seats DODGE RAM 2002 Service Owner's Manual
[x] Cancel search | Manufacturer: DODGE, Model Year: 2002, Model line: RAM, Model: DODGE RAM 2002Pages: 2255, PDF Size: 62.07 MB
Page 662 of 2255
WIRING
TABLE OF CONTENTS
page page
AIRBAG SYSTEM.................... 8W-43-1
AIR CONDITIONING-HEATER........... 8W-42-1
ALL WHEEL ANTILOCK BRAKES........ 8W-35-1
AUDIO SYSTEM..................... 8W-47-1
BUS COMMUNICATIONS.............. 8W-18-1
CENTRAL TIMER MODULE............. 8W-45-1
CHARGING SYSTEM.................. 8W-20-1
COMPONENT INDEX.................. 8W-02-1
CONNECTOR/GROUND/SPLICE
LOCATION........................ 8W-91-1
CONNECTOR PIN-OUTS............... 8W-80-1
FRONT LIGHTING.................... 8W-50-1
FUEL/IGNITION SYSTEM.............. 8W-30-1
GROUND DISTRIBUTION.............. 8W-15-1
HORN/CIGAR LIGHTER/POWER OUTLET . . 8W-41-1
INSTRUMENT CLUSTER............... 8W-40-1
INTERIOR LIGHTING.................. 8W-44-1
JUNCTION BLOCK.................... 8W-12-1OVERHEAD CONSOLE................. 8W-49-1
POWER DISTRIBUTION............... 8W-10-1
POWER DISTRIBUTION............... 8W-97-1
POWER DOOR LOCKS................ 8W-61-1
POWER MIRRORS................... 8W-62-1
POWER SEATS...................... 8W-63-1
POWER WINDOWS................... 8W-60-1
REAR LIGHTING..................... 8W-51-1
REAR WHEEL ANTILOCK BRAKES....... 8W-34-1
SPLICE INFORMATION................ 8W-70-1
STARTING SYSTEM.................. 8W-21-1
TRAILER TOW....................... 8W-54-1
TRANSMISSION CONTROL SYSTEM..... 8W-31-1
TURN SIGNALS...................... 8W-52-1
VEHICLE SPEED CONTROL............ 8W-33-1
VEHICLE THEFT SECURITY SYSTEM..... 8W-39-1
WIPERS............................ 8W-53-1
WIRING DIAGRAM INFORMATION....... 8W-01-1 BR/BEWIRING 8W - 1
Page 920 of 2255
8W-63 POWER SEATS
Component Page
Circuit Breaker 2.................. 8W-63-2, 3
Driver Heated Seat Cushion.......... 8W-63-6, 8
Driver Heated Seat Switch............. 8W-63-5
Driver Lumbar Motor................. 8W-63-3
Driver Power Seat Front Vertical
Motor......................... 8W-63-2, 3
Driver Power Seat Horizontal Motor.... 8W-63-2, 3
Driver Power Seat Rear Vertical Motor . . 8W-63-2, 3
Driver Power Seat Switch............ 8W-63-2, 3
Fuse 1 (JB)....................... 8W-63-5, 7
Fuse 2 (JB)....................... 8W-63-5, 7
G201............................ 8W-63-5, 7
G300........................ 8W-63-3, 4, 6, 8
G301.............................. 8W-63-2Component Page
Heated Seat Relay................. 8W-63-5, 7
Joint Connector No. 5............... 8W-63-5, 7
Joint Connector No. 8............... 8W-63-5, 7
Junction Block................ 8W-63-2, 3, 5, 7
Passenger Heated Seat Cushion..... 8W-63-4, 6, 8
Passenger Heated Seat Switch.......... 8W-63-7
Passenger Lumbar Motor.............. 8W-63-4
Passenger Power Seat Front Vertical
Motor........................... 8W-63-4
Passenger Power Seat Horizontal Motor . . . 8W-63-4
Passenger Power Seat Rear Vertical
Motor........................... 8W-63-4
