radiator DODGE RAM 2001 Service Repair Manual

PAINT
TABLE OF CONTENTS
page page
PAINT
SPECIFICATIONS........................129
BASE COAT/CLEAR COAT FINISH
DESCRIPTION..........................129
OPERATION............................129
PAINT CODE
DESCRIPTION..........................129PAINT TOUCH-UP
DESCRIPTION..........................129
WET SANDING/BUFFING & POLISHING
DESCRIPTION..........................130
PAINT
SPECIFICATIONS
2001 BR PAINT COLOR CODES
EXTERIOR COLORS
DC
CODEEXTERIOR
COLORDC
CODEEXTERIOR
COLOR
DX8Black Clear
CoatGW7Bright White
Clear Coat
PR4Flame Red
Clear CoatVB3Intense Blue
Pearl Coat
WBT/
WB7Patriot Blue
Pearl CoatSG8Forest Green
Pearl Coat
XV3/XVLAmber Fire
Pearl CoatWSB/
WS2Bright Silver
Metallic
Clear Coat
XTLSierra
BronzeXRVDark Garnet
Red
INTERIOR COLORS
DC
CODEINTERIOR
COLORDC
CODEINTERIOR
COLOR
A Agate M Mist Gray
C Camel
BASE COAT/CLEAR COAT
FINISH
DESCRIPTION
The original equipment finish is a multi-step pro-
cess that involves cleaning, electrodeposition (e-coat),
base coat, and clear coat steps. Additionally, selectedareas of the vehicle may be coated with an anti-chip
finish.
OPERATION
On most vehicles a two-part paint application (base
coat/clear coat) is used. Color paint that is applied to
primer is called base coat. The clear coat protects the
base coat from ultraviolet light and provides a dura-
ble high-gloss finish.
CAUTION: Do not use abrasive chemicals or com-
pounds on painted surfaces. Damage to finish can
result.
Do not use harsh alkaline based cleaning solvents
on painted surfaces. Damage to finish or color can
result.
PAINT CODE
DESCRIPTION
Exterior vehicle body colors are identified on the
Body Code plate. The plate is located on the floor pan
under the passenger seat or attached to the front
face of the radiator closure panel. Refer to the Intro-
duction section at the front of this manual for body
code plate description. The paint code is also identi-
fied on the Vehicle Safety Certification Label which
is located on the drivers door shut face. The color
names provided in the Paint and Trim Code Descrip-
tion chart are the color names used on most repair
product containers.
PAINT TOUCH-UP
DESCRIPTION
When a painted metal surface has been scratched
or chipped, it should be touched-up as soon as possi-
ble to avoid corrosion. For best results, use Moparž
BR/BEPAINT 23 - 129

HEATING & AIR CONDITIONING
TABLE OF CONTENTS
page page
HEATING & AIR CONDITIONING
DESCRIPTION............................1
OPERATION.............................1
DIAGNOSIS AND TESTING..................2
A/C PERFORMANCE.....................2
HEATER PERFORMANCE.................6STANDARD PROCEDURE...................7
DIODE REPLACEMENT...................7
SPECIFICATIONS.........................8
CONTROLS..............................9
DISTRIBUTION..........................31
PLUMBING.............................40
HEATING & AIR
CONDITIONING
DESCRIPTION - HEATER AND AIR
CONDITIONER
All vehicles are equipped with a common HVAC
housing assembly (Fig. 1). The system combines air
conditioning, heating, and ventilating capabilities in
a single unit housing mounted under the instrument
panel. On heater-only systems, the evaporator coil
and recirculation door are omitted from the housing.
DESCRIPTION - COOLING SYSTEM
REQUIREMENTS
To maintain the performance level of the HVAC
system, the engine cooling system must be properly
maintained. The use of a bug screen is not recom-
mended. Any obstructions in front of the radiator or
condenser will reduce the performance of the air con-
ditioning and engine cooling systems.The engine cooling system includes the heater core
and the heater hoses. Refer to Cooling for more infor-
mation before the opening of, or attempting any ser-
vice to the engine cooling system.
DESCRIPTION - REFRIGERANT SYSTEM
SERVICE PORT
The two refrigerant system service ports are used
to charge, recover/recycle, evacuate, and test the air
conditioning refrigerant system. Unique service port
coupler sizes are used on the R-134a system, to
ensure that the refrigerant system is not accidentally
contaminated by the use of the wrong refrigerant
(R-12), or refrigerant system service equipment.
