Electrical DODGE RAM 1500 1998 2.G Workshop Manual

SIDE IMPACT SENSOR
DESCRIPTION
On vehicles equipped with the optional side curtain
airbags, two side impact sensors are used, one each
for the left and right sides of the vehicle (Fig. 54).
These sensors are mounted remotely from the bi-di-
rectional safing sensor that is internal to the Airbag
Control Module (ACM). The side impact sensors are
secured within the right and left B-pillars just above
the front seat belt retractors and behind the lower
B-pillar trim in the passenger compartment.
The impact sensor housing has an integral connec-
tor receptacle, an integral mounting stud, and an
integral locating tab. A cavity in the center of the
molded black plastic impact sensor housing contains
the electronic circuitry of the sensor, which includes
an electronic communication chip and an electronic
impact sensor. Potting material fills the cavity to seal
and protect the internal electronic circuitry and com-
ponents. The side impact sensors are each connected
to the vehicle electrical system through a dedicated
take out and connector of the body wire harness.
The side impact sensors cannot be repaired or
adjusted and, if damaged or faulty, they must be
replaced.
OPERATION
The side impact sensors are electronic accelerome-
ters that sense the rate of vehicle deceleration, which
provides verification of the direction and severity of
an impact. Each sensor also contains an electronic
communication chip that allows the unit to commu-
nicate the sensor status as well as sensor fault infor-
mation to the microprocessor in the Airbag Control
Module (ACM). The ACM microprocessor continu-
ously monitors all of the passive restraint system
electrical circuits to determine the system readiness.
If the ACM detects a monitored system fault, it sets
a Diagnostic Trouble Code (DTC) and controls the
airbag indicator operation accordingly.
The impact sensors each receive battery current
and ground through dedicated left and right sensor
plus and minus circuits from the ACM. The impact
sensors and the ACM communicate by modulating
the voltage in the sensor plus circuit. The hard wired
circuits between the side impact sensors and the
ACM may be diagnosed and tested using conven-
tional diagnostic tools and procedures. However, con-
ventional diagnostic methods will not prove
conclusive in the diagnosis of the ACM or the impact
sensors. The most reliable, efficient, and accurate
means to diagnose the impact sensors, the ACM, and
the electronic message communication between the
sensors and the ACM requires the use of a DRBIIIt
scan tool. Refer to the appropriate diagnostic infor-
mation.
REMOVAL
REMOVAL - STANDARD CAB
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT
TENSIONER, IMPACT SENSOR, OR INSTRUMENT
PANEL COMPONENT DIAGNOSIS OR SERVICE.
DISCONNECT AND ISOLATE THE BATTERY NEGA-
TIVE (GROUND) CABLE, THEN WAIT TWO MINUTES
FOR THE SYSTEM CAPACITOR TO DISCHARGE
BEFORE PERFORMING FURTHER DIAGNOSIS OR
SERVICE. THIS IS THE ONLY SURE WAY TO DIS-
ABLE THE SUPPLEMENTAL RESTRAINT SYSTEM.
FAILURE TO TAKE THE PROPER PRECAUTIONS
COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY-
MENT.
Fig. 54 Side Impact Sensor
1 - SENSOR
2 - CONNECTOR RECEPTACLE
3 - STUD
DRRESTRAINTS 8O - 59

WARNING: TO AVOID PERSONAL INJURY OR
DEATH, NEVER STRIKE OR DROP THE SIDE
IMPACT SENSOR, AS IT CAN DAMAGE THE IMPACT
SENSOR OR AFFECT ITS CALIBRATION. THE SIDE
IMPACT SENSOR ENABLES THE SYSTEM TO
DEPLOY THE SIDE CURTAIN AIRBAGS. IF AN
IMPACT SENSOR IS ACCIDENTALLY DROPPED
DURING SERVICE, THE MODULE MUST BE
SCRAPPED AND REPLACED WITH A NEW UNIT.
FAILURE TO OBSERVE THIS WARNING COULD
RESULT IN ACCIDENTAL, INCOMPLETE, OR
IMPROPER SUPPLEMENTAL RESTRAINT DEPLOY-
MENT.
(1) Adjust the front seat to its most forward posi-
tion for easiest access to the lower B-pillar trim.
