fuse box DODGE RAM 2001 Service User Guide
[x] Cancel search | Manufacturer: DODGE, Model Year: 2001, Model line: RAM, Model: DODGE RAM 2001Pages: 2889, PDF Size: 68.07 MB
Page 756 of 2889
8W-02 COMPONENT INDEX
Component Page
4WD Switch.......................... 8W-31
A/C Compressor Clutch Relay............ 8W-42
A/C Compressor Clutch................. 8W-42
A/C-Heater Control.................... 8W-42
A/C Heater Temperature Select........... 8W-42
A/C High Pressure Switch............... 8W-42
A/C Low Pressure Switch................ 8W-42
Accelerator Pedal Position Sensor......... 8W-30
Aftermarket Center High Mounted
Stop Lamp......................... 8W-51
Aftermarket Trailer Tow Connector........ 8W-54
Airbag Control Module.................. 8W-43
Ambient Temperature Sensor............ 8W-49
Ash Receiver Lamp.................... 8W-44
Automatic Day/Night Mirror............. 8W-49
Automatic Shut Down Relay............. 8W-30
Auxiliary Battery...................... 8W-20
Back-Up Lamp Switch.................. 8W-51
Back-Up Lamps....................... 8W-51
Battery Temperature Sensor............. 8W-30
Battery............................. 8W-20
Blend Door Actuator................... 8W-42
Blower Motor Relay.................... 8W-42
Blower Motor Resistor Block............. 8W-42
Blower Motor......................... 8W-42
Brake Lamp Switch.................... 8W-51
Brake Pressure Switch............... 8W-34, 35
Bypass Jumper....................... 8W-21
Camshaft Position Sensor............... 8W-30
Capacitor......................... 8W-10, 30
Cargo Lamps......................... 8W-44
Center High Mounted Stop Lamps........ 8W-51
Center Identification Lamp.............. 8W-50
Central Timer Module.................. 8W-45
Cigar Lighter......................... 8W-41
Circuit Breakers...................... 8W-12
Clockspring.................. 8W-33, 41, 43, 47
Clutch Pedal Position Switch............. 8W-21
Combination Flasher................... 8W-52
Controller Antilock Brake............ 8W-34, 35
Crankshaft Position Sensor.............. 8W-30
Cummins Bus........................ 8W-18
Cup Holder Lamp..................... 8W-44
Cylinder Lock Switches................ 8W-39
Data Link Connector................... 8W-18
Daytime Running Lamp Module.......... 8W-50
Dome Lamp.......................... 8W-44
Door Ajar Switches.................... 8W-45
Door Lock Motors..................... 8W-61
Door Window/Lock Switches.......... 8W-60, 61
Driver Airbag......................... 8W-43
Duty Cycle EVAP/Purge Solenoid......... 8W-30Component Page
Electric Brake Provision................ 8W-54
Engine Control Module.............. 8W-30, 70
Engine Coolant Temperature Sensor....... 8W-30
Engine Oil Pressure Sensor.............. 8W-30
Engine Starter Motor Relay.............. 8W-21
Engine Starter Motor................... 8W-21
Fender Lamp......................... 8W-51
Fog Lamp Indicator.................... 8W-50
Fog Lamp Relay....................... 8W-50
Fog Lamp............................ 8W-50
Fuel Heater Relay..................... 8W-30
Fuel Heater.......................... 8W-30
Fuel Injection Pump................... 8W-30
Fuel Injectors......................... 8W-30
Fuel Transfer Pump.................... 8W-30
Fuses (JB)........................... 8W-12
Fuses (PDC).......................... 8W-10
Fusible Link....................... 8W-20, 30
Generator............................ 8W-20
Glove Box Lamp And Switch............. 8W-44
Grounds............................. 8W-15
Headlamp Beam Select Switch........... 8W-50
Headlamp Switch...................... 8W-50
Headlamp........................... 8W-50
Heated Mirror Relay................... 8W-62
Heated Mirror Switch.................. 8W-62
Heated Seat Cushions.................. 8W-63
Heated Seat Relay..................... 8W-12
Heated Seat Switches.................. 8W-63
High Beam Indicator................... 8W-40
High Note Horn....................... 8W-41
Horn Relay.......................... 8W-41
Horn Switch.......................... 8W-41
Idle Air Control Motor.................. 8W-30
Ignition Coil 4-Pack.................... 8W-30
Ignition Coil 6-Pack.................... 8W-30
Ignition Coil.......................... 8W-30
Ignition Switch....................... 8W-10
Instrument Cluster.................... 8W-40
Intake Air Heater Relays................ 8W-30
Intake Air Heater..................... 8W-30
Intake Air Temperature Sensor........... 8W-30
Intermittent Wiper Switch............... 8W-53
Joint Connectors . . 8W-10, 12, 15, 30, 31, 34, 35, 40,
44, 45, 51, 53, 70
Junction Block........................ 8W-12
Leak Detection Pump.................. 8W-30
License Lamp......................... 8W-51