OPERATION - HEATER AND AIR CONDITIONER
The heater and optional air conditioner are blend-air
type systems. In a blend-air system, a blend door con-
trols the amount of unconditioned air (or cooled air from
the evaporator on models with air conditioning) that is
allowed to flow through, or around, the heater core. A
temperature control knob on the A/C Heater control
panel determines the discharge air temperature by con-
trolling an electric actuator, which moves the blend
door. This allows an almost immediate control of the
output air temperature of the system.
The mode control knob on the heater-only or A/C
Heater control panel is used to direct the conditioned
air to the selected system outlets. Both mode control
switches use engine vacuum to control the mode
doors, which are operated by vacuum actuators.
On air conditioned vehicles, the outside air intake
can be shut off by selecting the Recirculation Mode
with the mode control knob. This will operate a vac-
uum actuated recirculation door that closes off the
outside fresh air intake and recirculates the air that
is already inside the vehicle.
The optional air conditioner for all models is designed
for the use of non-CFC, R-134a refrigerant. The air con-
ditioning system has an evaporator to cool and dehu-
midify the incoming air prior to blending it with the
Fig. 1 COMMON BLEND-AIR HEATER-AIR
1 - HEATER CORE
2 - BLEND DOOR
3 - EVAPORATOR (A/C ONLY)
4 - RECIRCULATION DOOR (A/C ONLY)
5 - FLOOR/PANEL DOOR
6 - FLOOR/DEFROST DOOR
BR/BEHEATING & AIR CONDITIONING 24 - 1

DIAGNOSIS AND TESTING - HEATER
PERFORMANCE
Before performing the following tests, refer to Cool-
ing for the procedures to check the engine coolant
level and flow, engine coolant reserve/recovery sys-
tem operation, accessory drive belt condition and ten-
sion, radiator air flow and the fan drive operation.
Also be certain that the accessory vacuum supply
line is connected at the engine vacuum source.
MAXIMUM HEATER OUTPUT
Engine coolant is delivered to the heater core
through two heater hoses. With the engine idling atnormal operating temperature, set the temperature
control knob in the full hot position, the mode control
switch knob in the floor position, and the blower
motor switch knob in the highest speed position.
Using a test thermometer, check the temperature of
the air being discharged at the HVAC housing floor
outlets. Compare the test thermometer reading to the
Temperature Reference chart.
Temperature Reference
Ambient Air Temperature15.5É C
(60É F)21.1É C
(70É F)26.6É C
(80É F)32.2É C
(90É F)
Minimum Air Temperature at
Floor Outlet62.2É C
(144É F)63.8É C
(147É F)65.5É C
(150É F)67.2É C
(153É F)
If the floor outlet air temperature is too low, refer
to Cooling to check the engine coolant temperature
specifications. Both of the heater hoses should be hot
to the touch. The coolant return heater hose should
be slightly cooler than the coolant supply heater
hose. If the return hose is much cooler than the sup-
ply hose, locate and repair the engine coolant flow
obstruction in the cooling system. Refer to Cooling
for the procedures.
An alternate method of checking heater perfor-
mance is to use a DRBIIItscan tool to monitor the
engine coolant temperature. The floor outlet air tem-
perature reading should be no more than 4.5É C (40É
F) lower than the engine coolant temperature read-
ing.
OBSTRUCTED COOLANT FLOW Possible loca-
tions or causes of obstructed coolant flow:
²Faulty water pump.
²Faulty thermostat.
²Pinched or kinked heater hoses.
²Improper heater hose routing.
²Plugged heater hoses or supply and return ports
at the cooling system connections.
²A plugged heater core.If proper coolant flow through the cooling system is
verified, and heater outlet air temperature is still
low, a mechanical problem may exist.
MECHANICAL PROBLEMS Possible locations or
causes of insufficient heat:
²An obstructed cowl air intake.
²Obstructed heater system outlets.
²A faulty, obstructed or improperly installed
blend door.
²A faulty blower system.
²A faulty a/c heater control.
TEMPERATURE CONTROL
If the heater outlet air temperature cannot be
adjusted with the temperature control knob on the
a/c heater control panel, the following could require
service:
²A faulty a/c heater control.
²A faulty blend door actuator.
²A faulty, obstructed or improperly installed
blend door.
²An obstructed cowl air intake.
²The engine cooling system.