(2) Disconnect and isolate the battery negative
cable. Wait two minutes for the system capacitor to
discharge before further service.
(3) Remove the front outboard seat belt and retrac-
tor from the inside of the B-pillar. (Refer to 8 -
ELECTRICAL/RESTRAINTS/FRONT OUTBOARD
SEAT BELT & RETRACTOR - REMOVAL - STAN-
DARD CAB).
(4) Remove the nut that secures the side impact
sensor stud to the inner B-pillar (Fig. 55).(5) Reach through the retractor mounting hole in
the inner B-pillar to access the side impact sensor
and disengage the locating pin and mounting stud
from the holes in the inner B-pillar.
(6) Pull the side impact sensor out of the B-pillar
far enough to access and disconnect the body wire
harness connector for the sensor from the sensor con-
nector receptacle.
(7) Remove the side impact sensor from the B-pil-
lar.
REMOVAL - QUAD CAB
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT
TENSIONER, IMPACT SENSOR, OR INSTRUMENT
PANEL COMPONENT DIAGNOSIS OR SERVICE.
DISCONNECT AND ISOLATE THE BATTERY NEGA-
TIVE (GROUND) CABLE, THEN WAIT TWO MINUTES
FOR THE SYSTEM CAPACITOR TO DISCHARGE
BEFORE PERFORMING FURTHER DIAGNOSIS OR
SERVICE. THIS IS THE ONLY SURE WAY TO DIS-
ABLE THE SUPPLEMENTAL RESTRAINT SYSTEM.
FAILURE TO TAKE THE PROPER PRECAUTIONS
COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY-
MENT.
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, NEVER STRIKE OR DROP THE SIDE
IMPACT SENSOR, AS IT CAN DAMAGE THE IMPACT
SENSOR OR AFFECT ITS CALIBRATION. THE SIDE
IMPACT SENSOR ENABLES THE SYSTEM TO
DEPLOY THE SIDE CURTAIN AIRBAGS. IF AN
IMPACT SENSOR IS ACCIDENTALLY DROPPED
DURING SERVICE, THE MODULE MUST BE
SCRAPPED AND REPLACED WITH A NEW UNIT.
FAILURE TO OBSERVE THIS WARNING COULD
RESULT IN ACCIDENTAL, INCOMPLETE, OR
IMPROPER SUPPLEMENTAL RESTRAINT DEPLOY-
MENT.
(1) Adjust the front seat to its most forward posi-
tion for easiest access to the lower B-pillar trim.
(2) Disconnect and isolate the battery negative
cable. Wait two minutes for the system capacitor to
discharge before further service.
(3) Remove the nut that secures the side impact
sensor stud to the inner B-pillar (Fig. 56).
(4) Reach through the large hole above the retrac-
tor mounting hole in the inner B-pillar to access the
side impact sensor and disengage the locating pin
and mounting stud from the holes in the inner B-pil-
lar.
Fig. 55 Side Impact Sensor Remove/Install -
Standard Cab
1 - SIDE IMPACT SENSOR
2 - WIRE HARNESS CONNECTOR
3 - B-PILLAR
4 - NUT
8O - 60 RESTRAINTSDR
SIDE IMPACT SENSOR (Continued)

(5) Pull the side impact sensor out through the
large hole in the B-pillar far enough to access and
disconnect the body wire harness connector for the
sensor from the sensor connector receptacle.
(6) Remove the side impact sensor from the B-pil-
lar.
INSTALLATION
INSTALLATION - STANDARD CAB
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT
TENSIONER, IMPACT SENSOR, OR INSTRUMENT
PANEL COMPONENT DIAGNOSIS OR SERVICE.
DISCONNECT AND ISOLATE THE BATTERY NEGA-
TIVE (GROUND) CABLE, THEN WAIT TWO MINUTES
FOR THE SYSTEM CAPACITOR TO DISCHARGE
BEFORE PERFORMING FURTHER DIAGNOSIS OR
SERVICE. THIS IS THE ONLY SURE WAY TO DIS-
ABLE THE SUPPLEMENTAL RESTRAINT SYSTEM.
