steering DODGE RAM 2001 Service Manual PDF

WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
CHIME WARNING SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
SEAT BELT WARNING
CHIME WITH SEAT BELT
BUCKLED1. Seat belt switch sense
circuit shorted.1. Disconnect the body wire harness connector
for the seat belt switch and the instrument panel
wire harness connector (Connector C2) for the
EMIC. Check for continuity between the seat belt
switch sense circuit cavity and a good ground.
There should be no continuity. Repair the seat
belt switch sense circuit, if required.
2. Faulty seat belt switch. 2. Check for continuity between the ground circuit
cavity and the seat belt switch sense circuit cavity
of the seat belt switch connector receptacle.
There should be no continuity with the seat belt
buckled. Replace the faulty seat belt, if required.
NO SEAT BELT WARNING
CHIME WITH SEAT BELT
UNBUCKLED, BUT OTHER
CHIME FEATURES OK1. Seat belt switch ground
circuit open.1. Disconnect the body wire harness connector
for the seat belt switch. Check for continuity
between the ground circuit cavity of the connector
for the seat belt switch and a good ground. There
should be continuity. If not OK, repair the open
ground circuit to ground as required.
2. Seat belt switch sense
circuit open.2. With the body wire harness connector for the
seat belt switch and the instrument panel wire
harness connector (Connector C2) for the EMIC
disconnected, there should be continuity between
the seat belt switch sense circuit cavities of the
two connectors. Repair the seat belt switch sense
circuit, if required.
3. Faulty seat belt switch. 3. Check for continuity between the ground circuit
cavity and the seat belt switch sense circuit cavity
of the seat belt switch connector receptacle.
There should be continuity with the seat belt
unbuckled. Replace the faulty seat belt, if
required.
BR/BECHIME/BUZZER 8B - 3
CHIME WARNING SYSTEM (Continued)

ELECTRONIC CONTROL MODULES
TABLE OF CONTENTS
page page
BODY CONTROL/CENTRAL TIMER MODULE
DESCRIPTION............................1
OPERATION.............................3
DIAGNOSIS AND TESTING..................4
CENTRAL TIMER MODULE................4
REMOVAL...............................5
INSTALLATION............................6
COMMUNICATION
DESCRIPTION............................6
OPERATION.............................7
DIAGNOSIS AND TESTING.................11
CCDDATABUS ........................11
CONTROLLER ANTILOCK BRAKE
DESCRIPTION...........................11
OPERATION.............................11REMOVAL..............................12
INSTALLATION...........................12
DATA LINK CONNECTOR
DESCRIPTION...........................12
OPERATION.............................12
ENGINE CONTROL MODULE
DESCRIPTION...........................13
OPERATION.............................13
REMOVAL..............................14
INSTALLATION...........................14
POWERTRAIN CONTROL MODULE
DESCRIPTION...........................14
OPERATION.............................17
REMOVAL..............................19
INSTALLATION...........................20
BODY CONTROL/CENTRAL
TIMER MODULE
DESCRIPTION
Three versions of the Central Timer Module (CTM)
are available on this vehicle, a base version (Fig. 1),a high-line version (Fig. 2), and a premium version.
Whichever version of the CTM the vehicle is
equipped with, it is concealed under the driver side
end of the instrument panel inboard of the instru-
ment panel steering column opening, where it is
secured with two screws to a stamped steel bracket
that is integral to the instrument panel armature.
The CTM is enclosed in a molded plastic housing
with one (base) or two (high-line/premium) integral
Fig. 1 Central Timer Module (Base)
1 - SCREWS
2 - BRACKET
3 - WIRE HARNESS CONNECTOR
4 - CENTRAL TIMER MODULE (BASE)
Fig. 2 Central Timer Module (High-Line/Premium)
1 - SCREWS
2 - BRACKET
3 - WIRE HARNESS CONNECTORS
4 - CENTRAL TIMER MODULE (HIGH-LINE/PREMIUM)
BR/BEELECTRONIC CONTROL MODULES 8E - 1

base version of the CTM and the hard wired inputs
or outputs of all CTM versions can be diagnosed
using conventional diagnostic tools and methods;
however, for diagnosis of the high-line or premium
versions of the CTM or the CCD data bus, the use of
a DRBIIItscan tool is required. Refer to the appro-
priate diagnostic information.