24 - 6 HEATING & AIR CONDITIONINGBR/BE
HEATING & AIR CONDITIONING (Continued)

Heater Diagnosis
CONDITION POSSIBLE CAUSE CORRECTION
INSUFFICIENT HEATER
OUTPUT.1. Incorrect engine
coolant level.1. Check the engine coolant level. Refer to Cooling for
the procedures.
2. Air trapped in engine
cooling system.2. Check the operation of the coolant reserve/recovery
system. Refer to Cooling for the procedures.
3. Incorrect engine
coolant temperature.3. Check the performance and operation of the engine
cooling system including: thermostat, water pump, fan
drive, accessory drive belt, coolant flow (plugged radiator
or heater core, plugged or kinked coolant hoses), air flow
(missing or improperly installed radiator air seals or fan
shroud). Refer to Cooling for the procedures.
4. Blend door actuator
inoperative or defective.4. (Refer to Controls/Blend Door Actuator) in this group.
5. Blend door not
operating properly.5. Check for a damaged, obstructed or improperly
installed blend door or seals. (Refer to Controls/Blend
Door Actuator) in this group.
6. Insufficient air flow
through heater housing.6. Remove foreign material or obstructions from cowl air
intake.
7. Improper blower motor
operation.7. (Refer to Distribution/Blower Motor/ Diagnosis and
Testing) in this group.
STANDARD PROCEDURE - DIODE
REPLACEMENT
(1) Disconnect the battery.
(2) Locate the diode in the harness, and remove
the protective covering.
(3) Remove the diode from the harness, pay atten-
tion to the current flow direction (Fig. 3).(4) Remove the insulation from the wires in the
harness. Only remove enough insulation to solder in
the new diode.
(5) Install the new diode in the harness, making
sure current flow is correct. If necessary refer to the
appropriate wiring diagram for current flow.
(6) Solder the connection together using rosin core
type solder only.Do not use acid core solder.
(7) Tape the diode to the harness using electrical
tape making, sure the diode is completely sealed
from the elements.
(8) Re-connect the battery, and test affected sys-
tems.
Fig. 3 DIODE IDENTIFICATION
1 - CURRENT FLOW
2 - BAND AROUND DIODE INDICATES CURRENT FLOW
3 - DIODE AS SHOWN IN THE DIAGRAMS
BR/BEHEATING & AIR CONDITIONING 24 - 7
HEATING & AIR CONDITIONING (Continued)

(3) Install the serpentine drive belt. Refer to Cool-
ing for the procedures.
(4) Plug in the compressor clutch coil wire harness
connector.
(5) Connect the battery negative cable.
(6) Evacuate the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE)
(7) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE)
A/C CONDENSER
DESCRIPTION
The condenser is located in the air flow in front of
the engine cooling radiator. The condenser is a heat
exchanger that allows the high-pressure refrigerant
gas being discharged by the compressor to give up itsheat to the air passing over the condenser fins, thus
causing the refrigerant to change to a liquid state.
OPERATION
When the refrigerant gas gives up its heat, it con-
denses. When the refrigerant leaves the condenser, it
has become a high-pressure liquid refrigerant. The
volume of air flowing over the condenser fins is crit-
ical to the proper cooling performance of the air con-
ditioning system. Therefore, it is important that
there are no objects placed in front of the radiator
grille openings in the front of the vehicle or foreign
material on the condenser fins that might obstruct
proper air flow. Also, any factory-installed air seals or
shrouds must be properly reinstalled following radia-
tor or condenser service.
The condenser cannot be repaired and, if faulty or
damaged, it must be replaced.
Fig. 4 COMPRESSOR REMOVE/INSTALL - GASOLINE ENGINE
1 - BRACKET
2 - A/C COMPRESSOR
3 - BOLT AND WASHER4 - BRACE
5 - BOLT
24 - 48 PLUMBINGBR/BE
A/C COMPRESSOR (Continued)

REMOVAL
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - WARNING) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION)
(1) Disconnect and isolate the battery negative
cable.
(2) Recover the refrigerant from the refrigerant
system. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - STANDARD PROCEDURE -
REFRIGERANT RECOVERY)
(3) Remove the nut that secures the block fitting
to the stud on the condenser inlet, and disconnect the
discharge line from the condenser. Install plugs in, or
tape over all of the opened refrigerant line fittings.
