DODGE RAM 2001 Service Repair Manual

SPECIAL TOOLS
SPECIAL TOOLS - WIRING/TERMINALCONNECTOR - AUGAT
REMOVAL
(1) Disconnect battery.
(2) Disconnect the connector from its mating half/
component.
(3) Push down on the yellow connector locking tab
to release the terminals (Fig. 8).
(4) Using special tool 6932, push the terminal to
remove it from the connector (Fig. 9).
(5) Repair or replace the terminal as necessary.
INSTALLATION
(1) Reset the terminal locking tang.
PROBING TOOL PACKAGE 6807
TERMINAL PICK 6680
TERMINAL REMOVING TOOL 6932
TERMINAL REMOVING TOOL 6934
Fig. 8 AUGAT CONNECTOR REPAIR
1 - LOCKING TAB
2 - CONNECTOR
Fig. 9 USING
1 - SPECIAL TOOL 6932
2 - CONNECTOR
8W - 01 - 8 8W-01 WIRING DIAGRAM INFORMATIONBR/BE
WIRING DIAGRAM INFORMATION (Continued)

(2) Insert the removed wire in the same cavity on
the repair connector.
(3) Repeat steps for each wire in the connector,
being sure that all wires are inserted into the proper
cavities. For additional connector pin-out identifica-
tion, refer to the wiring diagrams.
(4) When the connector is re-assembled, the lock-
ing tab must be placed in the locked position to pre-
vent terminal push out.
(5) Connect connector to its mating half/compo-
nent.
(6) Connect battery and test all affected systems.
CONNECTOR - MOLEX
REMOVAL
(1) Disconnect battery.
(2) Disconnect the connector from its mating half/
component.
(3) Insert special tool 6742 into the terminal end of
the connector (Fig. 10).
(4) Using special tool 6742, release the locking fin-
gers on the terminal (Fig. 11).
(5) Pull on the wire to remove it from the connec-
tor.
(6) Repair or replace the terminal as necessary.
INSTALLATION
(1) Reset the terminal locking tang.
(2) Insert the removed wire in the same cavity on
the repair connector.
(3) Repeat steps for each wire in the connector,
being sure that all wires are inserted into the proper
cavities. For additional connector pin-out identifica-
tion, refer to the wiring diagrams.(4) Connect connector to its mating half/compo-
nent.
(5) Connect battery and test all affected systems.
CONNECTOR - THOMAS AND
BETTS
REMOVAL
(1) Disconnect battery.
(2) Disconnect the connector from its mating half/
component.
(3) Push in the two lock tabs on the side of the
connector (Fig. 12).
Fig. 10 MOLEX CONNECTOR REPAIR
1 - CONNECTOR
2 - SPECIAL TOOL 6742
Fig. 11 USING SPECIAL TOOL 6742
1 - CONNECTOR
2 - SPECIAL TOOL 6742
Fig. 12 THOMAS AND BETTS CONNECTOR LOCK
RELEASE TABS
1 - LOCK TABS
BR/BE8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 9
CONNECTOR - AUGAT (Continued)

(4) Insert the probe end of special tool 6934 into
the back of the connector cavity (Fig. 13).
(5) Grasp the wire and tool 6934, then slowly
remove the wire and terminal from the connector.
(6) Repair or replace the terminal as necessary.
INSTALLATION
(1) Reset the terminal locking tang.
(2) Insert the removed wire in the same cavity on
the repair connector.
(3) Repeat steps for each wire in the connector,
being sure that all wires are fully seated into the
proper cavities. For additional connector pin-out
identification, refer to the wiring diagrams.
(4) Push in the single lock tab on the side of the
connector (Fig. 14).
(5) Connect connector to its mating half/compo-
nent.
(6) Connect battery and test all affected systems.
DIODE
REMOVAL
(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. 15).
INSTALLATION
(1) Remove the insulation from the wires in the
harness. Only remove enough insulation to solder in
the new diode.
(2) Install the new diode in the harness, making
sure current flow is correct. If necessary, refer to the
appropriate wiring diagram for current flow (Fig. 15).
(3) Solder the connection together using rosin core
type solder only.Do not use acid core solder.
(4) Tape the diode to the harness using electrical
tape. Make sure the diode is completely sealed from
the elements.
(5) Re-connect the battery and test affected sys-
tems.
Fig. 13 REMOVING WIRE TERMINAL
1 - SPECIAL TOOL 6934
Fig. 14 SINGLE LOCK TAB
1 - SINGLE LOCK TAB
Fig. 15 DIODE IDENTIFICATION
1 - CURRENT FLOW
2 - BAND AROUND DIODE INDICATES CURRENT FLOW
3 - DIODE AS SHOWN IN THE DIAGRAMS
8W - 01 - 10 8W-01 WIRING DIAGRAM INFORMATIONBR/BE
CONNECTOR - THOMAS AND BETTS (Continued)