Low Note Horn....................... 8W-41
Lumbar Motors....................... 8W-63
Manifold Absolute Pressure Sensor........ 8W-30
Manifold Air Pressure Sensor............ 8W-30
BR/BE8W-02 COMPONENT INDEX 8W - 02 - 1
Page 786 of 2889
8W-12 JUNCTION BLOCK
Component Page
A/C Compressor Clutch Relay.......... 8W-12-13
A/C-Heater Control................... 8W-12-9
A/C Heater Temperature Select......... 8W-12-8
Airbag Control Module............... 8W-12-17
Ambient Temperature Sensor.......... 8W-12-19
Ash Receiver Lamp................... 8W-12-9
Automatic Day/Night Mirror..... 8W-12-13, 15, 21
Back-Up Lamp Switch............. 8W-12-11, 21
Blend Door Actuator.................. 8W-12-8
Blower Motor Relay.................. 8W-12-8
Cargo Lamp No. 1................... 8W-12-14
Cargo Lamp No. 2................... 8W-12-14
Central Timer Module C1....... 8W-12-10, 13, 15
Central Timer Module C2........... 8W-12-8, 13
Cigar Lighter...................... 8W-12-16
Circuit Breaker 1.................. 8W-12-6, 7
Circuit Breaker 2.................... 8W-12-7
Combination Flasher......... 8W-12-6, 12, 15, 20
Controller Antilock Brake.............. 8W-12-8
Cup Holder Lamp.................... 8W-12-9
Data Link Connector................. 8W-12-14
Daytime Running Lamp Module........ 8W-12-11
Dome Lamp....................... 8W-12-14
Driver Door Window/Lock Switch..... 8W-12-15, 7
Driver Heated Seat Switch........... 8W-12-8, 9
Driver Power Seat Switch.............. 8W-12-7
Duty Cycle EVAP/Purge Solenoid....... 8W-12-13
Engine Control Module............... 8W-12-12
Fuel Heater Relay................... 8W-12-13
Fuel Pump Relay................... 8W-12-12
Fuse 1 (JB)......................... 8W-12-8
Fuse 1 (PDC)...................... 8W-12-16
Fuse 2 (JB)....................... 8W-12-6, 8
Fuse 3 (JB)....................... 8W-12-6, 8
Fuse 4 (JB)........................ 8W-12-10
Fuse 4 (PDC)...................... 8W-12-20
Fuse 5 (JB)......................... 8W-12-9
Fuse 6 (JB)...................... 8W-12-6, 10
Fuse 7 (JB)...................... 8W-12-6, 11
Fuse 8 (JB)...................... 8W-12-6, 11
Fuse 9 (JB)...................... 8W-12-6, 12
Fuse 10 (JB).................. 8W-12-6, 12, 20
Fuse 11 (JB)..................... 8W-12-6, 13
Fuse 12 (JB)....................... 8W-12-14
Fuse 13 (JB)....................... 8W-12-15
Fuse 14 (JB)....................... 8W-12-16Component Page
Fuse 15 (JB)..................... 8W-12-6, 16
Fuse 16 (JB)..................... 8W-12-6, 16
Fuse 17 (JB)..................... 8W-12-6, 17
Fuse 18 (JB)..................... 8W-12-6, 17
Fuse 19 (JB)..................... 8W-12-6, 17
G100............................. 8W-12-18
G200.......................... 8W-12-15, 19
G201....................... 8W-12-15, 18, 20
Glove Box Lamp And Switch........... 8W-12-14
Headlamp Switch.................... 8W-12-9
Heated Mirror Switch................. 8W-12-8
Heated Seat Relay................... 8W-12-8
Ignition Switch................... 8W-12-6, 20
Instrument Cluster.......... 8W-12-9, 16, 17, 18
Intermittent Wiper Switch............ 8W-12-10
Joint Connector No. 1............. 8W-12-11, 21
Joint Connector No. 3................ 8W-12-18
Joint Connector No. 4................ 8W-12-18
Joint Connector No. 5.............. 8W-12-9, 14
Joint Connector No. 6................ 8W-12-10
Joint Connector No. 8........... 8W-12- 8, 9, 17
Junction Block............ 8W-12-2, 3, 6, 7, 8, 9,
10, 11, 12, 13, 14, 15, 16,
17, 18, 19, 20, 21
Left Park/Turn Signal Lamp........... 8W-12-18
Left Visor/Vanity Lamp............ 8W-12-14, 15
Overhead Console.......... 8W-12-13, 14, 19, 21
Park/Neutral Position Switch....... 8W-12-11, 21
Passenger Airbag On/Off Switch........ 8W-12-17
Passenger Door Window/Lock Switch . . 8W-12-7, 15
Passenger Heated Seat Switch........ 8W-12-8, 9
Passenger Power Seat Switch........... 8W-12-7
Power Distribution Center......... 8W-12-16, 20
Power Mirror Switch.............. 8W-12-14, 21
Powertrain Control Module............ 8W-12-12
Radio Choke Relay.................. 8W-12-10
Radio....................... 8W-12-9, 11, 14,
Right Park/Turn Signal Lamp.......... 8W-12-18
Right Visor/Vanity Lamp........... 8W-12-14, 15
Seat Heat Interface Module............ 8W-12-8
Turn Signal/Hazard Switch......... 8W-12-18, 20
Underhood Lamp................... 8W-12-14
Windshield Washer Pump............. 8W-12-10
Wiper Motor Relay.................. 8W-12-10
Wiper Motor....................... 8W-12-10
BR/BE8W-12 JUNCTION BLOCK 8W - 12 - 1
Page 924 of 2889
8W-44 INTERIOR LIGHTING
Component Page
Ash Receiver Lamp................... 8W-44-6
Cargo Lamp No. 1.................... 8W-44-4
Cargo Lamp No. 2.................... 8W-44-4
Central Timer Module C1.............. 8W-44-5