FAILURE TO TAKE THE PROPER PRECAUTIONS
COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY-
MENT.WARNING: TO AVOID PERSONAL INJURY OR
DEATH, NEVER STRIKE OR DROP THE SIDE
IMPACT SENSOR, AS IT CAN DAMAGE THE IMPACT
SENSOR OR AFFECT ITS CALIBRATION. THE SIDE
IMPACT SENSOR ENABLES THE SYSTEM TO
DEPLOY THE SIDE CURTAIN AIRBAGS. IF AN
IMPACT SENSOR IS ACCIDENTALLY DROPPED
DURING SERVICE, THE MODULE MUST BE
SCRAPPED AND REPLACED WITH A NEW UNIT.
FAILURE TO OBSERVE THIS WARNING COULD
RESULT IN ACCIDENTAL, INCOMPLETE, OR
IMPROPER SUPPLEMENTAL RESTRAINT DEPLOY-
MENT.
(1) Position the side impact sensor to the retractor
mounting hole in the inner B-pillar (Fig. 55).
(2) Reconnect the body wire harness connector for
the side impact sensor to the sensor connector recep-
tacle.
(3) Reach through the retractor mounting hole in
the inner B-pillar to position and engage the locating
pin and the stud on the side impact sensor to the
locating slot and mounting hole from the inside of
the B-pillar.
(4) Install and tighten the nut that secures the
side impact sensor stud to the inner B-pillar. Tighten
the nut to 8 N´m (70 in. lbs.).
(5) Reinstall the front outboard seat belt and
retractor to the inside of the B-pillar. (Refer to 8 -
ELECTRICAL/RESTRAINTS/FRONT OUTBOARD
SEAT BELT & RETRACTOR - INSTALLATION -
STANDARD CAB).
(6) Do not reconnect the battery negative cable at
this time. The supplemental restraint system verifi-
cation test procedure should be performed following
service of any supplemental restraint system compo-
nent. (Refer to 8 - ELECTRICAL/RESTRAINTS -
STANDARD PROCEDURE - VERIFICATION TEST).
INSTALLATION - QUAD CAB
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT
TENSIONER, IMPACT SENSOR, OR INSTRUMENT
PANEL COMPONENT DIAGNOSIS OR SERVICE.
DISCONNECT AND ISOLATE THE BATTERY NEGA-
TIVE (GROUND) CABLE, THEN WAIT TWO MINUTES
FOR THE SYSTEM CAPACITOR TO DISCHARGE
BEFORE PERFORMING FURTHER DIAGNOSIS OR
SERVICE. THIS IS THE ONLY SURE WAY TO DIS-
ABLE THE SUPPLEMENTAL RESTRAINT SYSTEM.
FAILURE TO TAKE THE PROPER PRECAUTIONS
COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY-
MENT.
Fig. 56 Side Impact Sensor Remove/Install - Quad
Cab
1 - B-PILLAR
2 - SIDE IMPACT SENSOR
3 - NUT
4 - WIRE HARNESS CONNECTOR
DRRESTRAINTS 8O - 61
SIDE IMPACT SENSOR (Continued)

WARNING: TO AVOID PERSONAL INJURY OR
DEATH, NEVER STRIKE OR DROP THE SIDE
IMPACT SENSOR, AS IT CAN DAMAGE THE IMPACT
SENSOR OR AFFECT ITS CALIBRATION. THE SIDE
IMPACT SENSOR ENABLES THE SYSTEM TO
DEPLOY THE SIDE CURTAIN AIRBAGS. IF AN
IMPACT SENSOR IS ACCIDENTALLY DROPPED
DURING SERVICE, THE MODULE MUST BE
SCRAPPED AND REPLACED WITH A NEW UNIT.
FAILURE TO OBSERVE THIS WARNING COULD
RESULT IN ACCIDENTAL, INCOMPLETE, OR
IMPROPER SUPPLEMENTAL RESTRAINT DEPLOY-
MENT.
(1) Position the side impact sensor to the large
hole above the retractor mounting hole in the inner
B-pillar (Fig. 56).
(2) Reconnect the body wire harness connector for
the side impact sensor to the sensor connector recep-
tacle.(3) Reach through the large hole above the retrac-
tor mounting hole in the inner B-pillar to position
and engage the locating pin and the stud on the side
impact sensor to the locating slot and mounting hole
from the inside of the B-pillar.