OPERATION
The Central Timer Module (CTM) is designed to
control and integrate many of the electronic features
and functions of the vehicle. The base version of the
CTM monitors only hard wired inputs and responds
with the proper hard wired outputs. The microproces-
sor-based high-line/premium version of the CTM
monitors many hard wired switch and sensor inputs
as well as those resources it shares with other elec-
tronic modules in the vehicle through its communica-
tion over the Chrysler Collision Detection (CCD) data
bus network. The internal programming and all of
these inputs allow the high-line/premium CTM
microprocessor to determine the tasks it needs to
perform and their priorities, as well as both the stan-
dard and optional features that it should provide.
The high-line/premium CTM programming then per-
forms those tasks and provides those features
through both CCD data bus communication with
other electronic modules and through hard wired out-
puts to a number of circuits, relays, and actuators.
These outputs allow the high-line/premium CTM the
ability to control numerous accessory systems in the
vehicle.
All versions of the CTM operate on battery current
received through fuses in the Junction Block (JB) on
a non-switched fused B(+) circuit, a fused ignition
switch output (st-run) circuit (base version only), and
a fused ignition switch output (run-acc) circuit (high-
line/premium version only). This arrangement allows
the CTM to provide some features regardless of the
ignition switch position, while other features will
operate only with the ignition switch in the Acces-
sory, On, and/or Start positions. All versions of the
CTM are grounded through their connector and take
out of the instrument panel wire harness. The high-
line/premium CTM has another ground received
through a second connector and take out of the
instrument panel wire harness. The first ground cir-
cuit receives ground through a take out with an eye-
let terminal connector of the instrument panel wire
harness that is secured by a nut to a ground stud
located on the left instrument panel end bracket,
while the second ground circuit (high-line/premium
version only) receives ground through a take out with
an eyelet terminal connector of the instrument panel
wire harness that is secured by a nut to a ground
stud located on the back of the instrument panelarmature above the inboard side of the instrument
panel steering column opening.
The high-line/premium CTM monitors its own
internal circuitry as well as many of its input and
output circuits, and will store a Diagnostic Trouble
Code (DTC) in electronic memory for any failure it
detects. These DTCs can be retrieved and diagnosed
using a DRBIIItscan tool. Refer to the appropriate
diagnostic information.
HARD WIRED INPUTS
The hard wired inputs to the CTM include the fol-
lowing:
²CCD bus± - high-line/premium version only
²CCD bus+ - high-line/premium version only
²Cylinder lock switch mux - high-line premium
version only
²Driver door ajar switch sense
²Fused B(+)
²Fused ignition switch output (run-acc) - high-
line/premium version only
²Fused ignition switch output (st-run) - base ver-
sion only
²Ground (one circuit - base version, two circuits -
high-line/premium version)
²Key-in ignition switch sense
²Passenger door ajar switch sense - high-line/pre-
mium version only
²Power door lock motor B(+) lock - high-line/pre-
mium version only
²Power door lock motor B(+) unlock - high-line/
premium version only
²Radio control mux - high-line/premium version
only
²Tone request signal
²Washer switch sense
²Wiper park switch sense
²Wiper switch mode sense
²Wiper switch mode signal
HARD WIRED OUTPUTS
The hard wired outputs of the CTM include the fol-
lowing:
²CCD bus± - high-line/premium version only
²CCD bus+ - high-line/premium version only
²Courtesy lamp switch output - high-line/pre-
mium version only
²Door lock driver - high-line/premium version
only