Cup Holder Lamp.................... 8W-44-6
Data Link Connector................. 8W-44-2
Dome Lamp........................ 8W-44-4
Fuse 5 (JB)......................... 8W-44-6
Fuse 11 (JB)........................ 8W-44-5
Fuse 12 (JB)...................... 8W-44-2, 3
G100.............................. 8W-44-2
G200.............................. 8W-44-3
G201.......................... 8W-44-2, 4, 6
Glove Box Lamp And Switch............ 8W-44-2Component Page
Headlamp Switch................ 8W-44-4, 5, 6
Ignition Switch...................... 8W-44-5
Joint Connector No. 4................. 8W-44-2
Joint Connector No. 5............... 8W-44-2, 6
Joint Connector No. 6................. 8W-44-5
Joint Connector No. 8............. 8W-44-4, 5, 6
Junction Block............... 8W-44-2, 3, 4, 5, 6
Left Visor/Vanity Lamp................ 8W-44-2
Overhead Console.................... 8W-44-3
Power Mirror Switch.................. 8W-44-4
Radio............................ 8W-44-2, 6
Right Visor/Vanity Lamp............... 8W-44-2
Underhood Lamp.................... 8W-44-2
BR/BE8W-44 INTERIOR LIGHTING 8W - 44 - 1
Page 1058 of 2889
GENERATOR - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 K20 18DG GENERATOR FIELD
2 T125 18DB GENERATOR SOURCE
GLOVE BOX LAMP AND SWITCH-2WAY
CAV CIRCUIT FUNCTION
1 M1 22PK FUSED B(+)
2 Z3 22BK/OR GROUND
HEADLAMP SWITCH C1 - BLACK 14 WAY
CAV CIRCUIT FUNCTION
1 L7 16BK/YL HEADLAMP SWITCH OUTPUT
2 F33 16PK/RD FUSED B(+)
3 G26 22LB KEY-IN IGNITION SWITCH SENSE
4 G75 22TN (BASE) DRIVER DOOR AJAR SWITCH SENSE
4 Z3 22BK/OR (HIGHLINE/PREMIUM) GROUND
5 Z3 18BK/OR GROUND
6 L2 18LG HEADLAMP SWITCH OUTPUT
7 L39 22LB FOG LAMP SWITCH OUTPUT
8 E17 18YL/BK DAY BRIGHTNESS SENSE
9 Z3 20BK/OR GROUND
10 M22 22WT ILLUMINATED ENTRY SWITCH SENSE
11 M3 22PK/DB CARGO LAMP DRIVER
12 M2 22YL COURTESY LAMPS DRIVER
13 M11 22PK/LB (HIGHLINE/PREMIUM) COURTESY LAMPS SWITCH OUTPUT
13 M22 22WT (BASE) ILLUMINATED ENTRY SWITCH SENSE
14 E1 18TN PANEL LAMPS DIMMER SWITCH SIGNAL
HEADLAMP SWITCH C2-2WAY
CAV CIRCUIT FUNCTION
1 Z3 20BK/OR GROUND
2 L35 22BR/YL FOG LAMP RELAY OUTPUT
HEATED MIRROR SWITCH-3WAY
CAV CIRCUIT FUNCTION
1 F15 22DB FUSED IGNITION SWITCH OUTPUT (RUN)
2 Z3 22BK/OR GROUND
3 C16 22LB/YL HEATED MIRROR
BR/BE8W-80 CONNECTOR PIN-OUTS 8W - 80 - 45
Page 1136 of 2889
8W-97 POWER DISTRIBUTION
TABLE OF CONTENTS
page page
POWER DISTRIBUTION
DESCRIPTION............................1
OPERATION.............................1
SPECIAL TOOLS..........................2
CIGAR LIGHTER OUTLET
DESCRIPTION............................2
OPERATION.............................2
DIAGNOSIS AND TESTING..................2
CIGAR LIGHTER........................2
REMOVAL...............................3
INSTALLATION............................3
CIRCUIT BREAKER
DESCRIPTION............................4
DIAGNOSIS AND TESTING..................4
CIRCUIT BREAKER......................4
GENERATOR CARTRIDGE FUSE
DESCRIPTION............................4
OPERATION.............................4
REMOVAL...............................4
INSTALLATION............................4
IOD FUSE
DESCRIPTION............................4OPERATION.............................5
REMOVAL...............................5
INSTALLATION............................5
JUNCTION BLOCK
DESCRIPTION............................6
OPERATION.............................6
REMOVAL...............................6
INSTALLATION............................7
POWER DISTRIBUTION CENTER
DESCRIPTION............................7
OPERATION.............................8
REMOVAL...............................8
INSTALLATION............................8
POWER OUTLET
DESCRIPTION............................9
OPERATION.............................10
DIAGNOSIS AND TESTING.................10
POWER OUTLET.......................10
REMOVAL..............................10
INSTALLATION...........................11
POWER DISTRIBUTION
DESCRIPTION
This group covers the various standard and
optional power distribution components used on this
model. The power distribution system for this vehicle
consists of the following components:
²Power Distribution Center (PDC)
²Junction Block (JB).
The power distribution system also incorporates
various types of circuit control and protection fea-
tures, including:
²Automatic resetting circuit breakers
²Blade-type fuses
²Cartridge fuses
²Circuit splice blocks
²Flashers
²Relays.
Following are general descriptions of the major
components in the power distribution system. See the
owner's manual in the vehicle glove box for more
information on the features and use of all of thepower distribution system components. Refer to the
index in this service manual for the location of com-
plete circuit diagrams for the various power distribu-
tion system components.