(4) Install and tighten the nut that secures the
side impact sensor stud to the inner B-pillar. Tighten
the nut to 8 N´m (70 in. lbs.).
(5) Do not reconnect the battery negative cable at
this time. The supplemental restraint system verifi-
cation test procedure should be performed following
service of any supplemental restraint system compo-
nent. (Refer to 8 - ELECTRICAL/RESTRAINTS -
STANDARD PROCEDURE - VERIFICATION TEST).
8O - 62 RESTRAINTSDR
SIDE IMPACT SENSOR (Continued)

(5) Verify operation of one-way check valve and
check it for leaks.
(a) Locate one-way check valve. The valve is
located in vacuum line between vacuum reservoir
and engine vacuum source. Disconnect vacuum
hoses (lines) at each end of valve.
(b) Connect a hand-operated vacuum pump to
reservoir end of check valve. Apply vacuum. Vac-
uum should not bleed off. If vacuum is being lost,
replace one-way check valve.
(c) Connect a hand-operated vacuum pump to
vacuum source end of check valve. Apply vacuum.
Vacuum should flow through valve. If vacuum is
not flowing, replace one-way check valve. Seal the
fitting at opposite end of valve with a finger and
apply vacuum. If vacuum will not hold, diaphragm
within check valve has ruptured. Replace valve.
5.7 Gas
Vacuum is not used for any part of the speed con-
trol system if equipped with a 5.7L V-8 engine.
5.9L Diesel Engine With Manual Trans.
Vacuum is not used for any part of the speed con-
trol system if equipped with a diesel engine and a
manual transmission.
5.9L Diesel Engines With Automatic Trans.
If equipped with a diesel powered engine and an
automatic transmission, an electric vacuum pump
and vacuum lines are used to supply vacuum to the
speed control servo. A vacuum reservoir is not used.
DIAGNOSIS AND TESTING - ROAD TEST
Perform a vehicle road test to verify reports of
speed control system malfunction. The road test
should include attention to the speedometer. Speed-ometer operation should be smooth and without flut-
ter at all speeds.
Flutter in the speedometer indicates a problem
which might cause surging in the speed control sys-
tem. The cause of any speedometer problems should
be corrected before proceeding. Refer to Instrument
Cluster for speedometer diagnosis.
If a road test verifies a system problem and the
speedometer operates properly, check for:
²A Diagnostic Trouble Code (DTC). If a DTC
exists, conduct tests per the Powertrain Diagnostic
Procedures service manual.
²A misadjusted brake (stop) lamp switch. This
could also cause an intermittent problem.
²Loose, damaged or corroded electrical connec-
tions at the servo (if used). Corrosion should be
removed from electrical terminals and a light coating
of Mopar MultiPurpose Grease, or equivalent,
applied.
²Leaking vacuum reservoir (if used).
²Loose or leaking vacuum hoses or connections (if
used).
²Defective one-way vacuum check valve (if used).
²Secure attachment of both ends of the speed con-
trol servo cable (if used).
²Smooth operation of throttle linkage (if used)
and throttle body air valve.
²Failed speed control servo (if used). Do the servo
vacuum test.
CAUTION: When test probing for voltage or conti-
nuity at electrical connectors, care must be taken
not to damage connector, terminals or seals. If
these components are damaged, intermittent or
complete system failure may occur.
SPECIFICATIONS
TORQUE - SPEED CONTROL
DESCRIPTION N-m Ft. Lbs. In. Lbs.
Servo Mounting Bracket-
to-Servo Nuts7-60
Servo Mounting Bracket-
to-Battery Tray Screws4-30
Speed Control Switch
Mounting Screws1.7 - 15
Vacuum Reservoir
Mounting Nuts3-20
DRSPEED CONTROL 8P - 3
SPEED CONTROL (Continued)

(5) Before starting engine, operate accelerator
pedal to check for any binding.
(6) Install cable/lever cover.
SERVO
DESCRIPTION
A speed control servo is not used with any
5.7L V-8 engine, or with the 5.9L diesel engine
when equipped with a manual transmission.
The speed control servo is attached to the bottom
of the battery tray.