²Door unlock driver - high-line/premium version
only
²Headlamp relay control - high-line/premium ver-
sion only
²Heated seat relay control - premium version
only
BR/BEELECTRONIC CONTROL MODULES 8E - 3
BODY CONTROL/CENTRAL TIMER MODULE (Continued)

²Horn relay control - high-line/premium version
only
²VTSS indicator driver - high-line/premium ver-
sion only
²Wiper motor relay control
MESSAGING
The high-line/premium CTM uses the following
messages received from other electronic modules over
the CCD data bus:
²Airbag Deploy (ACM)
²Charging System Failure (PCM)
²Engine RPM (PCM)
²System Voltage (PCM)
²Vehicle Speed (PCM)
²Voltage Fault (PCM)
The high-line/premium CTM provides the following
messages to other electronic modules over the CCD
data bus:
²Engine Enable (PCM)
²Radio Seek Up (Radio)
²Radio Seek Down (Radio)
²Radio Volume Up (Radio)
²Radio Volume Down (Radio)
²Preset Scan (Radio)
DIAGNOSIS AND TESTING - CENTRAL TIMER
MODULE
The hard wired inputs to and outputs from the
Central Timer Module (CTM) may be diagnosed and
tested using conventional diagnostic tools and meth-
ods. Refer to the appropriate wiring information. The
wiring information includes wiring 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 har-
ness connectors, splices and grounds.
However, conventional diagnostic methods may not
prove conclusive in the diagnosis of the high-line/pre-
mium CTM. In order to obtain conclusive testing of
the high-line/premium CTM, the Chrysler Collision
Detection (CCD) data bus network and all of the elec-
tronic modules that provide inputs to or receive out-
puts from the CTM must also be checked. The most
reliable, efficient, and accurate means to diagnose
the high-line/premium CTM, the CCD data bus net-
work, and the electronic modules that provide inputs
to or receive outputs from the high-line/premium
CTM requires the use of a DRBIIItscan tool and the
appropriate diagnostic information. The DRBIIIt
scan tool can provide confirmation that the CCD data
bus network is functional, that all of the electronic
modules are sending and receiving the proper mes-
sages over the CCD data bus, and that the CTM is
receiving the proper hard wired inputs and respond-ing with the proper hard wired outputs needed to
perform its many functions.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
NOTE: The following tests may not prove conclu-
sive in the diagnosis of the high-line or premium
versions of the Central Timer Module (CTM). The
most reliable, efficient, and accurate means to diag-
nose the high-line or premium CTM requires the
use of a DRBIIITscan tool and the appropriate diag-
nostic information.
(1) Check the fused B(+) fuse (Fuse 13 - 10
ampere) in the Junction Block (JB). If OK, go to Step
2. If not OK, repair the shorted circuit or component
as required and replace the faulty fuse.
(2) Check for battery voltage at the fused B(+) fuse
(Fuse 13 - 10 ampere) in the JB. If OK, go to Step 3.
If not OK, repair the open fused B(+) circuit between
the JB and the Power Distribution Center (PDC) as
required.
(3) For a base version CTM, check the fused igni-
tion switch output (st-run) fuse (Fuse 11 - 10 ampere)
in the JB. For a high-line/premium version CTM,
check the fused ignition switch output (run-acc) fuse
(Fuse6-25ampere) in the JB. If OK, go to Step 4. If
not OK, repair the shorted circuit or component as
required and replace the faulty fuse.
(4) Turn the ignition switch to the On position. For
a base version CTM, check for battery voltage at the
fused ignition switch output (st-run) fuse (Fuse 11 -
10 ampere) in the JB. For a high-line/premium ver-
sion CTM, check for battery voltage at the fused igni-
tion switch output (run-acc) fuse (Fuse6-25
ampere) in the JB. If OK, go to Step 5. If not OK,
repair the shorted circuit or component as required
and replace the faulty fuse.
(5) Turn the ignition switch to the Off position.
Disconnect and isolate the battery negative cable.