OPERATION
The power distribution system for this vehicle is
designed to provide safe, reliable, and centralized dis-
tribution points for the electrical current required to
operate all of the many standard and optional facto-
ry-installed electrical and electronic powertrain,
chassis, safety, security, comfort and convenience sys-
tems. At the same time, the power distribution sys-
tem was designed to provide ready access to these
electrical distribution points for the vehicle techni-
cian to use when conducting diagnosis and repair of
faulty circuits. The power distribution system can
also prove useful for the sourcing of additional elec-
trical circuits that may be required to provide the
electrical current needed to operate many accessories
that the vehicle owner may choose to have installed
in the aftermarket.
BR/BE8W-97 POWER DISTRIBUTION 8W - 97 - 1
Page 2678 of 2889
hook formations on the lower edge of the glove box
door are engaged with and pivot on three hinge pins
integral to the lower edge of the instrument panel
support structure. The glove box door also serves as
the passenger side knee blocker. A honeycomb struc-
ture between the inner and outer glove box door pan-
els helps to absorb the impact load and distribute it
to the instrument panel structure.
²Steering Column Opening Cover- The steer-
ing column opening cover serves as the driver side
knee blocker. This molded plastic cover has an inte-
gral ribbed plastic liner concealed behind it, for
increased strength and integrity. The steering column
opening cover transfers impact loads to the instru-
ment panel structural support.
²Top Cover- The instrument panel top cover or
base trim is the molded, grained, and color impreg-
nated plastic outer skin of the instrument panel
structural support.
Hard wired circuitry connects the electrical compo-
nents on the instrument panel to each other through
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 con-
nected to each other, to the vehicle electrical system
and to the instrument panel 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 information. The wiring informa-
tion includes complete circuit diagrams, proper wire
and connector repair procedures, further details on
wire harness routing and retention, as well as pin-
out and location views for the various wire harness
connectors, splices, and grounds.
OPERATION
The instrument panel serves as the command cen-
ter of the vehicle, which necessarily makes it a very
complex unit. The instrument panel is designed to
house the controls and monitors for standard and
optional powertrains, climate control systems, audio
systems, safety systems, and many other comfort or
convenience items. When the components of the
instrument panel structural support are properly
assembled and secured in the vehicle they provide
superior instrument panel stiffness and integrity to
help reduce buzzes, squeaks, and rattles. This type of
construction also provides improved energy absorp-
tion which, in conjunction with the dual airbags and
seat belts, helps to improve occupant protection.
The instrument panel is also designed so that all of
the various controls can be safely reached and the
monitors can be easily viewed by the vehicle operator
when driving, while still allowing relative ease ofaccess to each of these items for service. Modular
instrument panel construction allows all of the
gauges and controls to be serviced from the front of
the panel. In addition, most of the instrument panel
electrical components can be accessed without com-
plete instrument panel removal. However, if neces-
sary, the instrument panel can be removed from the
vehicle as an assembly.
The steering column opening cover with its inte-
gral knee blocker located on the driver side of the
instrument panel works in conjunction with the air-
bag system in a frontal vehicle impact to keep the
driver properly positioned for an airbag deployment.
In addition, removal of this component provides
access to the steering column mounts, the steering
column wiring, the Junction Block (JB) (removal of a
snap-fit fuse access panel on the left end of the
instrument panel allows access to the fuses and cir-
cuit breakers), the Central Timer Module (CTM), the
Infinity speaker filter choke and relay unit, much of
the instrument panel wiring, and the gear selector
indicator cable (automatic transmission).
In a frontal collision, the glove box door on the pas-
senger side of the instrument panel provides the
same function for the front seat passenger as the
knee blocker does for the driver. The glove box door
also incorporates a recessed latch handle. Removal of
the glove box provides access to the passenger airbag,
the glove box lamp and switch, the radio antenna
coaxial cable, the heating and air conditioning vac-
uum harness connector, and additional instrument
panel wiring.
Removal of the instrument panel cluster bezel
allows access to the headlamp switch, instrument
cluster, radio, passenger airbag on-off switch, heated
seat switches (if equipped), and the heating and air
conditioning control. Removal of the instrument clus-
ter allows access to the cluster illumination and indi-
cator bulbs, and more of the instrument panel
wiring. Complete instrument panel removal is
required for service of most components internal to
the heating and air conditioning system housing,
including the heater core and the evaporator.
See the owner's manual in the vehicle glove box for
more information on the features, use and operation
of all of the components and systems mounted on or
in the instrument panel.
BR/BEINSTRUMENT PANEL SYSTEM 23 - 105
INSTRUMENT PANEL SYSTEM (Continued)
Page 2747 of 2889
(1) The relay common feed terminal cavity (30) is
connected to fused battery feed. There should be bat-
tery voltage at the cavity for relay terminal 30 at all
times. If OK, go to Step 2. If not OK, repair the open
circuit to the fuse in the PDC as required.
(2) The relay normally closed terminal (87A) is not
used in this application. Go to Step 3.
(3) The relay normally open terminal cavity (87) is
connected to the compressor clutch coil. There should
be continuity between this cavity and the A/C com-
pressor clutch relay output circuit cavity of the com-
pressor clutch coil wire harness connector. If OK, go
to Step 4. If not OK, repair the open circuit as
required.