The servo unit consists of a solenoid valve body,
and a vacuum chamber. The solenoid valve body con-
tains three solenoids:
²Vacuum
²Vent
²Dump
The vacuum chamber contains a diaphragm with a
cable attached to control the throttle linkage.
OPERATION
A speed control servo is not used with any
5.7L V-8 engine, or with the 5.9L diesel engine
when equipped with a manual transmission.
The following information applies only to
vehicles equipped with a mechanical servo.
When/if a servo is used on gasoline powered vehi-
cles, the Powertrain Control Module (PCM) controls
the solenoid valve body. When/if a servo is used on
certain diesel powered vehicles, the Engine Control
Module (ECM) controls the solenoid valve body. The
solenoid valve body controls the application and
release of vacuum to the diaphragm of the vacuum
servo. The servo unit cannot be repaired and is ser-
viced only as a complete assembly.
Power is supplied to the servo's by the PCM/ECM
through the brake switch. The PCM/ECM controls
the ground path for the vacuum and vent solenoids.
The dump solenoid is energized anytime it receives
power. If power to the dump solenoid is interrupted,
the solenoid dumps vacuum in the servo. This pro-
vides a safety backup to the vent and vacuum sole-
noids.
The vacuum and vent solenoids must be grounded
at the PCM/ECM to operate. When the PCM/ECM
grounds the vacuum servo solenoid, the solenoid
allows vacuum to enter the servo and pull open the
throttle plate using the cable. When the PCM/ECM
breaks the ground, the solenoid closes and no more
vacuum is allowed to enter the servo. The PCM/ECM
also operates the vent solenoid via ground. The vent
solenoid opens and closes a passage to bleed or hold
vacuum in the servo as required.The PCM/ECM duty cycles the vacuum and vent
solenoids to maintain the set speed, or to accelerate
and decelerate the vehicle. To increase throttle open-
ing, the PCM/ECM grounds the vacuum and vent
solenoids. To decrease throttle opening, the PCM/
ECM removes the grounds from the vacuum and
vent solenoids. When the brake is released, if vehicle
speed exceeds 30 mph to resume, 35 mph to set, and
the RES/ACCEL switch has been depressed, ground
for the vent and vacuum circuits is restored.
REMOVAL
The speed control servo assembly is attached to the
bottom of the battery tray (Fig. 6).
(1) Disconnect negative battery cable at battery
(both cables at both batteries if diesel).
(2) To gain access to servo, remove plastic wheel-
house splash shield over left-front wheel.
(3) Disconnect vacuum line at servo (Fig. 6).
(4) Disconnect electrical connector at servo (Fig. 6).
(5) Remove 3 servo mounting screws (Fig. 6).
Depending on engine application, different sets of
mounting lugs (Fig. 6) are used to support servo to
battery tray. While removing, note proper lugs.
(6) Disconnect servo cable at throttle body. Refer to
Servo Cable Removal/Installation.
(7) Remove 2 mounting nuts holding servo cable
sleeve to bracket (Fig. 7).
(8) Pull speed control cable sleeve and servo away
from servo mounting bracket to expose cable retain-
ing clip (Fig. 7) and remove clip. Note: The servo
mounting bracket displayed in (Fig. 7) is a typical
bracket and may/may not be applicable to this model
vehicle.
(9) Remove servo from mounting bracket. While
removing, note orientation of servo to bracket.
INSTALLATION
(1) Position servo to mounting bracket (Fig. 7).
(2) Align hole in cable connector with hole in servo
pin. Install cable-to-servo retaining clip (Fig. 7).
(3) Insert servo mounting studs through holes in
servo mounting bracket.
(4) Install 2 servo-to-mounting bracket nuts and
tighten. Refer to torque specifications.
(5) Position servo assembly to correct mounting
lugs on battery tray (Fig. 6) and install 3 screws.
Tighten 3 screws. Refer to torque specifications.
(6) Connect vacuum line at servo.
(7) Connect electrical connector at servo.
(8) Connect servo cable to throttle body. Refer to
servo Cable Removal/Installation.
(9) Install left-front wheel-well liner.
(10) Connect negative battery cable to battery
(connect both cables if diesel).