Passenger Power Seat Switch........... 8W-63-4
Seat Heat Interface Module...... 8W-63-5, 6, 7, 8
BR/BE8W-63 POWER SEATS 8W - 63 - 1
Page 936 of 2255
8W-80 CONNECTOR PIN-OUTS
Component Page
4WD Switch........................ 8W-80-4
A/C Compressor Clutch................ 8W-80-4
A/C Heater Control................... 8W-80-4
A/C Heater Temperature Select......... 8W-80-4
A/C High Pressure Switch............. 8W-80-4
A/C Low Pressure Switch.............. 8W-80-5
Accelerator Pedal Position Sensor
(Diesel).......................... 8W-80-5
Aftermarket Trailer Tow Connector...... 8W-80-5
Airbag Control Module................ 8W-80-5
Ambient Temperature Sensor........... 8W-80-6
Ash Receiver Lamp................... 8W-80-6
Automatic Day/Night Mirror............ 8W-80-6
Back-Up Lamp Switch (M/T)........... 8W-80-6
Battery Temperature Sensor............ 8W-80-7
Blend Door Actuator.................. 8W-80-7
Blower Motor....................... 8W-80-7
Blower Motor Resistor Block............ 8W-80-7
Brake Lamp Switch.................. 8W-80-7
Brake Pressure Switch................ 8W-80-8
Bypass Jumper (A/T)................. 8W-80-8
C105.............................. 8W-80-8
C105.............................. 8W-80-8
C106.............................. 8W-80-8
C106.............................. 8W-80-8
C114 .............................. 8W-80-9
C114 .............................. 8W-80-9
C125 (Diesel)....................... 8W-80-9
C125 (Diesel)....................... 8W-80-9
C126 (Diesel)....................... 8W-80-10
C126 (Diesel)....................... 8W-80-10
C129............................. 8W-80-10
C129............................. 8W-80-11
C130 (Diesel)....................... 8W-80-11
C130 (Diesel) (In PDC)............... 8W-80-12
C130 (Gas)........................ 8W-80-13
C130 (Gas) (In PDC)................. 8W-80-14
C134............................. 8W-80-15
C134............................. 8W-80-17
C203............................. 8W-80-18
C203............................. 8W-80-19
C205............................. 8W-80-20
C205............................. 8W-80-20
C206 (Heated Seats)................. 8W-80-20
C206 (Heated Seats)................. 8W-80-21
C237............................. 8W-80-21
C237............................. 8W-80-21
C303............................. 8W-80-22
C303............................. 8W-80-22
C308............................. 8W-80-22
C308............................. 8W-80-22
C329 (Club Cab).................... 8W-80-22Component Page
C329 (Club Cab).................... 8W-80-23
C329 (Standard Cab)................ 8W-80-23
C329 (Standard Cab)................ 8W-80-23
C333 (Club Cab).................... 8W-80-23
C333 (Club Cab).................... 8W-80-23
C333 (Standard Cab)................ 8W-80-24
C333 (Standard Cab)................ 8W-80-24
C342............................. 8W-80-24
C342............................. 8W-80-24
C343............................. 8W-80-24