(4) The relay coil battery terminal (86) is con-
nected to the fused ignition switch output (run/start)
circuit. There should be battery voltage at the cavity
for relay terminal 86 with the ignition switch in the
On position. If OK, go to Step 5. If not OK, repair the
open circuit to the fuse in the junction block as
required.
(5) The coil ground terminal cavity (85) is switched
to ground through the Powertrain Control Module
(PCM). There should be continuity between this cav-
ity and the A/C compressor clutch relay control cir-
cuit cavity of the PCM wire harness connector C
(gray) at all times. If not OK, repair the open circuit
as required.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the cover from the Power Distribution
Center (PDC) (Fig. 17).(3) Refer to the label on the PDC for compressor
clutch relay identification and location.
(4) Unplug the compressor clutch relay from the
PDC.
INSTALLATION
(1) Install the compressor clutch relay by aligning
the relay terminals with the cavities in the PDC and
pushing the relay firmly into place.
(2) Install the PDC cover.
(3) Connect the battery negative cable.
(4) Test the relay operation.
A/C HEATER CONTROL
DESCRIPTION
Both the heater-only and a/c heater systems use a
combination of electrical and vacuum controls. These
controls provide the vehicle operator with a number
of setting options to help control the climate and
comfort within the vehicle. Refer to the owner's man-
ual in the vehicle glove box for more information on
the features, use, and suggested operation of these
controls.
OPERATION
The heater-only or a/c heater control panel is
located to the right of the instrument cluster on the
instrument panel. The control panel contains a rota-
ry-type temperature control knob, a rotary-type mode
control switch knob, and a rotary-type blower motor
speed switch knob. On models with the optional
heated mirror system, a momentary push button
switch and indicator lamp are located near the bot-
Fig. 16 COMPRESSOR CLUTCH RELAY
TERMINAL LEGEND
NUMBER IDENTIFICATION
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
Fig. 17 POWER DISTRIBUTION CENTER
1 - COVER
2 - POWER DISTRIBUTION CENTER
24 - 18 CONTROLSBR/BE
A/C COMPRESSOR CLUTCH RELAY (Continued)
Page 2761 of 2889
REMOVAL - PANEL OUTLET BARRELS
WARNING: THE PANEL OUTLET BARRELS
INSTALLED IN THE PASSENGER SIDE AIRBAG
DOOR PANEL OUTLET HOUSINGS MUST NEVER
BE REINSTALLED FOLLOWING REMOVAL FOR ANY
REASON. THEY MUST BE REPLACED WITH NEW
BARRELS. FAILURE TO OBSERVE THIS WARNING
COULD RESULT IN OCCUPANT INJURIES UPON
AIRBAG DEPLOYMENT.
(1) Using a trim stick or another suitable wide
flat-bladed tool, gently pry near the center of either
side of the panel outlet barrel to release the snap-fit
pivots on the barrel from the pivot pins in the outlet
housing of the passenger side airbag module or the
instrument cluster bezel (Fig. 2).
(2)
Remove the barrel from the panel outlet housing.
INSTALLATION - DEMISTER GRILLES
(1) To install the demister grille, position the grille
in the opening of the instrument panel top cover and
press inwards firmly and evenly near the center of
both sides of the grille until it snaps into place.
INSTALLATION - PANEL OUTLET BARRELS
WARNING: THE PANEL OUTLET BARRELS INSTALLED
IN THE PASSENGER SIDE AIRBAG DOOR PANEL OUT-
LET HOUSINGS MUST NEVER BE REINSTALLED FOL-
LOWING REMOVAL FOR ANY REASON. THEY MUST
BE REPLACED WITH NEW BARRELS. FAILURE TO
OBSERVE THIS WARNING COULD RESULT IN OCCU-
PANT INJURIES UPON AIRBAG DEPLOYMENT.
(1) To install a new panel outlet barrel, position
the barrel in the outlet housing and press inwards
firmly and evenly near the center of both sides of the
panel outlet barrel until the pivots snap into place.
BLOWER MOTOR
DESCRIPTION
The blower motor and blower wheel are located in
the passenger side end of the HVAC housing, below
the glove box. The blower motor controls the velocity
of the air flowing through the HVAC housing by spin-
ning a squirrel cage-type blower wheel within the
housing at the selected speed. The blower motor and
blower wheel can be serviced from the passenger
compartment side of the housing.
OPERATION
The blower motor will only operate when the igni-
tion switch is in the On position, and the a/c heater
mode control switch knob is in any position, except
Off. The blower motor receives a fused battery feed
through the blower motor relay whenever the igni-
tion switch is in the On position.
The blower motor battery feed circuit is protected
by a fuse in the Power Distribution Center (PDC).
The blower motor relay control circuit is protected by
a fuse in the junction block. Blower motor speed is
controlled by regulating the ground path through the
a/c heater mode control switch, the blower motor
switch, and the blower motor resistor.
The blower motor and blower wheel cannot be
repaired and, if faulty or damaged, they must be
replaced. The blower motor and blower wheel may be
serviced separately, although if the motor is to be
replaced, a blower wheel will come as part of a pre-
balanced assembly.
Fig. 2 PANEL OUTLET BARRELS
1 - DEFROSTER OUTLETS
2 - DEMISTER OUTLET GRILLE
3 - PANEL OUTLET BARRELS
4 - DEMISTER OUTLET GRILLE
24 - 32 DISTRIBUTIONBR/BE
AIR OUTLETS (Continued)
Page 2828 of 2889
Items found requiring adjustment and/or repair
should be corrected before delivery of the vehicle.