Remove the CTM from its mounting bracket to access
the CTM wire harness connector(s). Disconnect the
instrument panel wire harness connector(s) for the
8E - 4 ELECTRONIC CONTROL MODULESBR/BE
BODY CONTROL/CENTRAL TIMER MODULE (Continued)

CTM from the CTM connector receptacle(s). Check
the wire harness connectors and the CTM receptacles
for loose, corroded, or damaged terminals and pins. If
OK, go to Step 6. If not OK, repair as required.
(6) Check for continuity between the ground cir-
cuit cavity of the instrument panel wire harness con-
nector (Connector C1) for the CTM and a good
ground. For the high-line/premium version of the
CTM only, repeat the check between the ground cir-
cuit cavity of the instrument panel wire harness con-
nector (Connector C2) for the CTM and a good
ground. In each case, there should be continuity. If
OK, go to Step 7. If not OK, repair the open ground
circuit(s) to ground as required.
(7) Reconnect the battery negative cable. Check for
battery voltage at the fused B(+) circuit cavity of the
instrument panel wire harness connector (Connector
C1) for the CTM. If OK, go to Step 8. If not OK,
repair the open fused B(+) circuit between the CTM
and the JB as required.
(8) Turn the ignition switch to the On position.
Check for battery voltage at the fused ignition switch
output (st-run) circuit cavity (base version) or fused
ignition switch output (run-acc) circuit cavity (high-
line/premium version) of the instrument panel wire
harness connector (Connector C1) for the CTM. If OK
with a base version CTM, replace the faulty CTM. If
OK with a high-line/premium version CTM, use a
DRBIIItscan tool and the appropriate diagnostic
information to perform further diagnosis of the CTM.
If not OK, repair the open fused ignition switch out-
put circuit between the CTM and the JB.
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
NOTE: Before replacing a high-line/premium version
Central Timer Module (CTM), use a DRBIIITscan
tool to retrieve the current settings for the CTM pro-
grammable features. Refer to the appropriate diag-
nostic information. These settings should be
duplicated in the replacement high-line/premiumCTM using the DRBIIITscan tool before returning
the vehicle to service.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the steering column opening cover
from the instrument panel. (Refer to 23 - BODY/IN-
STRUMENT PANEL/STEERING COLUMN OPEN-
ING COVER - REMOVAL).
(3) Remove the two screws that secure the Central
Timer Module (CTM) to the bracket on the inboard
side of the instrument panel steering column opening
(Fig. 3) or (Fig. 4).
(4) Pull the CTM into the instrument panel steer-
ing column opening far enough to access the instru-
ment panel wire harness connector(s).
(5) Disconnect the instrument panel wire harness
connector(s) (one connector for the base version CTM,
two connectors for the high-line/premium version)
from the CTM connector receptacle(s).
(6) Remove the CTM from the instrument panel.
Fig. 3 Central Timer Module (Base) Remove/Install
1 - SCREWS
2 - BRACKET
3 - WIRE HARNESS CONNECTOR
4 - CENTRAL TIMER MODULE (BASE)
BR/BEELECTRONIC CONTROL MODULES 8E - 5
BODY CONTROL/CENTRAL TIMER MODULE (Continued)

INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
NOTE: Before replacing a high-line/premium version
Central Timer Module (CTM), use a DRBIIITscan
tool to retrieve the current settings for the CTM pro-
grammable features. Refer to the appropriate diag-
nostic information. These settings should be
duplicated in the replacement high-line/premium
CTM using the DRBIIITscan tool before returning
the vehicle to service.(1) Position the CTM to the inboard side of the
instrument panel steering column opening.
(2) Reconnect the instrument panel wire harness
connector(s) for the CTM (one connector for the base
version CTM, two connectors for the high-line/pre-
mium version) to the CTM connector receptacle(s)
(Fig. 3) or (Fig. 4).
(3) Position the CTM to the bracket on the inboard
side of the instrument panel steering column open-
ing.