C343............................. 8W-80-24
C344 (Dual Rear Wheels)............. 8W-80-25
C344 (Dual Rear Wheels)............. 8W-80-25
C345............................. 8W-80-25
C345............................. 8W-80-25
C346............................. 8W-80-26
C346............................. 8W-80-26
C347............................. 8W-80-26
C347............................. 8W-80-27
C348............................. 8W-80-27
C348............................. 8W-80-28
C352............................. 8W-80-28
C352............................. 8W-80-28
C353............................. 8W-80-28
C353............................. 8W-80-28
C358............................. 8W-80-29
C358............................. 8W-80-29
C359 (Heated Seat).................. 8W-80-29
C359 (Heated Seat).................. 8W-80-29
C360 (Club Cab).................... 8W-80-30
C360 (Club Cab).................... 8W-80-30
C361............................. 8W-80-30
C361............................. 8W-80-30
C364............................. 8W-80-31
C364............................. 8W-80-31
C365 (Heated Seat).................. 8W-80-31
C365 (Heated Seat).................. 8W-80-31
Camshaft Position Sensor (8.0L Gas).... 8W-80-32
Camshaft Position Sensor (Diesel)...... 8W-80-32
Camshaft Position Sensor
(Gas Except 8.0L)................. 8W-80-32
Cargo Lamp No. 1................... 8W-80-32
Cargo Lamp No. 2................... 8W-80-32
Center High Mounted Stop Lamp No. 1 . . 8W-80-33
Center High Mounted Stop Lamp No. 2 . . 8W-80-33
Center Identification Lamp............ 8W-80-33
Central Timer Module C1............. 8W-80-33
Central Timer Module C2............. 8W-80-34
Cigar Lighter...................... 8W-80-34
Clockspring C1..................... 8W-80-34
Clockspring C2..................... 8W-80-34
Clockspring C3..................... 8W-80-35
BR/BE8W-80 CONNECTOR PIN-OUTS 8W - 80 - 1
Page 955 of 2255
C203 - (I/P HARNESS SIDE)
CAV CIRCUIT
21 X54 18VT
21 X54 18VT
22 P34 22PK/BK (CTM)
22 P34 20PK/BK (POWER LOCK/WINDOW
(CTM))
23 P31 22PK/DG (CTM)
23 P31 22PK/DG (CTM)
24 X55 18BR/RD
24 X55 18BR/RD
25 X53 18DG
25 X53 18DG
26 X56 18DB/RD
26 X56 18DB/RD
C205 - NATURAL (ASH RECEIVER LAMP SIDE)
CAV CIRCUIT
1 E2 22OR
2 Z3 20BK/OR
C205 - NATURAL (I/P SIDE)
CAV CIRCUIT
1 E2 22OR
2 Z3 22BK/OR
C206 (HEATED SEATS) - (BODY SIDE)
CAV CIRCUIT
1 P137 20DG
2 P7 20LB/BK
3 P140 20VT/BK
4 P138 20VT/LG
5 P139 20WT
6 F235 16RD
7 P8 20LB/WT
8W - 80 - 20 8W-80 CONNECTOR PIN-OUTSBR/BE
Page 956 of 2255
C206 (HEATED SEATS) - (I/P SIDE)
CAV CIRCUIT
1 P137 20DG
2 P7 20LB/BK
3 P140 20VT/BK
4 P138 20VT/LG
5 P139 20WT
6 F235 16RD
7 P8 20LB/WT
C237 - (I/P SIDE)
CAV CIRCUIT
1 C5 16LG
2 Z2 22BK/LG
3-
4-
5-
6 C82 22YL/OR
7-
8 C7 12BK/TN
9-
10 -
11 C4 16TN
12 F15 22DB
13 -
14 C6 14LB
C237 - (RESISTOR BLOCK SIDE)
CAV CIRCUIT
1 C5 16LG
2 Z2 20BK/LG
3-
4-
5-
6 C82 20YL/OR
7-
8 C7 12BK/TN
9-
10 -
11 C4 16TN
12 F15 20DB
13 -
14 C6 14LB
BR/BE8W-80 CONNECTOR PIN-OUTS 8W - 80 - 21
Page 987 of 2255