NOTE: It is the dealer's responsibility to protect
new vehicles from damage and deterioration prior
to retail delivery both before and after new vehicle
preparation.
The information includes the following features:
Inspection points are cross-referenced to the New
Vehicle Preparation Form as follows:
²Titles indicate the general area being inspected
or the types of checks being made (i.e., underhood,
body-exterior, road test, etc.).
²Sub-Titles identify the types of items to be
inspected in that area (i.e., lines/hoses, wiring, etc.).
Procedures follow a logical order to prevent dupli-
cation and wasted effort.
Tips to help you do a better job are found as
NOTES.
RECEIVING
INSPECTION
The following procedures are recommended for
your own protection upon receipt of new vehicles.
When a new car is delivered by the carrier, it should
be inspected to ensure that it is in good condition
and to determine if there is any shortage or transpor-
tation damage.
EXTERIOR
Upon receipt of a new vehicle, check immediately
for:
²Under carriage damage
²Chipped or cracked windshield, broken windows,
and loose or missing moldings and name-plates
²Dents, scrapes, scratches, chips, dirt in paints or
other damage to the body exterior
²Damaged or missing side view mirror(s)
²Missing wheel nuts
²Broken or missing lenses
²Chafing, bruises, cuts, or scrapes on tire side-
walls or tread
²Missing underhood items
²Missing fuel filler cap
²Shipped loose items-license plate bracket, spare
tire, jack and tire wrench, radio antenna, floor mats,
wheel covers, cargo nets, fuses and other items²Ensure that IOD fuse is removed
²Check battery test indicator when easily visible,
or use voltmeter (battery must be at 12.4 volts or
greater). Charge to ensure green dot-visibility, per-
manent damage may occur if battery remains in a
discharged state for any length of time.
INTERIOR
Check interior items such as:
²Rearview mirror
²Accessory control knobs
²Smokers package items
²Keys
²Radio
²Special equipment items listed on shipper
²Owner's Manual and Consumer information Bro-
chures (normally stored in the glove box).
²Cuts, abrasions or stains on interior trim.
NOTE: Remember a careful look at new vehicles
when they are received may prevent problems when
preparing vehicles for delivery to your customers.
MAJOR INSPECTION POINTS
(1) Check operation of hood latch and safety catch-
adjust as required.
(2) Check all fluids for proper level and top off
with the proper fluid as required-engine oil, auto-
matic transmission fluid, brake master cylinder,
clutch master cylinder, power steering, windshield
washer, and cooling system. (Vehicle must be at nor-
mal operating temperature for some of these checks.)
(3) Check brake, clutch, fuel, and power steering
lines and hoses for leaks and clearance from moving
and hot objects-reroute to the proper location and
tighten as required.
(4) Check battery state of charge-recharge if neces-
sary, to ensure green dot is visible or instrument
panel voltmeter indicates 12.4 volts or greater.
(5) Check routing and connections of underhood
wiring, vacuum hoses, refrigerant lines and coolant
hoses for leaks, loose connections and clearance from
moving objects reroute and tighten connections as
required. Install IOD fuse on applicable vehicles.
NOTE: Reset radio, clock, compass, etc., after
installing, if vehicle is being delivered.
BR/BENEW VEHICLE PREPARATION 30 - 3
INTRODUCTION (Continued)
Page 2853 of 2889
CABLE - INSTALLATION, RELEASE.......23-83
CABLE - INSTALLATION, SPARK PLUG....8I-20
CABLE - INSTALLATION, THROTTLE
CONTROL....................14-105,14-50
CABLE - OPERATION...................8P-4
CABLE - OPERATION, ANTENNA BODY.....8A-4
CABLE - OPERATION, BATTERY..........8F-20
CABLE - OPERATION, SPARK PLUG.......8I-19
CABLE - REMOVAL, CHECK.............23-62
CABLE - REMOVAL, FRONT PARKING
BRAKE..............................5-37
CABLE - REMOVAL, INSTRUMENT PANEL
ANTENNA...........................8A-9
CABLE - REMOVAL, LATCH RELEASE....23-101
CABLE - REMOVAL, RELEASE...........23-82
CABLE - REMOVAL, SPARK PLUG........8I-20
CABLE - REMOVAL, THROTTLE
CONTROL....................14-104,14-50
CABLE 2500/3500 SERIES WITH DRUM
BRAKES - INSTALLATION, REAR PARK
BRAKE..............................5-39
CABLE INSTALLATION, GASOLINE -