(4) Install and tighten the two screws that secure
the CTM to the bracket on the inboard side of instru-
ment panel steering column opening. Tighten the
screws to 1.6 N´m (15 in. lbs.).
(5) Reinstall the steering column opening cover
onto the instrument panel. (Refer to 23 - BODY/IN-
STRUMENT PANEL/STEERING COLUMN OPEN-
ING COVER - INSTALLATION).
(6) Reconnect the battery negative cable.
COMMUNICATION
DESCRIPTION - CCD DATA BUS
The Chrysler Collision Detection (also referred to
as CCD or C2D ) data bus system is a multiplex sys-
tem used for vehicle communications on many
Chrysler Corporation vehicles. Within the context of
the CCD system, the term ªcollisionª refers to the
system's ability to avoid collisions of the electronic
data that enters the data bus from various electronic
control modules at approximately the same time.
Multiplexing is a system that enables the trans-
mission of several messages over a single channel or
circuit. Many Chrysler vehicles use this principle for
communication between the various microprocessor-
based electronic control modules.
Many of the electronic control modules in a vehicle
require information from the same sensing device. In
the past, if information from one sensing device was
required by several controllers, a wire from each con-
troller needed to be connected in parallel to that sen-
sor. In addition, each controller utilizing analog
sensors required an Analog/Digital (A/D) converter in
order to ªreadª these sensor inputs. Multiplexing
reduces wire harness complexity, sensor current
loads and controller hardware because each sensing
device is connected to only one controller, which
reads and distributes the sensor information to the
other controllers over the data bus. Also, because
each controller on the data bus can access the con-
troller sensor inputs to every other controller on the
data bus, more function and feature capabilities are
possible.
Fig. 4 Central Timer Module (High-Line/Premium)
Remove/Install
1 - SCREWS
2 - BRACKET
3 - WIRE HARNESS CONNECTORS
4 - CENTRAL TIMER MODULE (HIGH-LINE/PREMIUM)
8E - 6 ELECTRONIC CONTROL MODULESBR/BE
BODY CONTROL/CENTRAL TIMER MODULE (Continued)

²ABS Warning Lamp
²Brake Warning Lamp
REMOVAL
(1) Disconnect battery negative cable.
(2) Push the harness connector locks to release the
locks, (Fig. 11) then remove the connectors from the
CAB.
(3) Disconnect the pump motor connector (Fig. 12)
.
(4) Remove screws attaching CAB to the HCU
(Fig. 13).
(5) Remove the CAB.
INSTALLATION
(1) Place the CAB onto the HCU.
NOTE: Insure the CAB seal is in position before
installation.
(2) Install the mounting screws and tighten to
4-4.7 N´m (36-42 in. lbs.).
(3) Connect the pump motor harness.
(4) Connect the harnesses to the CAB and lock the
connectors.
(5) Connect battery.
DATA LINK CONNECTOR
DESCRIPTION - DATA LINK CONNECTOR
The data link connector is located at the lower
edge of the instrument panel near the steering col-
umn.
OPERATION - DATA LINK CONNECTOR
The 16±way data link connector (diagnostic scan
tool connector) links the Diagnostic Readout Box
(DRB) scan tool or the Mopar Diagnostic System
(MDS) with the Powertrain Control Module (PCM).
Fig. 11 Harness Connector Locks
1 - CONNECTOR LOCK
2 - CAB
Fig. 12 Pump
1 - PUMP MOTOR
2 - PUMP CONNECTOR
Fig. 13 Controller Mounting Screws
1 - CAB
2 - MOUNTING LOCATIONS
8E - 12 ELECTRONIC CONTROL MODULESBR/BE
CONTROLLER ANTILOCK BRAKE (Continued)

DIESEL ENGINE
Diesel engine models feature a clamping type
female battery terminal made of soft lead die cast
onto one end of the battery cable wire. A square
headed pinch-bolt and hex nut are installed at the
open end of the female battery terminal clamp. The
pinch-bolt on the left side battery positive cable
female terminal clamp also has a stud extending
from the head of the bolt. Large eyelet type terminals
are crimped onto the opposite end of the battery
cable wire and then solder-dipped. The battery posi-
tive cable wires have a red insulating jacket to pro-
vide visual identification and feature a larger female
battery terminal clamp to allow connection to the
larger battery positive terminal post. The battery
negative cable wires have a black insulating jacket
and a smaller female battery terminal clamp.