JOINT CONNECTOR NO.5-NATURAL 22 WAY
CAV CIRCUIT FUNCTION
1 M1 20PK FUSED B(+)
2 M1 22PK FUSED B(+)
3 M1 22PK FUSED B(+)
4 Z3 20BK/OR GROUND
5 Z3 18BK/OR GROUND
6 Z3 22BK/OR GROUND
7 Z3 18BK/OR GROUND
8 E2 22OR PANEL LAMPS FEED
9 E2 22OR PANEL LAMPS FEED
10 E2 22OR PANEL LAMPS FEED
11 - -
12 M1 22PK FUSED B(+)
13 M1 22PK FUSED B(+)
14 Z3 20BK/OR (HEATED SEATS) GROUND
15 Z3 20BK/OR (HEATED SEATS) GROUND
16 Z3 22BK/OR (EXCEPT BASE/MIDLINE) GROUND
17 Z3 22BK/OR (EXCEPT BASE/MIDLINE) GROUND
18 - -
19 - -
20 E2 22OR PANEL LAMPS FEED
21 E2 22OR PANEL LAMPS FEED
22 E2 22OR PANEL LAMPS FEED
JOINT CONNECTOR NO.6-NATURAL 22 WAY
CAV CIRCUIT FUNCTION
1- -
2- -
3- -
4 L50 16WT/TN BRAKE LAMP SWITCH OUTPUT
5 L50 16WT/TN BRAKE LAMP SWITCH OUTPUT
6 L50 18WT/TN BRAKE LAMP SWITCH OUTPUT
7 L50 18WT/TN BRAKE LAMP SWITCH OUTPUT
8 Z9 16BK/VT(EXCEPT BASE/LOWLINE) GROUND
9 Z9 20BK/VT(SLT+HIGHLINE) GROUND
10 X3 20BK/RD(EXCEPT BASE/MIDLINE) HORN RELAY CONTROL
10 M22 22WT(BASE/MIDLINE) DOME LAMPS SWITCH SENSE
11 X3 20BK/RD(EXCEPT BASE/MIDLINE) HORN RELAY CONTROL
11 M22 22WT(BASE/MIDLINE) DOME LAMPS SWITCH SENSE
12 M22 22WT(BASE/MIDLINE) DOME LAMPS SWITCH SENSE
12 X3 20BK/RD(EXCEPT BASE/MIDLINE) HORN RELAY CONTROL
13 V10 16BR WASHER SWITCH SENSE
14 V10 16BR WASHER SWITCH SENSE
15 V10 16BR WASHER SWITCH SENSE
16 - -
17 - -
18 Z9 16BK/VT GROUND
19 Z9 16BK/VT(XECEPT BASE/LOWLINE) GROUND
20 G26 22LB KEY-IN IGNITION SWITCH SENSE
21 G26 22LB KEY-IN IGNITION SWITCH SENSE
22 G26 22LB KEY-IN IGNITION SWITCH SENSE
8W - 80 - 52 8W-80 CONNECTOR PIN-OUTSBR/BE
Page 988 of 2255
JOINT CONNECTOR NO.7-NATURAL 22 WAY
CAV CIRCUIT FUNCTION
1 D1 18VT/BR CCD BUS (+)
2 D1 18VT/BR CCD BUS (+)
3 D1 20VT/BR CCD BUS (+)
4 D2 18WT/BK CCD BUS (-)
5 D2 18WT/BK CCD BUS (-)
6 D2 20WT/BK CCD BUS (-)
7 D2 20WT/BK CCD BUS (-)
8 D1 20VT/BR CCD BUS (+)
9 D1 20VT/BR CCD BUS (+)
10 D1 20VT/BR CCD BUS (+)
11 D1 20VT/BR CCD BUS (+)
12 D1 20VT/BR CCD BUS (+)
13 D1 20VT/BR CCD BUS (+)
14 D2 20WT/BK CCD BUS (-)
15 D2 20WT/BK CCD BUS (-)
16 D2 20WT/BK CCD BUS (-)
17 D2 20WT/BK (REMOTE RADIO) CCD BUS (-)
18 - -
19 - -
20 D1 20VT/BR (REMOTE RADIO) CCD BUS (+)
21 - -
22 - -
JOINT CONNECTOR NO.8-NATURAL 22 WAY
CAV CIRCUIT FUNCTION
1 M2 22YL COURTESY LAMPS DRIVER
2 M2 22YL COURTESY LAMPS DIRVER
3 M2 22YL COURTESY LAMPS DRIVER
4 F15 22DB FUSED IGNITION SWITCH OUTPUT(RUN)
5 F15 22DB FUSED IGNITION SWITCH OUTPUT(RUN)
6 F15 22DB FUSED IGNITION SWITCH OUTPUT(RUN)
7 F15 20DB(HEATED SEATS) FUSED IGNITION SWITCH OUTPUT(RUN)
8 G75 22TN(BASE/MIDLINE) DRIVER DOOR AJAR SWITCH SENSE
8 E2 22OR(HEATED SEATS) PANEL LAMPS FEED
9 E2 22OR(HEATED SEATS) PANEL LAMPS FEED
9 G75 22TN(BASE/MIDLINE) DRIVER DOOR AJAR SWITCH SENSE
10 Z6 18 BK/PK GROUND
11 Z6 18BK/PK GROUND
12 Z6 18BK/PK GROUND
13 E17 18YL/BK DAY BRIGHTNESS SENSE
14 E17 18YL/BK DAY BRIGHTNESS SENSE
15 E17 18YL/BK DAY BRIGHTNESS SENSE
16 F15 18DB FUSED IGNITION SWITCH OUTPUT(RUN)
17 F15 22DB FUSED IGNITION SWITCH OUTPUT(RUN)
18 E2 22OR(HEATED SEATS) PANEL LAMPS FEED