(4) Disconnect the refrigerant line fitting that
secures the liquid line to the condenser outlet. (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING - STANDARD PROCEDURE - A/C LINE COU-
PLER) Install plugs in, or tape over all of the opened
refrigerant line fittings.
(5) On gasoline engine models:(a) Remove the two screws that secure the con-
denser upper mounting brackets to the outside of
the upper radiator crossmember (Fig. 6).
(b) Tilt the condenser away from the engine
compartment far enough to grasp the top of the
condenser with both hands.
(c) Lift the condenser far enough to remove the
two lower condenser locators from the isolators in
the holes of the lower crossmember.
(d) Remove the condenser from the vehicle.
(6) On diesel engine models:
(a) Remove the two screws that secure the
brackets on the passenger side end of the con-
denser to the charge air cooler (Fig. 7).
(b) Remove the two nuts that secure the driver
side end of the condenser to the studs on the
charge air cooler.
(c) Remove the condenser from the vehicle.
INSTALLATION
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - WARNING) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION)(Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING -
CAUTION - REFRIGERANT HOSES/LINES/TUBES
PRECAUTIONS)
Fig. 5 COMPRESSOR REMOVE/INSTALL - DIESEL
ENGINE
1 - ENGINE
2 - BRACKET
3 - A/C COMPRESSOR
4 - BOLTS
Fig. 6 CONDENSER REMOVE/INSTALL - GASOLINE
ENGINE
1 - CONDENSER
2 - LOCATOR
3 - ISOLATOR
4 - SCREW
BR/BEPLUMBING 24 - 49
A/C CONDENSER (Continued)

(1) On gasoline engine models:
(a) Insert the two lower condenser locators into
the isolators in the holes of the lower crossmember.
(b) Tilt the condenser up towards the engine
compartment far enough to align the upper mount-
ing bracket holes with the holes in the upper radi-
ator crossmember.
(c) Install the two screws that secure the con-
denser upper mounting brackets to the outside of
the upper radiator crossmember. Tighten the
mounting screws to 10.5 N´m (95 in. lbs.).
(2) On diesel engine models:
(a) Install the driver side condenser mounting
brackets over the two studs on the charge air
cooler.
(b) Install the two screws that secure the brack-
ets on the passenger side end of the condenser to
the charge air cooler. Tighten the mounting screws
to 10.5 N´m (95 in. lbs.).
(c) Install the two nuts that secure the driver
side end of the condenser to the studs on the
charge air cooler. Tighten the mounting nuts to
10.5 N´m (95 in. lbs.).
(3) Remove the plugs or tape from the refrigerant
line fittings on the liquid line and the condenser out-
let. Connect the liquid line to the condenser outlet.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - STANDARD PROCEDURE - A/C LINE
COUPLERS)
(4) Install a new gasket and the discharge line
block fitting over the stud on the condenser inlet.
Tighten the mounting nut to 20 N´m (180 in. lbs.).
(5) Check that all of the condenser and radiator
air seals are in their proper locations.(6) Connect the battery negative cable.
(7) Evacuate the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE)
(8) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE)
NOTE: If the condenser is replaced, add 30 millili-
ters (1 fluid ounce) of refrigerant oil to the refriger-
ant system. Use only refrigerant oil of the type
recommended for the compressor in the vehicle.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/REFRIGERANT OIL - DESCRIPTION)
SUCTION AND DISCHARGE
LINE
REMOVAL
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - WARNING) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION)
(1) Disconnect and isolate the battery negative
cable.
(2) Recover the refrigerant from the refrigerant
system. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - STANDARD PROCEDURE -
REFRIGERANT RECOVERY)
(3) Unplug the wire harness connector from the a/c
high pressure switch.
(4) Disconnect the suction line refrigerant line cou-
pler at the accumulator. (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - STANDARD
PROCEDURE - A/C LINE COUPLER) Install plugs
in, or tape over all of the opened refrigerant line fit-
tings.
(5) Remove the nut that secures the block fitting
to the stud on the condenser inlet and disconnect the
discharge line from the condenser. Install plugs in, or
tape over all of the opened refrigerant line fittings.
(6) On models with a gasoline engine, remove the
nut that secures the refrigerant line support bracket
to the stud on the compressor mounting bracket.
(7) Remove the bolt that secures the refrigerant
line manifold to the compressor (Fig. 8) or (Fig. 9).
Install plugs in, or tape over all of the opened refrig-
erant line fittings.