OPERATION
The battery cables connect the battery terminal
posts to the vehicle electrical system. These cables
also provide a return path for electrical current gen-
erated by the charging system for restoring the volt-
age potential of the battery. The female battery
terminal clamps on the ends of the battery cable
wires provide a strong and reliable connection of the
battery cable to the battery terminal posts. The ter-
minal pinch bolts allow the female terminal clamps
to be tightened around the male terminal posts on
the top of the battery. The eyelet terminals secured
to the ends of the battery cable wires opposite the
female battery terminal clamps provide secure and
reliable connection of the battery to the vehicle elec-
trical system.
GASOLINE ENGINE
The battery positive cable terminal clamp is
crimped onto the ends of two wires. One wire has an
eyelet terminal that connects the battery positive
cable to the B(+) terminal stud of the Power Distri-
bution Center (PDC), and the other wire has an eye-
let terminal that connects the battery positive cable
to the B(+) terminal stud of the engine starter motor
solenoid. The battery negative cable terminal clamp
is also crimped onto the ends of two wires. One wire
has an eyelet terminal that connects the battery neg-
ative cable to the vehicle powertrain through a stud
on the front of the left engine cylinder head. The
other wire has an eyelet terminal that connects the
battery negative cable to the vehicle body through a
ground screw on the left front fender inner shield,
just ahead of the battery. An additional ground wire
with two eyelet terminals is used to provide ground
to the vehicle frame. One eyelet terminal of this
ground wire is installed under the head of the bat-
tery negative cable terminal clamp pinch-bolt, andthe other eyelet terminal is secured with a ground
screw to the outer surface of the left frame rail,
below the battery.
DIESEL ENGINE
The left battery positive cable terminal clamp is
die cast onto the ends of two wires. One wire has an
eyelet terminal that connects the left battery positive
cable to the B(+) terminal stud of the Power Distri-
bution Center (PDC), and the other wire has an eye-
let terminal that connects the left battery positive
cable to the B(+) terminal stud of the engine starter
motor solenoid. The right battery positive cable ter-
minal clamp is die cast onto the end of a single wire.
The eyelet terminal on the other end of the right bat-
tery positive cable is connected to the stud on the
pinch-bolt of the left battery positive cable terminal
clamp. This stud also provides a connection point for
the eyelet terminals from the fuel heater relay and
intake air heater relay jumper harness take outs. All
of these eyelet terminals are secured to the left bat-
tery positive cable terminal clamp pinch-bolt stud
with a single hex nut.
The left battery negative cable terminal clamp is
die cast onto the ends of two wires. One wire has an
eyelet terminal that connects the left battery nega-
tive cable to the vehicle powertrain through a ground
screw on the left side of the engine block, below the
power steering and vacuum pumps. The other wire
has an eyelet terminal that connects the left battery
negative cable to the vehicle body through a ground
screw on the left front fender inner shield, just ahead
of the left battery. An additional ground wire with
two eyelet terminals is used to provide ground to the
vehicle frame. One eyelet terminal of this ground
wire is installed under the nut of the left battery
negative cable terminal clamp pinch-bolt, and the
other eyelet terminal is secured with a ground screw
to the outer surface of the left frame rail, below the
left battery. The right battery negative cable terminal
is also die cast onto the ends of two wires. One wire
has an eyelet terminal that connects the right bat-
tery negative cable to the vehicle powertrain through
a ground screw on the right side of the engine block,
just forward of the right engine mount. The other
wire has an eyelet terminal that connects the right
battery negative cable to the vehicle body through a
ground screw on the right front fender inner shield,
just behind the right battery.