8P - 6 SPEED CONTROLDR
CABLE (Continued)

The previous disengagement conditions are pro-
grammed for added safety.
Once the speed control has been disengaged,
depressing the ACCEL switch restores the vehicle to
the target speed that was stored in the PCM's RAM
(ECM for diesel).
NOTE: Depressing the OFF switch will erase the set
speed stored in the PCM's/ECM's RAM.
If, while the speed control is engaged, the driver
wishes to increase vehicle speed, the PCM(ECM for
diesel)is programmed for an acceleration feature.
With the ACCEL switch held closed, the vehicle
accelerates slowly to the desired speed. The new tar-
get speed is stored in the PCM's/ECM's RAM when
the ACCEL switch is released. The PCM/ECM also
has a9tap-up9feature in which vehicle speed
increases at a rate of approximately 2 mph for each
momentary switch activation of the ACCEL switch.
The PCM/ECM also provides a means to decelerate
without disengaging speed control. To decelerate from
an existing recorded target speed, depress and hold
the COAST switch until the desired speed is reached.
Then release the switch. The ON, OFF switch oper-
ates two components: the PCM's/ECM's ON, OFF
input, and the battery voltage to the brake switch.
REMOVAL
Depending on engine control computer (JTEC
having a 3±plug connector or 5.7L V-8 NGC hav-
ing a 4±plug connector), 2 types of switches are
used. Both types of switches are internally and
externally different. The switches used with the
NGC system have attached pigtail leads (Fig. 9).
The switch used with the JTEC system does not
have an attached pigtail lead.
(1) Remove switch mounting screw (Fig. 8). or
(Fig. 9)
(2) Pull switch from steering wheel.
(3) Unplug electrical connector from switch (Fig.
8), or, switch pigtail wire harness from steering
wheel wire harness (Fig. 9) and remove switch.
INSTALLATION
(1) Plug electrical connector into switch (Fig. 8), or
connect pigtail wire harness to steering wheel wire
harness (Fig. 9). Be sure wires are not pinched.
(2) Position switch to steering wheel.
(3) Install switch mounting screw and tighten.
Refer to torque specifications.
Fig. 8 SPEED CONTROL SWITCHES (EXCEPT 5.7L
V-8 ENGINE)
1 - ELECTRICAL CONNECTORS
2 - MOUNTING SCREWS
3 - RIGHT SWITCH
4 - LEFT SWITCH
Fig. 9 SPEED CONTROL SWITCHES (WITH 5.7L V-8
ENGINE)
1 - MOUNTING SCREWS
2 - RIGHT SWITCH
3 - LEFT SWITCH
4 - PIGTAIL LEADS
8P - 8 SPEED CONTROLDR
SWITCH (Continued)

WIPERS/WASHERS
TABLE OF CONTENTS
page page
WIPERS/WASHERS
DESCRIPTION..........................1
OPERATION............................4
DIAGNOSIS AND TESTING - WIPER &
WASHER SYSTEM.....................6
CLEANING - WIPER & WASHER SYSTEM.....6
INSPECTION - WIPER & WASHER SYSTEM . . . 7
CHECK VALVE
DESCRIPTION..........................7
OPERATION............................8
REMOVAL.............................8
INSTALLATION..........................8
WASHER FLUID LEVEL SWITCH
DESCRIPTION..........................9
OPERATION............................9
REMOVAL.............................10
INSTALLATION.........................11
WASHER HOSES/TUBES
DESCRIPTION.........................11
OPERATION...........................11
WASHER NOZZLE
DESCRIPTION.........................11
OPERATION...........................12
REMOVAL.............................12
INSTALLATION.........................12
WASHER PUMP/MOTOR
DESCRIPTION.........................13
OPERATION...........................13
REMOVAL.............................14
INSTALLATION.........................14
WASHER RESERVOIR
DESCRIPTION.........................14
OPERATION...........................15
REMOVAL
REMOVAL - EXCEPT DIESEL ENGINE.....15REMOVAL - DIESEL ENGINE............16
INSTALLATION
INSTALLATION - EXCEPT DIESEL ENGINE . . 17
INSTALLATION - DIESEL ENGINE.........17
WIPER ARM
DESCRIPTION.........................17
OPERATION...........................18
REMOVAL.............................18
INSTALLATION.........................18
WIPER BLADE
DESCRIPTION.........................18
OPERATION...........................19
REMOVAL.............................19