Fig. 7 CONDENSER REMOVE/INSTALL - DIESEL
ENGINE
1 - CHARGE AIR COOLER
2 - NUT
3 - CONDENSER
4 - SCREW
24 - 50 PLUMBINGBR/BE
A/C CONDENSER (Continued)

(M)Malfunction Indicator Lamp (MIL) illuminated during engine operation if this DTC was recorded
(depending if required by CARB and/or EPA). MIL is displayed as an engine icon on instrument panel.
(G)Generator lamp illuminated
Generic Scan
Tool P-CodeDRB Scan Tool Display Brief Description of DTC
P1195 (M) 1/1 O2 Sensor Slow During Catalyst
MonitorA slow switching oxygen sensor has been detected in
bank 1/1 during catalyst monitor test. (Also see SCI DTC
$66) (was P0133)
P1196 (M) 2/1 O2 Sensor Slow During Catalyst
MonitorA slow switching oxygen sensor has been detected in
bank 2/1 during catalyst monitor test. (Also see SCI DTC
$7A) (was P0153)
P1197 1/2 O2 Sensor Slow During Catalyst
MonitorA slow switching oxygen sensor has been detected in
bank 1/2 during catalyst monitor test. (Also see SCI DTC
$68) (was P0139)
P1198 Radiator Temperature Sensor Volts
Too HighRadiator coolant temperature sensor input above the
maximum acceptable voltage.
P1199 Radiator Temperature Sensor Volts
Too LowRadiator coolant temperature sensor input below the
minimum acceptable voltage.
P1281 Engine is Cold Too Long Engine coolant temperature remains below normal
operating temperatures during vehicle travel (Thermostat).
P1282 Fuel Pump Relay Control Circuit An open or shorted condition detected in the fuel pump
relay control circuit.
P1283 Idle Select Signal Invalid ECM or fuel injection pump module internal fault condition
detected.
P1284 (M) Fuel Injection Pump Battery Voltage
Out-Of-RangeFuel injection pump module internal fault condition
detected. Engine power will be derated.
P1285 (M) Fuel Injection Pump Controller
Always OnFuel injection pump module relay circuit failure detected.
Engine power will be derated.
P1286 Accelerator Position Sensor (APPS)
Supply Voltage Too HighHigh voltage detected at APPS.
P1287 Fuel Injection Pump Controller
Supply Voltage LowECM or fuel injection pump module internal fault condition
detected. Engine power will be derated.
P1288 Intake Manifold Short Runner
Solenoid CircuitAn open or shorted condition detected in the short runner
tuning valve circuit.
P1289 Manifold Tune Valve Solenoid Circuit An open or shorted condition detected in the manifold
tuning valve solenoid control circuit.
P1290 CNG Fuel System Pressure Too
HighCompressed natural gas system pressure above normal
operating range.
P1291 No Temp Rise Seen From Intake
HeatersEnergizing Heated Air Intake does not change intake air
temperature sensor an acceptable amount.
P1291 (M) No Temperature Rise Seen From
Intake Air HeatersProblem detected in intake manifold air heating system.
P1292 CNG Pressure Sensor Voltage Too
HighCompressed natural gas pressure sensor reading above
acceptable voltage.
P1293 CNG Pressure Sensor Voltage Too
LowCompressed natural gas pressure sensor reading below
acceptable voltage.
P1294 (M) Target Idle Not Reached Target RPM not achieved during drive idle condition.
Possible vacuum leak or IAC (AIS) lost steps.
25 - 10 EMISSIONS CONTROLBR/BE
EMISSIONS CONTROL (Continued)

(M)Malfunction Indicator Lamp (MIL) illuminated during engine operation if this DTC was recorded
(depending if required by CARB and/or EPA). MIL is displayed as an engine icon on instrument panel.
(G)Generator lamp illuminated
Generic Scan
Tool P-CodeDRB Scan Tool Display Brief Description of DTC
P1482 Catalyst Temperature Sensor Circuit
Shorted LowCatalyst temperature sensor circuit shorted low.
P1483 Catalyst Temperature Sensor Circuit
Shorted High.Catalyst temperature sensor circuit shorted high.
P1484 Catalytic Converter Overheat
DetectedA catalyst overheat condition has been detected by the
catalyst temperature sensor.
P1485 Air Injection Solenoid Circuit An open or shorted condition detected in the air assist
solenoid circuit.
