
Using a suitable solvent, Clean and dry gasket
mating surfaces on cylinder head and rocker housing.
Wipe gasket dry and inspect for re-use.
INSPECTION
The cylinder head cover gasket and rocker hous-
ing gasket, are reusable.However, should cracks,
nicks, or tears be present in the rubber/silicone construc-
tion, the defective components should be replaced. Also
replace gasket if it is no longer flexible. Inspect o-rings
on cylinder head cover bolts.Do not reuse gasket if it
has been removed from the groove in the rocker
housing or cylinder head cover.
INSTALLATION
INSTALLATIONÐCYLINDER HEAD COVER
(1) Inspect cylinder head cover gasket for cuts and
proper installation in groove. Replace if damaged.
(2)
Position cylinder cover on top of rocker housing.
(3) Install bolts.
(4) Starting with the center bolt, torque to 24 N´m
(18 ft. lbs.).
(5) Install breather hose to breather.
(6) Install breather drain hose to breather.
(7) Install breather cover and wire harness clip.
Torque to 24 N´m (18 ft. lbs.).
INSTALLATION - ROCKER HOUSING
(1) Inspect rocker housing gasket for cuts, nicks,
or tears. Replace if damaged or if gasket has come
out of groove.
(2) Inspect rocker housing gasket for proper instal-
lation in groove. Gasket bead must be centered in
groove. A gasket bead that is tilted to the side will
cause an oil leak.
CAUTION: When installing rocker housing onto cyl-
inder head, do not slide housing from side to side,
The gasket could fall out or be damaged.
(3) Install the rocker housing. Carefully guide the
rocker housing evenly down onto the cylinder head.
(4) Install rocker housing bolts and tighten finger
tight.
(5) Torque bolts, working from center out, to 24
Nm (18ft. lbs.).
(6) Install injector harness nuts to injector sole-
noid. Torque to 1.25 Nm (11 in. lbs.).
(7) Connect rocker housing injector harness con-
nections.
DRENGINE 5.9L DIESEL 9 - 255
CYLINDER HEAD (Continued)

(7) With the engine in this position, valve lash can
be measured at the remaining rocker arms:INTAKE
3±5±6 / EXHAUST 2±4±6. Use the same method as
above for determining whether adjustment is neces-
sary, and adjust those that are found to be outside of
the limits.
(8) Install the cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(9) Connect the battery negative cables.
REMOVAL - VALVE SPRINGS AND SEALS
(1) Disconnect the battery negative cables.
(2) Remove the cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(3) Disconnect rocker housing injector harness con-
nector. Remove all injector harness solenoid nuts.
(4) Remove injector(s) for cylinder(s) to be serviced.
Refer to Group 14 for injector removal.
(5) Remove the rocker housing.
(6) Remove the rocker arms and crossheads from
the cylinder(s) to be serviced. Mark each component
so they can be installed in their original position.
(7) Using the crankshaft barring tool #7471±B
(Fig. 33), rotate the engine to position the damper
mark in the 12 o'clock position.At this engine posi-
tion, cylinders #1 and #6 can be serviced.
(8) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(9) With the damper TDC mark in the 12 o'clock
position, add a paint mark anywhere on the gear
housing cover next to the crankshaft damper. Place
another mark on the vibration damper in alignment
with the mark you just made on the cover.(10) Divide the crankshaft damper into three
equally sized segments as follows:
(a) Using a tape measure, measure the circum-
ference of the crankshaft damper and divide the
measurement by three (3).
(b) Measure that distance in a counter-clockwise
direction from the first balancer mark and place
another mark on the balancer.
(c) From the second damper mark, again mea-
sure in a counter-clockwise direction and place a
mark on the damper at the same distance you
measured when placing the second damper mark.
The damper should now be marked in three
equally spaced locations and the damper TDC
mark should be in the 12 o'clock position.
(d) Remove injectors, fuel lines, and high pres-
sure connectors for every cylinder that requires
repair.
(11) Compress the valve springs at cyls. #1 and #6
as follows:
(a) Install the valve spring compressor mounting
base as shown in (Fig. 34).
(b) Install the top plate, washer, and nut. Using
a suitable wrench tighten the nut (clock-wise) (Fig.
35) to compress the valve springs and remove the
collets.
(c) Rotate the compressor nut counter-clockwise
to relieve tension on springs. Remove spring com-
pressor.
(d) Remove and replace retainers, springs, and
seals as necessary.
(e)Do not rotate the engine until the
springs and retainers are re-installed.
(f) Install seals, springs and retainers. Install
spring compressor, compress valve springs and
install the collets.
Fig. 32 Measuring Valve Lash - Typical
1 - INTAKE
2 - FEELER GAUGE
3 - EXHAUST
Fig. 33 Rotating Engine with Barring Tool - Typical
1 - REAR FLANGE
2 - BARRING TOOL
9 - 260 ENGINE 5.9L DIESELDR
INTAKE/EXHAUST VALVES & SEATS (Continued)