INSTALLATION.........................20
WIPER HIGH/LOW RELAY
DESCRIPTION.........................20
OPERATION...........................20
DIAGNOSIS AND TESTING - WIPER HIGH/
LOW RELAY.........................21
REMOVAL.............................21
INSTALLATION.........................22
WIPER MODULE
DESCRIPTION.........................22
OPERATION...........................23
REMOVAL.............................23
INSTALLATION.........................23
WIPER ON/OFF RELAY
DESCRIPTION.........................24
OPERATION...........................25
DIAGNOSIS AND TESTING - WIPER ON/OFF
RELAY..............................25
REMOVAL.............................26
INSTALLATION.........................26
WIPERS/WASHERS
DESCRIPTION
An electrically operated intermittent wiper and
washer system is standard factory-installed safety
equipment on this model (Fig. 1). The wiper and
washer system includes the following major compo-
nents, which are described in further detail else-
where in this service information:
²Check Valve- The washer system check valve
is integral to the wye fitting located in the washer
plumbing between the cowl plenum washer hose andthe washer nozzles, and is concealed beneath the
cowl plenum cover/grille panel at the base of the
windshield.
²Front Control Module- The Front Control
Module (FCM) is integral to the Integrated Power
Module (IPM). The IPM is located in the engine com-
partment, near the battery. (Refer to 8 - ELECTRI-
CAL/POWER DISTRIBUTION/INTEGRATED
POWER MODULE - DESCRIPTION).
²Instrument Cluster- In this model, the instru-
ment cluster is also sometimes referred to as the Cab
Control Node (CCN). The instrument cluster is
located in the instrument panel above the steering
DRWIPERS/WASHERS 8R - 1

column opening, directly in front of the driver. (Refer
to 8 - ELECTRICAL/INSTRUMENT CLUSTER -
DESCRIPTION).
²Multi-Function Switch- The multi-function
switch is located on the top of the steering column,
just below the steering wheel. The multi-function
switch includes a control stalk that extends through
an opening on the left side of the steering column
shrouds and a control knob on the end of the stalk is
dedicated to providing all of the driver controls for
the wiper and washer systems. (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING - EXTERIOR/MULTI-
FUNCTION SWITCH - DESCRIPTION).
²Washer Fluid Level Switch- The washer fluid
level switch is located in a dedicated hole on the out-
board side of the washer reservoir in the engine com-
partment.²Washer Nozzle- Two fluidic washer nozzles are
secured with integral snap features to dedicated
openings in the cowl plenum cover/grille panel
located near the base of the windshield.
²Washer Plumbing- The plumbing for the
washer system consists of rubber hoses and molded
plastic fittings. The plumbing is routed along the
right side of the engine compartment from the
washer reservoir, and through a trough near the
right end of the cowl plenum cover/grille panel into
the cowl plenum to the washer nozzle fittings.
²Washer Pump/Motor- The electric washer
pump/motor unit is located in a dedicated hole on the
rearward facing surface of the washer reservoir in
the engine compartment.
²Washer Reservoir- On all models except those
with an optional diesel engine, the washer reservoir
Fig. 1 Wiper & Washer System
1 - WASHER RESERVOIR, PUMP/MOTOR, FLUID LEVEL
SWITCH (EXCEPT DIESEL ENGINE)
2 - WASHER RESERVOIR, PUMP/MOTOR, FLUID LEVEL
SWITCH (DIESEL ENGINE ONLY)3 - WIPER MODULE
4 - WASHER NOZZLE (2)
5 - WIPER ARM & BLADE (2)
6 - MULTI-FUNCTION (WIPER, WASHER, & LIGHTING) SWITCH
8R - 2 WIPERS/WASHERSDR
WIPERS/WASHERS (Continued)

is secured by integral mounting tabs and a snap fea-
ture to slots in the right side of the cooling module
shroud in the engine compartment. On models with
an optional diesel engine, the washer reservoir is
secured by screws to the back of the upright left ver-
tical member of the radiator support in the engine
compartment. The washer reservoir filler neck is
accessed from the engine compartment.
