DODGE RAM 2002 Service Repair Manual

²Terminals in the wiring assembly are fully
seated into the connector/component and locked into
position
²Dirt or corrosion on the terminals. Any amount
of corrosion or dirt could cause an intermittent prob-
lem
²Damaged connector/component casing exposing
the item to dirt or moisture
²Wire insulation that has rubbed through causing
a short to ground
²Some or all of the wiring strands broken inside
of the insulation
²Wiring broken inside of the insulation
TROUBLESHOOTING WIRING PROBLEMS
When troubleshooting wiring problems there are
six steps which can aid in the procedure. The steps
are listed and explained below. Always check for non-
factory items added to the vehicle before doing any
diagnosis. If the vehicle is equipped with these items,
disconnect them to verify these add-on items are not
the cause of the problem.
(1) Verify the problem.
(2) Verify any related symptoms. Do this by per-
forming operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
(3) Analyze the symptoms. Use the wiring dia-
grams to determine what the circuit is doing, where
the problem most likely is occurring and where the
diagnosis will continue.
(4) Isolate the problem area.
(5) Repair the problem area.
(6) Verify the proper operation. For this step,
check for proper operation of all items on the
repaired circuit. Refer to the wiring diagrams.
STANDARD PROCEDURE
STANDARD PROCEDURE - ELECTROSTATIC
DISCHARGE (ESD) SENSITIVE DEVICES
All ESD sensitive components are solid state and a
symbol (Fig. 6) is used to indicate this. When han-
dling any component with this symbol, comply with
the following procedures to reduce the possibility of
electrostatic charge build up on the body and inad-
vertent discharge into the component. If it is not
known whether the part is ESD sensitive, assume
that it is.
(1) Always touch a known good ground before han-
dling the part. This should be repeated while han-
dling the part and more frequently after sliding
across a seat, sitting down from a standing position,
or walking a distance.
(2) Avoid touching electrical terminals of the part,
unless instructed to do so by a written procedure.(3) When using a voltmeter, be sure to connect the
ground lead first.
(4) Do not remove the part form it's protective
packing until it is time to install the part.
(5) Before removing the part from it's pakage,
ground the pakage to a known good ground on the
vehicle.
STANDARD PROCEDURE - TESTING OF
VOLTAGE POTENTIAL
(1) Connect the ground lead of a voltmeter to a
known good ground (Fig. 7).
(2) Connect the other lead of the voltmeter to the
selected test point. The vehicle ignition may need to
be turned ON to check voltage. Refer to the appropri-
ate test procedure.
Fig. 6 ELECTROSTATIC DISCHARGE SYMBOL
Fig. 7 TESTING FOR VOLTAGE POTENTIAL
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WIRING DIAGRAM INFORMATION (Continued)

STANDARD PROCEDURE - TESTING FOR
CONTINUITY
(1) Remove the fuse for the circuit being checked
or, disconnect the battery.
(2) Connect one lead of the ohmmeter to one side
of the circuit being tested (Fig. 8).
(3) Connect the other lead to the other end of the
circuit being tested. Low or no resistance means good
continuity.
STANDARD PROCEDURE - TESTING FOR A
SHORT TO GROUND
(1) Remove the fuse and disconnect all items
involved with the fuse.
(2) Connect a test light or a voltmeter across the
terminals of the fuse.
(3) Starting at the fuse block, wiggle the wiring
harness about six to eight inches apart and watch
the voltmeter/test lamp.
(4) If the voltmeter registers voltage or the test
lamp glows, there is a short to ground in that gen-
eral area of the wiring harness.
STANDARD PROCEDURE - TESTING FOR A
SHORT TO GROUND ON FUSES POWERING
SEVERAL LOADS
(1) Refer to the wiring diagrams and disconnect or
isolate all items on the suspected fused circuits.
(2) Replace the blown fuse.(3) Supply power to the fuse by turning ON the
ignition switch or re-connecting the battery.
(4) Start connecting or energizing the items in the
fuse circuit one at a time. When the fuse blows the
circuit with the short to ground has been isolated.
STANDARD PROCEDURE - TESTING FOR A
VOLTAGE DROP
(1) Connect the positive lead of the voltmeter to
the side of the circuit closest to the battery (Fig. 9).
(2) Connect the other lead of the voltmeter to the
other side of the switch, component or circuit.
(3) Operate the item.
(4) The voltmeter will show the difference in volt-
age between the two points.
SPECIAL TOOLS
WIRING/TERMINAL
Fig. 8 TESTING FOR CONTINUITY
1 - FUSE REMOVED FROM CIRCUIT
Fig. 9 TESTING FOR VOLTAGE DROP
PROBING TOOL PACKAGE 6807
BR/BE8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 9
WIRING DIAGRAM INFORMATION (Continued)