NEGATIVE..........................8F-24
CABLE INSTALLATION, GASOLINE -
POSITIVE...........................8F-23
CABLE ORDER, 8.0L V-10 ENGINE -
SPARK PLUG.........................8I-2
CABLE REMOVAL, GASOLINE -
NEGATIVE..........................8F-23
CABLE REMOVAL, GASOLINE - POSITIVE . . 8F-23
CABLE RESISTANCE, SPECIFICATIONS -
SPARK PLUG.........................8I-3
CABLE TENSIONER - ADJUSTMENT.......5-40
CABLES - 1500 SERIES - INSTALLATION,
REAR PARK BRAKE....................5-39
CABLES - 1500 SERIES - REMOVAL,
REAR PARK BRAKE....................5-37
CABLES - DIAGNOSIS & TESTING,
BATTERY...........................8F-20
CABLES - DIAGNOSIS AND TESTING,
SPARK PLUG........................8I-19
CABLES 2500/3500 SERIES WITH DRUM
BRAKES - REMOVAL, REAR PARK
BRAKE..............................5-38
CAB-TO- BED GROUND STRAP -
INSTALLATION.......................8A-14
CAB-TO- BED GROUND STRAP -
REMOVAL..........................8A-14
CALIBRATION - STANDARD PROCEDURE,
COMPASS...........................8M-4
CALIPERS - ASSEMBLY, DISC BRAKE......5-12
CALIPERS - CLEANING, DISC BRAKE......5-12
CALIPERS - DISASSEMBLY, DISC BRAKE . . . 5-11
CALIPERS - INSPECTION, DISC BRAKE....5-12
CAM - DESCRIPTION, TURN SIGNAL
CANCEL............................8L-30
CAM - OPERATION, TURN SIGNAL
CANCEL............................8L-31
CAM BORE REPAIR - STANDARD
PROCEDURE........................9-267
CAM/OVERDRIVE PISTON RETAINER -
ASSEMBLY, OVERRUNNING
CLUTCH.........21-236,21-406,21-581,21-752
CAM/OVERDRIVE PISTON RETAINER -
CLEANING, OVERRUNNING
CLUTCH.........21-236,21-406,21-580,21-752
CAM/OVERDRIVE PISTON RETAINER -
DESCRIPTION, OVERRUNNING
CLUTCH.........21-235,21-405,21-580,21-751
CAM/OVERDRIVE PISTON RETAINER -
DISASSEMBLY, OVERRUNNING
CLUTCH.........21-235,21-405,21-580,21-751
CAM/OVERDRIVE PISTON RETAINER -
INSPECTION, OVERRUNNING
CLUTCH.........21-236,21-406,21-580,21-752
CAM/OVERDRIVE PISTON RETAINER -
OPERATION, OVERRUNNING
CLUTCH.........21-235,21-405,21-580,21-751
CAMSHAFT & BEARINGS (IN BLOCK) -
INSPECTION
........................9-272
CAMSHAFT - INSTALLATION
. 9-144,9-201,9-273,
9-29,9-87
CAMSHAFT - REMOVAL
. 9-143,9-201,9-268,9-29,
9-86
CAMSHAFT BEARINGS - INSTALLATION
. . 9-144,
9-201,9-273,9-29,9-87
CAMSHAFT BEARINGS - REMOVAL
. 9-143,9-200,
9-268,9-29,9-86CANCEL CAM - DESCRIPTION, TURN
SIGNAL............................8L-30
CANCEL CAM - OPERATION, TURN
SIGNAL............................8L-31
CANISTER - DESCRIPTION, VAPOR......25-37
CANISTER - INSTALLATION, CRANKCASE
BREATHER VAPOR...................9-242
CANISTER - INSTALLATION, VAPOR......25-38
CANISTER - OPERATION, VAPOR........25-37
CANISTER - REMOVAL, CRANKCASE
BREATHER VAPOR...................9-241
CANISTER - REMOVAL, VAPOR..........25-37
CAP - CLEANING, RADIATOR PRESSURE . . . 7-66
CAP - DESCRIPTION, FUEL FILLER.......25-33
CAP - DESCRIPTION, RADIATOR
PRESSURE..........................7-65
CAP - DIAGNOSIS AND TESTING,
DISTRIBUTOR.......................8I-12
CAP - DIAGNOSIS AND TESTING,
RADIATOR...........................7-66
CAP - INSPECTION, RADIATOR
PRESSURE..........................7-66
CAP - OPERATION, FUEL FILLER........25-33
CAP - OPERATION, RADIATOR
PRESSURE..........................7-65
CAP - REMOVAL/INSTALLATION, FUEL
FILLER.............................25-33
CAPACITIES, SPECIFICATIONS - FLUID......0-6
CAPACITY TEST - DIAGNOSIS AND
TESTING, FUEL PUMP..................14-9
CAP-TO-FILLER NECK SEAL -
DIAGNOSIS AND TESTING, RADIATOR.....7-66
CARDAN UNIVERSAL JOINTS -
DISASSEMBLY, SINGLE.................3-11
CARDAN UNIVERSAL JOINTS -
INSTALLATION, SINGLE............3-34,3-66
CARDAN UNIVERSAL JOINTS -
REMOVAL, SINGLE................3-33,3-65
CAREFUL NEW VEHICLE PREPARATION -
DESCRIPTION, THE IMPORTANCE OF......30-1
CARGO BOX - INSTALLATION...........23-97
CARGO BOX - REMOVAL...............23-96
CARGO DOOR - ADJUSTMENT..........23-78
CARPETS AND FLOOR MATS -
INSTALLATION......................23-123
CARPETS AND FLOOR MATS - REMOVAL . 23-123
CARTRIDGE FUSE - DESCRIPTION,
GENERATOR......................8W-97-4
CARTRIDGE FUSE - INSTALLATION,
GENERATOR......................8W-97-4
CARTRIDGE FUSE - OPERATION,
GENERATOR......................8W-97-4
CARTRIDGE FUSE - REMOVAL,
GENERATOR......................8W-97-4
CASE - DIAGNOSIS AND TESTING,
TRANSFER.............21-821,21-856,21-892
CASE - INSPECTION, TRANSMISSION/