DIAGNOSIS & TESTING - BATTERY CABLES
A voltage drop test will determine if there is exces-
sive resistance in the battery cable terminal connec-
tions or the battery cables. If excessive resistance is
found in the battery cable connections, the connec-
tion point should be disassembled, cleaned of all cor-
8F - 20 BATTERY SYSTEMBR/BE
BATTERY CABLE (Continued)

(4) Connect the voltmeter to measure between the
battery negative cable terminal clamp and a good
clean ground on the engine block (Fig. 25). Rotate
and hold the ignition switch in the Start position.
Observe the voltmeter. If the reading is above 0.2
volt, clean and tighten the battery negative cable
eyelet terminal connection to the engine block.
Repeat the test. If the reading is still above 0.2 volt,
replace the faulty battery negative cable.
NOTE: If the vehicle is equipped with a dual battery
system, Step 4 must be performed twice, once for
each battery.
POSITIVE CABLE REMOVAL - GASOLINE
Both the battery negative cable and the battery
positive cable are serviced in the battery wire har-
ness. If either battery cable is damaged or faulty, the
battery wire harness assembly must be replaced.
(1) Remove the positive battery cable from the bat-
tery.
(2) Remove the cover from the PDC.
(3) Remove the positive battery cable from the
PDC.
(4) Disconnect the starter motor signal wire har-
ness connector, located on the PDC housing.
(5) Disengage wire harness assembly pushpin
retainers.
(6) From under the vehicle, disengage wire har-
ness assembly pushpin retainers.
(7) Remove the positive battery cable from the
starter motor B+ terminal stud.
(8) Remove the starter motor trigger wire from the
starter motor.
(9) Remove the positive cable wire harness assem-
bly from the vehicle.
NEGATIVE CABLE REMOVAL - GASOLINE
Both the battery negative cable and the battery
positive cable are serviced in the battery wire har-
ness. If either battery cable is damaged or faulty, the
battery wire harness unit must be replaced.
(1) Turn the ignition switch to the Off position. Be
certain that all electrical accessories are turned off.
(2) Loosen the battery negative cable terminal
clamp pinch-bolt hex nut.
(3) Disconnect the battery negative cable terminal
clamp from the battery negative terminal post. If
necessary, use a battery terminal puller to remove
the terminal clamp from the battery post.
(4) Remove the negative cable jumper from the left
side of the radiator closure panel.
(5) Remove the negative cable jumper from the left
side of the frame assembly.
(6) Remove the PDC cover and remove the gener-
ator output wire from the PDC.
(7) Following the wire, remove the pushpin retain-
ers holding the wire assembly in place.
(8) Remove the negative cable eyelet from the
power steering pump pivot bolt.
(9) Remove the generator output wire from the
generator.
(10) Remove the negative battery cable assembly,
by fishing out from under the compressor mounting
bracket, if equipped.
POSITIVE CABLE INSTALLATION - GASOLINE
(1) Position the battery wire harness into the
engine compartment.
(2) Install the positive battery cable on the battery.
(3) Install the positive battery cable on the PDC.
(4) Install the cover on the PDC.
(5) Connect the starter motor signal wire harness
connector, located on the PDC housing.
(6) Install wire harness assembly pushpin retain-
ers in their original position.
(7) From under the vehicle, install wire harness
assembly pushpin retainers.
(8) Install and tighten the nut that secures the
battery positive cable eyelet terminal to the B(+) ter-
minal stud on the starter solenoid. Tighten the nut to
10 N´m (90 in. lbs.).
(9) Connect the starter motor trigger wire on the
starter motor.
(10) Reconnect the battery positive cable terminal
clamp to the battery positive terminal post. Tighten
the terminal clamp pinch-bolt hex nut to 4 N´m (35
in. lbs.).