TERMINAL
REMOVAL
(1) Disconnect battery.
(2) Disconnect the connector being repaired from
its mating half/component.
(3) Remove the connector locking wedge, if
required (Fig. 16).
(4) Position the connector locking finger away from
the terminal using the proper pick from special tool
kit 6680. Pull on the wire to remove the terminal
from the connector (Fig. 17) (Fig. 18).(5) Cut the wire 6 inches from the back of the con-
nector.
INSTALLATION
(1) Select a wire from the terminal repair assem-
bly that best matches the color wire being repaired.
(2) Cut the repair wire to the proper length and
remove one±half (1/2) inch of insulation.
(3) Splice the repair wire to the wire harness .
(4) Insert the repaired wire into the connector.
(5) Install the connector locking wedge, if required,
and reconnect the connector to its mating half/compo-
nent.
(6) Re-tape the wire harness starting at 1±1/2
inches behind the connector and 2 inches past the
repair.
(7) Connect battery and test all affected systems.Fig. 16 CONNECTOR LOCKING WEDGE TAB
(TYPICAL)
1 - CONNECTOR
2 - CONNECTOR LOCKING WEDGE TAB
Fig. 17 TERMINAL REMOVAL
1 - CONNECTOR
2 - FROM SPECIAL TOOL KIT 6680
Fig. 18 TERMINAL REMOVAL USING SPECIAL TOOL
1 - FROM SPECIAL TOOL KIT 6680
2 - CONNECTOR
BR/BE8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 11

WIRE
STANDARD PROCEDURE - WIRE SPLICING
When splicing a wire, it is important that the cor-
rect gage be used as shown in the wiring diagrams.
(1) Remove one-half (1/2) inch of insulation from
each wire that needs to be spliced.
(2) Place a piece of adhesive lined heat shrink tub-
ing on one side of the wire. Make sure the tubing will
be long enough to cover and seal the entire repair
area.
(3) Place the strands of wire overlapping each
other inside of the splice clip (Fig. 19).
(4) Using crimping tool, Miller p/n 8272, crimp the
splice clip and wires together (Fig. 20)
(5) Solder the connection together using rosin core
type solder only (Fig. 21).
CAUTION: DO NOT USE ACID CORE SOLDER.
(6) Center the heat shrink tubing over the joint
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing (Fig. 22).
Fig. 19 SPLICE CLIP
Fig. 20 CRIMPING TOOL
Fig. 21 SOLDER
Fig. 22 HEAT SHRINK TUBING
8W - 01 - 12 8W-01 WIRING DIAGRAM INFORMATIONBR/BE