TRANSFER..........................30-15
CASE - NV231HD - ASSEMBLY,
TRANSFER.........................21-834
CASE - NV231HD - CLEANING,
TRANSFER.........................21-831
CASE - NV231HD - DESCRIPTION,
TRANSFER.........................21-820
CASE - NV231HD - DISASSEMBLY,
TRANSFER.........................21-822
CASE - NV231HD - INSPECTION,
TRANSFER.........................21-832
CASE - NV231HD - INSTALLATION,
TRANSFER.........................21-847
CASE - NV231HD - OPERATION,
TRANSFER.........................21-820
CASE - NV231HD - REMOVAL,
TRANSFER.........................21-822
CASE - NV241HD - ASSEMBLY,
TRANSFER.........................21-904
CASE - NV241HD - CLEANING,
TRANSFER.........................21-902
CASE - NV241HD - DESCRIPTION,
TRANSFER
.........................21-890
CASE - NV241HD - DISASSEMBLY,
TRANSFER
.........................21-894
CASE - NV241HD - INSPECTION,
TRANSFER
.........................21-902
CASE - NV241HD - INSTALLATION,
TRANSFER
.........................21-919
CASE - NV241HD - OPERATION,
TRANSFER
.........................21-892CASE - NV241HD - REMOVAL,
TRANSFER.........................21-894
CASE - NV241LD - ASSEMBLY,
TRANSFER.........................21-869
CASE - NV241LD - CLEANING,
TRANSFER.........................21-866
CASE - NV241LD - DESCRIPTION,
TRANSFER.........................21-855
CASE - NV241LD - DISASSEMBLY,
TRANSFER.........................21-858
CASE - NV241LD - INSPECTION,
TRANSFER.........................21-867
CASE - NV241LD - INSTALLATION,
TRANSFER.........................21-882
CASE - NV241LD - OPERATION,
TRANSFER.........................21-855
CASE - NV241LD - REMOVAL,
TRANSFER.........................21-858
CASE BEARINGS - INSTALLATION,
DIFFERENTIAL . . . 3-103,3-134,3-164,3-192,3-39,
3-71
CASE BEARINGS - REMOVAL,
DIFFERENTIAL . . . 3-103,3-134,3-164,3-192,3-39,
3-71
CASE FLUID - DESCRIPTION, TRANSFER....0-5
CASE, NV231HD - TRANSFER..........21-849
CASE, NV241HD - TRANSFER..........21-920
CASE, NV241LD - TRANSFER..........21-884
CASE SKID PLATE - INSTALLATION,
TRANSFER..........................13-11
CASE SKID PLATE - REMOVAL,
TRANSFER..........................13-11
CASE, SPECIFICATIONS - TRANSFER.....21-848,
21-883,21-919
CASTER CORRECTION MEASUREMENT -
STANDARD PROCEDURES...............2-3
CATALYTIC CONVERTER - 3.9L/5.2L/5.9L
- DESCRIPTION.......................11-5
CATALYTIC CONVERTER - 3.9L/5.2L/5.9L
- INSPECTION........................11-5
CATALYTIC CONVERTER - 3.9L/5.2L/5.9L
- INSTALLATION......................11-5
CATALYTIC CONVERTER - 3.9L/5.2L/5.9L
- OPERATION.........................11-5
CATALYTIC CONVERTER - 3.9L/5.2L/5.9L
- REMOVAL..........................11-5
CATALYTIC CONVERTER - 5.9L HEAVY
DUTY/8.0L - DESCRIPTION..............11-6
CATALYTIC CONVERTER - 5.9L HEAVY
DUTY/8.0L - INSPECTION...............11-7
CATALYTIC CONVERTER - 5.9L HEAVY
DUTY/8.0L - INSTALLATION.............11-7
CATALYTIC CONVERTER - 5.9L HEAVY
DUTY/8.0L - OPERATION................11-6
CATALYTIC CONVERTER - 5.9L HEAVY
DUTY/8.0L - REMOVAL.................11-6
CATCH - INSPECTION, HOOD LATCH/
SAFETY.............................30-4
CAUSES OF BURNT FLUID - DIAGNOSIS
AND TESTING....21-199,21-370,21-545,21-715
CAUTION, INTERIOR.................23-118
CAUTION, REFRIGERANT HOSES/LINES/
TUBES PRECAUTIONS.................24-42
CCD DATA BUS - DESCRIPTION..........8E-6
CCD DATA BUS - DIAGNOSIS AND
TESTING...........................8E-11
CCD DATA BUS - OPERATION............8E-7
CENTER - DESCRIPTION, POWER
DISTRIBUTION....................8W-97-7
CENTER - INSTALLATION, POWER
DISTRIBUTION
....................8W-97-8
CENTER - OPERATION, POWER
DISTRIBUTION
....................8W-97-8
CENTER - REMOVAL, POWER
DISTRIBUTION
....................8W-97-8
CENTER BEARING - CENTER BEARING
ADJUSTMENT
........................3-10
CENTER BEARING - DESCRIPTION
........3-10
CENTER BEARING - INSTALLATION
.......3-10
CENTER BEARING - OPERATION
..........3-10
CENTER BEARING - REMOVAL
...........3-10
CENTER BEARING ADJUSTMENT,
CENTER BEARING
.....................3-10
CENTER CONSOLE - INSTALLATION
.....23-122
CENTER CONSOLE - REMOVAL
.........23-122
CENTER CONSOLE LID - INSTALLATION
. . 23-132
CENTER CONSOLE LID - REMOVAL
.....23-131
6 INDEXBR/BE
Description Group-Page Description Group-Page Description Group-Page