(11) Apply a thin coating of petroleum jelly or
chassis grease to the exposed surfaces of the battery
cable terminal clamps and the battery terminal
posts.
Fig. 25 Test Ground Circuit
1 - VOLTMETER
2 - BATTERY
3 - ENGINE GROUND
BR/BEBATTERY SYSTEM 8F - 23
BATTERY CABLE (Continued)

NEGATIVE CABLE INSTALLATION - GASOLINE
(1) Position the battery wire harness into the
engine compartment and under the compressor
mounting bracket, if equipped.
(2) Install and tighten the nut that secures the
battery negative cable ground eyelet terminal to the
stud on the power steering pump pivot bolt.
(3) Install the generator output cable eyelet termi-
nal onto the generator output terminal stud.
(4) Install and tighten the nut that secures the
generator output cable eyelet terminal to the genera-
tor output terminal stud. Tighten the nut to 8.4 N´m
(75 in. lbs.).
(5) Position the cover for the generator output ter-
minal stud housing onto the back of the generator
and snap it into place.
(6) Secure wire assembly in place with pushpin
retainers in there original positions.
(7) Install and tighten the screw that secures the
battery negative cable eyelet terminal to the radiator
closure panel, near the battery. Tighten the screw to
40 in. lbs.
(8) Install and tighten the screw that secures the
battery negative cable eyelet terminal to the left
front side of the frame assembly. Tighten the screw
to 80 in. lbs.
(9) Install and tighten the nut that secures the
battery positive cable eyelet terminal and the gener-
ator output cable eyelet terminal to the PDC B(+)
terminal stud. Tighten the nut to 80 in. lbs.
(10) Reconnect the battery negative cable terminal
clamp to the battery negative terminal post. Tighten
the terminal clamp pinch-bolt hex nut to 35 in. lbs.
(11)
Apply a thin coating of petroleum jelly or chassis
grease to the exposed surfaces of the battery cable ter-
minal clamps and the battery terminal posts.
BATTERY TRAY
DESCRIPTION
The battery is mounted in a molded plastic tray (Fig.
26) with an integral support located in the left front cor-
ner of the engine compartment. A U-nut held in a
molded formation on each side of the battery tray pro-
vides anchor points for the battery hold down bolts. The
battery tray is secured on the outboard side to the inner
fender shield by two hex screws with washers, and from
underneath the integral battery tray support is secured
to the left front wheelhouse inner panel by two stud
plates. Each stud plate has two studs and is secured by
two nuts with washers. The stud plate that secures the
front of the battery tray support to the wheelhouse innerpanel is installed through the wheelhouse panel from
the top. The stud plate that secures the rear of the bat-
tery tray support to the wheelhouse inner panel is
installed through the wheelhouse panel from the bottom.
A hole in the bottom of the battery tray is fitted
with a battery temperature sensor. Refer toBattery
Temperature Sensorin the index of this service
manual for the location of more information on the
battery temperature sensor. Models that are
equipped with an optional vehicle speed control sys-
tem have the speed control servo secured to the inte-
gral battery tray support. Refer toSpeed Control
Servoin the index of this service manual for the
location of more information on the speed control
servo and its mounting.
Models that are equipped with the diesel engine
option have a second battery tray located in the right
front corner of the engine compartment. This second
battery tray and its mounting are mirror image of
the standard equipment left battery tray. However,
the right battery tray and support have no provisions
for a battery temperature sensor or a speed control
servo mounting bracket.
Fig. 26 Battery Tray - Typical
1 - STUD PLATE (2)
2 - NUT AND WASHER (4)
3 - FRONT WHEELHOUSE INNER PANEL
4 - SPEED CONTROL SERVO
5 - TRAY
6 - SCREW AND WASHER (2)
7 - BATTERY TREMPERATURE SENSOR
8 - U-NUT (2)
9 - FENDER INNER SHIELD
8F - 24 BATTERY SYSTEMBR/BE
BATTERY CABLE (Continued)