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

Component Page
Map Lamps.......................... 8W-49
Outboard Clearance Lamp............... 8W-50
Outboard Headlamp................... 8W-50
Outboard Identification Lamp............ 8W-50
Output Speed Sensor................... 8W-31
Overdrive Switch...................... 8W-31
Overhead Console..................... 8W-49
Oxygen Sensors....................... 8W-30
Park Brake Switch.................. 8W-40, 50
Park/Neutral Position Switch.......... 8W-30, 51
Park/Turn Signal Lamp................. 8W-52
Passenger Airbag On/Off Switch.......... 8W-43
Passenger Airbag...................... 8W-43
Power Distribution Center............... 8W-10
Power Mirror Switch................... 8W-62
Power Mirror......................... 8W-62
Power Outlet......................... 8W-41
Power Seat Front Vertical Motors......... 8W-63
Power Seat Horizontal Motors............ 8W-63
Power Seat Rear Vertical Motor........... 8W-63
Power Seat Switch..................... 8W-63
Power Window Motors.................. 8W-60
Powertrain Control Module.............. 8W-30
PTO Switch.......................... 8W-30
Quad High Beam Relay................. 8W-50
Radio Choke Relay..................... 8W-47Component Page
Radio............................... 8W-47
Remote Radio Switch................... 8W-47
Seat Belt Switch...................... 8W-40
Seat Heat Interface Module.............. 8W-63
Security Relay........................ 8W-39
Speakers............................ 8W-47
Speed Control Servo................... 8W-33
Speed Control Switch................... 8W-33
Splice Information..................... 8W-70
Tail/Stop/Turn Signal Lamp.............. 8W-51
Tailgate Lamp........................ 8W-51
Throttle Position Sensor................ 8W-30
Trailer Tow Connector.................. 8W-54
Trailer Tow Relay...................... 8W-54
Transmission Control Relay.............. 8W-31
Transmission Solenoid Assembly.......... 8W-31
Turn Signal/Hazard Switch.............. 8W-52
Underhood Lamp...................... 8W-44
Visor/Vanity Lamp..................... 8W-44
Washer Fluid Level Switch.............. 8W-40
Water In Fuel Sensor................... 8W-30
Wheel Speed Sensors................ 8W-34, 35
Windshield Washer Pump............... 8W-53
Wiper Motor Relay..................... 8W-53
Wiper Motor.......................... 8W-53
BR/BE8W-02 COMPONENT INDEX 8W - 02 - 1