18 G75 22TN(BASE/MIDLINE) DRIVER DOOR AJAR SWITCH SENSE
19 E2 22OR(HEATED SEATS) PANEL LAMPS FEED
19 G75 22TN(BASE/MIDLINE) DRIVER DOOR AJAR SWITCH SENSE
20 F14 18LG/YL FUSED IGNITION SWITCH OUTPUT(RUN-START)
21 F14 18LG/YL FUSED IGNITION SWITCH OUTPUT(RUN-START)
22 F14 18LG/YL FUSED IGNITION SWITCH OUTPUT(RUN-START)
BR/BE8W-80 CONNECTOR PIN-OUTS 8W - 80 - 53
Page 1014 of 2255
RIGHT TWEETER (PREMIUM)-2WAY
CAV CIRCUIT FUNCTION
1 X82 20LB/RD AMPLIFIED HIGH RIGHT FRONT SPEAKER (+)
2 X80 20LB/BK AMPLIFIED HIGH RIGHT FRONT SPEAKER (-)
RIGHT VISOR/VANITY LAMP - BLACK 2 WAY
CAV CIRCUIT FUNCTION
A M1 20PK FUSED B(+)
B Z4 20BK GROUND
SEAT BELT SWITCH (CLUB CAB)-2WAY
CAV CIRCUIT FUNCTION
1 Z2 20BK/LG GROUND
2 G10 22LG/RD (HEATED SEATS) SEAT BELT SWITCH SENSE
2 G10 20LG/RD (MANUAL NON-HEATED
SEATS)SEAT BELT SWITCH SENSE
SEAT BELT SWITCH (STANDARD CAB) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 Z2 20BK/LG GROUND
2 G10 20LG/RD SEAT BELT SWITCH SENSE
SEAT HEAT INTERFACE MODULE - 14 WAY
CAV CIRCUIT FUNCTION
1 P7 20LB/BK DRIVER HEATED SEAT SWITCH
2 P144 20BK/WT SEAT TEMPERATURE 5V SUPPLY
3 P130 16TN RIGHT SEAT HEATER B(+) DRIVER
4 F235 16RD B(+) TO HEATED SEAT MODULE
5 P131 16RD/DG LEFT SEAT HEATER B(+) DRIVER
6 F235 16RD B(+) TO HEATED SEAT MODULE
7 P142 22DB RIGHT SEAT TEMPERATURE SENSOR INPUT
8 P141 20TN/LB LEFT SEAT TEMPERATURE SENSOR INPUT
9 P8 20LB/WT PASSENGER HEATED SEAT SWITCH
10 P138 20VT/LG RIGHT SEAT LOW HEAT LED DRIVER
11 P140 20VT/BK RIGHT SEAT HIGH HEAT LED DRIVER
12 P137 20DG LEFT SEAT LOW HEAT LED DRIVER
13 Z2 18BK/LG GROUND
14 P139 20WT LEFT SEAT HIGH HEAT LED DRIVER
BR/BE8W-80 CONNECTOR PIN-OUTS 8W - 80 - 79
Page 1076 of 2255
ENGINE
TABLE OF CONTENTS
page page
ENGINE 5.9L.............................. 1
ENGINE 8.0L............................. 56ENGINE 5.9L DIESEL..................... 113
ENGINE 5.9L
TABLE OF CONTENTS
page page
ENGINE 5.9L
DESCRIPTION..........................3
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION............3
DIAGNOSIS AND TESTINGÐENGINE
DIAGNOSIS - PERFORMANCE............4
DIAGNOSIS AND TESTINGÐ ENGINE
DIAGNOSIS - MECHANICAL..............6
DIAGNOSIS AND TESTINGÐENGINE
DIAGNOSIS - LUBRICATION..............8
DIAGNOSIS AND TESTINGÐCYLINDER
COMPRESSION PRESSURE..............9
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE.......9
STANDARD PROCEDURE
STANDARD PROCEDURE - FORM-IN-
PLACE GASKETS AND SEALERS.........10
STANDARD PROCEDURE - REPAIR
DAMAGED OR WORN THREADS.........11
STANDARD PROCEDUREÐHYDROSTATIC
LOCK...............................11
STANDARD PROCEDURE - CYLINDER
BORE HONING.......................11
REMOVAL.............................12
INSTALLATION.........................12
SPECIFICATIONS
5.9L ENGINE.........................13
TORQUE............................17
SPECIAL TOOLS
5.9L ENGINE.........................18
CYLINDER HEAD
DESCRIPTION
DESCRIPTIONÐCYLINDER HEAD........20
DESCRIPTION - CYLINDER HEAD COVER
GASKET............................20OPERATION