²Wiper Arm- The two wiper arms are secured
with integral latches to the serrated ends of the two
wiper pivot shafts, which extend through the cowl
plenum cover/grille panel located near the base of the
windshield.
²Wiper Blade- The two wiper blades are
secured to the two wiper arms with an integral latch,
and are parked on the glass near the bottom of the
windshield when the wiper system is not in opera-
tion.
²Wiper High/Low Relay- The wiper high/low
relay is an International Standards Organization
(ISO) micro relay located in the Integrated Power
Module (IPM) in the engine compartment near the
battery.
²Wiper Module- The wiper pivot shafts are the
only visible components of the wiper module. The
remainder of the module is concealed within the cowl
plenum area beneath the cowl plenum cover/grille
panel. The wiper module includes the wiper module
bracket, four rubber-isolated wiper module mounts,
the wiper motor, the wiper motor crank arm, the two
wiper drive links, and the two wiper pivots.
²Wiper On/Off Relay- The wiper on/off relay is
an International Standards Organization (ISO) micro
relay located in the Integrated Power Module (IPM)
in the engine compartment near the battery.
Hard wired circuitry connects the wiper and
washer system components to the electrical system of
the vehicle. These hard wired circuits are integral to
several wire harnesses, which are routed throughout
the vehicle and retained by many different methods.
These circuits may be connected to each other, to the
vehicle electrical system and to the wiper and washer
system components through the use of a combination
of soldered splices, splice block connectors, and many
different types of wire harness terminal connectors
and insulators. Refer to the appropriate wiring infor-
mation. The wiring information includes wiring dia-
grams, proper wire and connector repair procedures,
further details on wire harness routing and reten-
tion, as well as pin-out and location views for the
various wire harness connectors, splices and grounds.
OPERATING MODES
The components of the wiper and washer system
are designed to work in concert to provide the follow-
ing operating modes:²Continuous Wipe Mode- The control knob on
the control stalk of the multi-function switch has two
continuous wipe positions, Low and High. When
selected, these switch positions will cause the two-
speed wiper motor to operate in a continuous low or
high speed cycle.
²Intermittent Wipe Mode- The control knob on
the control stalk of the multi-function switch has five
minor detent intermittent wipe positions. When
selected, these switch positions will cause the wiper
system to operate with one of five delay intervals
between complete wipe cycles. The intermittent wipe
delay intervals are speed sensitive and will be dou-
bled when the vehicle speed is about sixteen kilome-
ters-per-hour (ten miles-per-hour) or less.
²Pulse Wipe Mode- When the control knob on
the control stalk of the multi-function switch is
depressed to the momentary Wash position for less
than about one-half second, the wiper system will
operate the wipers for one complete low speed cycle,
then will park the wiper blades near the base of the
windshield.
²Washer Mode- When the control knob on the
control stalk of the multi-function switch is
depressed to the momentary Wash position for more
than about one-half second with the wiper system
turned Off, the washer pump/motor and the wipers
will operate for as long as the washer switch is held
closed up to about thirty seconds, then the wipe-af-
ter-wash mode is invoked when the control knob is
released. When the Wash position is selected with
the wiper system operating in a continuous wipe
mode, washer fluid will be dispensed onto the wind-
shield glass through the washer nozzles for as long
as the washer switch is held closed up to about thirty
seconds. When the Wash position is selected with the
wiper system operating in an intermittent wipe
mode, washer fluid is still dispensed until the control
knob is released; however, the wipers will operate in
a low speed continuous cycle from the time the
washer switch is closed until several wipe cycles
after the switch is released, before returning to the
selected intermittent wipe interval. If the control
knob is held in the depressed Wash position for more
than about thirty seconds, washer system operation
will be suspended until the control knob is released
for about two seconds then cycled back to the Wash
position.
²Wipe-After-Wash Mode- When the control
knob on the control stalk of the multi-function switch
is depressed to the momentary Wash position for
more than about one-half second with the wiper sys-
tem turned Off, the washer pump/motor and the wip-
ers will operate for as long as the washer switch is
held closed up to about thirty seconds, then provide
several additional wipe cycles after the control knob
DRWIPERS/WASHERS 8R - 3
WIPERS/WASHERS (Continued)