8W-10 POWER DISTRIBUTION
Component Page
A/C Compressor Clutch Relay.......... 8W-10-27
A/C Compressor Clutch............... 8W-10-27
Aftermarket Center High Mounted
Stop Lamp....................... 8W-10-13
Aftermarket Trailer Tow Connector...... 8W-10-21
Automatic Shut Down Relay......... 8W-10-14, 20
Auxiliary Battery..................... 8W-10-8
Battery............................ 8W-10-8
Blower Motor Relay.................. 8W-10-23
Blower Motor....................... 8W-10-23
Brake Lamp Switch.................. 8W-10-13
Capacitor.......................... 8W-10-16
Center High Mounted Stop Lamp No. 1 . . . 8W-10-13
Center High Mounted Stop Lamp No. 2 . . . 8W-10-13
Central Timer Module C1............. 8W-10-22
Central Timer Module C2............. 8W-10-26
Circuit Breaker 2.................... 8W-10-10
Clockspring........................ 8W-10-26
Combination Flasher................. 8W-10-13
Controller Antilock Brake............. 8W-10-23
Daytime Running Lamp Module........ 8W-10-25
Electric Brake Provision............ 8W-10-13, 21
Engine Control Module............... 8W-10-12
Engine Starter Motor Relay............ 8W-10-23
Engine Starter Motor................. 8W-10-23
Fog Lamp Relay..................... 8W-10-25
Fuel Heater Relay................... 8W-10-20
Fuel Heater........................ 8W-10-20
Fuel Injection Pump.................. 8W-10-12
Fuel Injector No. 1................ 8W-10-15, 16
Fuel Injector No. 2................ 8W-10-15, 16
Fuel Injector No. 3................ 8W-10-15, 16
Fuel Injector No. 4................ 8W-10-15, 16
Fuel Injector No. 5................ 8W-10-15, 16
Fuel Injector No. 6................ 8W-10-15, 16
Fuel Injector No. 7................ 8W-10-15, 16
Fuel Injector No. 8................ 8W-10-15, 16
Fuel Injector No. 9................... 8W-10-16
Fuel Injector No. 10.................. 8W-10-16
Fuel Pump Module................... 8W-10-11
Fuel Pump Relay................. 8W-10-11, 12
Fuse 1 (JB)........................ 8W-10-10
Fuse 1 (PDC)..................... 8W-10-10, 8
Fuse 2 (PDC).................. 8W-10-8, 10, 22
Fuse 3 (PDC).................. 8W-10-8, 11, 12
Fuse 4 (JB)........................ 8W-10-10
Fuse 4 (PDC)..................... 8W-10-13, 8
Fuse 5 (PDC)..................... 8W-10-13, 8
Fuse 6 (PDC).................. 8W-10-14, 20, 8
Fuse 7 (PDC)..................... 8W-10-20, 8
Fuse 8 (PDC)..................... 8W-10-21, 8
Fuse 9 (PDC)..................... 8W-10-23, 8
Fuse 10 (PDC).................... 8W-10-22, 8
Fuse 11 (PDC).................... 8W-10-23, 8
Fuse 12 (JB)....................... 8W-10-10
Fuse 12 (PDC).................... 8W-10-23, 8
Fuse 13 (JB)....................... 8W-10-10Component Page
Fuse 14 (JB)....................... 8W-10-10
Fuse B (PDC)..................... 8W-10-24, 9
Fuse C (PDC)..................... 8W-10-24, 9
Fuse E (PDC)..................... 8W-10-24, 9
Fuse F (PDC)..................... 8W-10-24, 9
Fuse G (PDC)..................... 8W-10-25, 9
Fuse GEN (PDC).................. 8W-10-27, 8
Fuse H (PDC).................... 8W-10-26, 9
Fuse I (PDC)..................... 8W-10-26, 9
Fuse J (PDC)..................... 8W-10-27, 9
Fuse K (PDC)..................... 8W-10-14, 9
Fuse L (PDC)..................... 8W-10-27, 9
G201............................. 8W-10-22
Generator......................... 8W-10-27
Headlamp Beam Select Switch.......... 8W-10-25
Headlamp Switch.................... 8W-10-24
High Note Horn..................... 8W-10-26
Horn Relay...................... 8W-10-26, 9
Ignition Coil 4-Pack.................. 8W-10-16
Ignition Coil 6-Pack.................. 8W-10-16
Ignition Coil........................ 8W-10-15
Ignition Switch................... 8W-10-10, 22
Joint Connector No. 1.............. 8W-10-25, 26
Joint Connector No. 2..... 8W-10-11, 12, 14, 20, 21
Joint Connector No. 5................ 8W-10-22
Joint Connector No. 6........... 8W-10-13, 22, 26
Joint Connector No. 8................ 8W-10-22
Junction Block................... 8W-10-10, 13
Left Fog Lamp...................... 8W-10-25
Left Headlamp...................... 8W-10-24
Left Outboard Headlamp........... 8W-10-24, 25
Low Note Horn..................... 8W-10-26
Oxygen Sensor 1/1 Left Bank Up . . 8W-10-17, 18, 19
Oxygen Sensor 1/1 Upstream........... 8W-10-17
Oxygen Sensor 1/2 Downstream......... 8W-10-17
Oxygen Sensor 1/2 Left Bank Down...... 8W-10-19
Oxygen Sensor 1/2 Pre-Catalyst......... 8W-10-18
Oxygen Sensor 1/3 Post-Catalyst........ 8W-10-18
Oxygen Sensor 2/1 Right Bank Up . 8W-10-17, 18, 19
Oxygen Sensor 2/2 Right Bank Down..... 8W-10-19
Oxygen Sensor Downstream Relay.... 8W-10-18, 19
Power Distribution Center . 8W-10-2, 8, 9, 10, 11, 12,
13, 14, 20, 21, 22, 23,
24, 25, 26, 27
Power Outlet....................... 8W-10-27
Powertrain Control Module . 8W-10-11, 12, 15, 16, 20
Quad High Beam Relay............... 8W-10-24
Right Fog Lamp..................... 8W-10-25
Right Headlamp..................... 8W-10-24
Right Outboard Headlamp.......... 8W-10-24, 25
Security Relay...................... 8W-10-25
Trailer Tow Connector................ 8W-10-21
Trailer Tow Relay.................... 8W-10-21
Transmission Control Relay............ 8W-10-26
Transmission Solenoid Assembly........ 8W-10-26
Turn Signal/Hazard Switch............ 8W-10-13
BR/BE8W-10 POWER DISTRIBUTION 8W - 10 - 1