OPERATIONÐCYLINDER HEAD..........21
OPERATION - CYLINDER HEAD COVER
GASKET............................21
DIAGNOSIS AND TESTINGÐCYLINDER HEAD
GASKET FAILURE.....................21
REMOVAL.............................21
CLEANING............................22
INSPECTION..........................22
INSTALLATION.........................22
CYLINDER HEAD COVER(S)
REMOVAL.............................23
CLEANING............................23
INSPECTION..........................23
INSTALLATION.........................23
INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION.........................23
STANDARD PROCEDUREÐVALVES, GUIDES
AND SPRINGS.......................23
REMOVAL.............................25
CLEANING............................26
INSPECTION..........................26
INSTALLATION.........................26
ROCKER ARM / ADJUSTER ASSEMBLY
REMOVAL.............................26
INSTALLATION.........................26
ENGINE BLOCK
CLEANING............................27
INSPECTION..........................27
CAMSHAFT & BEARINGS (IN BLOCK)
REMOVAL
REMOVALÐCAMSHAFT BEARINGS.......27
REMOVALÐCAMSHAFT................28
INSTALLATION
INSTALLATIONÐCAMSHAFT BEARINGS . . . 28
INSTALLATIONÐCAMSHAFT............29
BR/BEENGINE 9 - 1
Page 1081 of 2255
CONDITION POSSIBLE CAUSES CORRECTION
3. Dirt in fuel system 3. Clean fuel system
4. Burned, warped or pitted valves 4. Install new valves
5. Faulty coil 5. Test and replace as necessary
(Refer to 8 - ELECTRICAL/
IGNITION CONTROL/IGNITION
COIL - REMOVAL)
DIAGNOSIS AND TESTINGÐ ENGINE
DIAGNOSIS - MECHANICAL
ENGINE MECHANICAL DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
NOISY VALVES/LIFTERS 1. High or low oil level in crankcase 1. Check for correct oil level. Adjust
oil level by draining or adding as
needed
2. Thin or diluted oil 2. Change oil. (Refer to 9 -
ENGINE/LUBRICATION/OIL -
STANDARD PROCEDURE)
3. Low oil pressure 3. Check engine oil level. If ok,
Perform oil pressure test. (Refer to
9 - ENGINE/LUBRICATION -
DIAGNOSIS AND TESTING) for
engine oil pressure test/
specifications
4. Dirt in tappets/lash adjusters 4. Clean/replace hydraulic
tappets/lash adjusters
5. Bent push rod(s) 5. Install new push rods
6. Worn rocker arms 6. Inspect oil supply to rocker arms
and replace worn arms as needed
7. Worn tappets/lash adjusters 7. Install new hydraulic tappets/lash
adjusters
8. Worn valve guides 8. Inspect all valve guides and
replace as necessary
9. Excessive runout of valve seats
or valve faces9. Grind valves and seats
CONNECTING ROD NOISE 1. Insufficient oil supply 1. Check engine oil level.
2. Low oil pressure 2. Check engine oil level. If ok,
Perform oil pressure test. (Refer to
9 - ENGINE/LUBRICATION -
DIAGNOSIS AND TESTING) engine
oil pressure test/specifications
3. Thin or diluted oil 3. Change oil to correct viscosity.
(Refer to 9 - ENGINE/
LUBRICATION/OIL - STANDARD
PROCEDURE) for correct
procedure/engine oil specifications
9 - 6 ENGINE 5.9LBR/BE
ENGINE 5.9L (Continued)