P1486 Evap Leak Monitor Pinched Hose
FoundLDP has detected a pinched hose in the evaporative hose
system.
P1487 Hi Speed Rad Fan CTRL Relay
CircuitAn open or shorted condition detected in the control
circuit of the #2 high speed radiator fan control relay.
P1488 Auxiliary 5 Volt Supply Output Too
LowAuxiliary 5 volt sensor feed is sensed to be below an
acceptable limit.
P1488 5 Volt Supply Voltage Low Sensor supply voltage for ECM sensors is too low.
P1489 High Speed Fan CTRL Relay Circuit An open or shorted condition detected in the control
circuit of the high speed radiator fan control relay.
P1490 Low Speed Fan CTRL Relay Circuit An open or shorted condition detected in control circuit of
the low speed radiator fan control relay.
P1491 Rad Fan Control Relay Circuit An open or shorted condition detected in the radiator fan
control relay control circuit. This includes PWM solid state
relays.
P1492 Ambient/Batt Temp Sen Volts Too
HighExternal temperature sensor input above acceptable
voltage.
P1492 (M) Ambient/Batt Temp Sensor Volts Too
HighBattery temperature sensor input voltage above an
acceptable range.
P1493 (M) Ambient/Batt Temp Sen Volts Too
LowExternal temperature sensor input below acceptable
voltage.
P1493 (M) Ambient/Batt Temp Sen Volts Too
LowBattery temperature sensor input voltage below an
acceptable range.
P1494 (M) Leak Detection Pump Sw or
Mechanical FaultIncorrect input state detected for the Leak Detection
Pump (LDP) pressure switch.
P1495 Leak Detection Pump Solenoid
CircuitAn open or shorted condition detected in the Leak
Detection Pump (LDP) solenoid circuit.
P1496 5 Volt Supply, Output Too Low 5 volt sensor feed is sensed to be below an acceptable
limit. ( less than 4v for 4 sec )
P1498 High Speed Rad Fan Ground CTRL
Rly CircuitAn open or shorted condition detected in the control
circuit of the #3 high speed radiator fan control relay.
P1499 Hydraulic cooling fan solenoid circuit An open or shorted condition detected in the cooling fan
control solenoid circuit.
P1594 (G) Charging System Voltage Too High Battery voltage sense input above target charging voltage
during engine operation.
P1594 Charging System Voltage Too High Battery voltage sense input above target charging voltage
during engine operation.
25 - 12 EMISSIONS CONTROLBR/BE
EMISSIONS CONTROL (Continued)

Check windshield washer solvent reservoir and fill
as necessary (Fig. 6).
NOTE: When using concentrated solvent such as
MoparTAll-Weather Windshield Washer Solution,
dilute per container directions.
COOLING SYSTEM RESERVOIR
WARNING: DO NOT REMOVE RADIATOR CAP
WHILE COOLING SYSTEM IS UNDER PRESSURE.
NOTE: Add coolant only to plastic reserve tank if it is
required. Engine must be at normal operating temper-
ature before adding coolant to reserve tank. In cold
climates, coolant in reserve tank may appear low; do
not add coolant until normal temperature is reached.
Check coolant level with engine idling at normal
operating temperature. Coolant level in plastic
reserve tank must be between the minimum and
maximun marks (Fig. 7).
If coolant is added, use a 50/50 (-309F protection) con-
centration of the recommended (Refer to the Service
Information for specificate Mopartantifreeze recom-
mendation ) antifreeze and distilled water. Use a
higher concentration (up to 65%) if a lower freeze point
is required. Do not use recycled coolant in new vehicles.
INSPECTION - LINES/HOSES
Inspect the following for line and hose leaks. Also
inspect routing and connections and reroute and
tighten as required.²Brake Lines (Fig. 8)
²Fuel Lines (Fig. 9)
²Power Steering Hoses
²Vacuum Hoses
²Heating/Coolant Hoses
²Clutch Lines
²Refrigerant Lines
²Transmission oil cooler lines (Fig. 10)
Fig. 7 ENGINE COOLANT RESERVOIRFig. 8 PARKING BRAKE CABLE AND BRAKE LINE
Fig. 9 BRAKE LINES AND FUEL LINES
1 - FUEL LINE
2 - BRAKE LINE
30 - 6 NEW VEHICLE PREPARATIONBR/BE
UNDER HOOD (Continued)