CONNECTOR
REMOVAL
(1) Disconnect battery.
(2) Release Connector Lock (Fig. 10).
(3) Disconnect the connector being repaired from
its mating half/component.
(4) Remove the dress cover (if applicable) (Fig. 10).
(5) Release the Secondary Terminal Lock, if
required (Fig. 11).
(6) Position the connector locking finger away from
the terminal using the proper special tool. Pull on
the wire to remove the terminal from the connector
(Fig. 12).
INSTALLATION
(1) Insert the removed terminal in the same cavity
on the repair connector.
(2) Repeat steps for each terminal in the connec-
tor, being sure that all wires are inserted into the
proper cavities. For additional connector pin-out
identification, refer to the wiring diagrams.
(3) When the connector is re-assembled, the sec-
ondary terminal lock must be placed in the locked
position to prevent terminal push out.
(4) Replace dress cover (if applicable).
(5) Connect connector to its mating half/compo-
nent.
(6) Connect battery and test all affected systems.
TERMINAL PICK TOOL SET 6680
TERMINAL REMOVING TOOLS 6932 AND 8638
TERMINAL REMOVING TOOL 6934
Fig. 10 REMOVAL OF DRESS COVER
1 - DRESS COVER
2 - CONNECTOR LOCK
3 - CONNECTOR
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WIRING DIAGRAM INFORMATION (Continued)

Fig. 11 EXAMPLES OF CONNECTOR SECONDARY TERMINAL LOCKS
1 - Secondary Terminal Lock
BR/BE8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 11
CONNECTOR (Continued)

Fig. 12 TERMINAL REMOVAL
1 - TYPICAL CONNECTOR
2 - PICK FROM SPECIAL TOOL KIT 6680
3 - APEX CONNECTOR
4 - PICK FROM SPECIAL TOOL KIT 6680
5 - AUGAT CONNECTOR
6 - SPECIAL TOOL 6932
7 - MOLEX CONNECTOR8 - SPECIAL TOOL 6742
9 - THOMAS AND BETTS CONNECTOR
10 - SPECIAL TOOL 6934
11 - TYCO CONNECTOR
12 - SPECIAL TOOL 8638
8W - 01 - 12 8W-01 WIRING DIAGRAM INFORMATIONBR/BE
CONNECTOR (Continued)

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. 13).
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. 13).
(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.
TERMINAL
REMOVAL
(1) Follow steps for removing terminals described
in the connector removal section.
(2) Cut the wire 6 inches from the back of the con-
nector.
INSTALLATION
(1) Select a wire from the terminal repair kit that
best matches the color and gage of the 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 (see
wire splicing procedure).
(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.
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. 14).
(4) Using crimping tool, Mopar p/n 05019912AA,
crimp the splice clip and wires together (Fig. 15).
(5) Solder the connection together using rosin core
type solder only (Fig. 16).
Fig. 13 DIODE IDENTIFICATION
1 - CURRENT FLOW
2 - BAND AROUND DIODE INDICATES CURRENT FLOW
3 - DIODE AS SHOWN IN THE DIAGRAMS
Fig. 14 SPLICE BAND
1 - SPLICE BAND
BR/BE8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 13

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. 17).
Fig. 15 CRIMPING TOOL
1 - CRIMPING TOOL
Fig. 16 SOLDER SPLICE
1 - SOLDER
2 - SPLICE BAND
3 - SOLDERING IRON
Fig. 17 HEAT SHRINK TUBE
1 - SEALANT
2 - HEAT SHRINK TUBE
8W - 01 - 14 8W-01 WIRING DIAGRAM INFORMATIONBR/BE
WIRE (Continued)

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 Lamp........................ 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
Data Link Connector................... 8W-18
Daytime Running Lamp Module.......... 8W-50
Dome Lamp.......................... 8W-44
Driver Airbag......................... 8W-43
Driver Cylinder Lock Switch............. 8W-39
Driver Door Ajar Switch................ 8W-45
Driver Door Lock Motor................. 8W-61
Driver Door Window/Lock Switch...... 8W-60, 61
Driver Heated Seat Cushion............. 8W-63Component Page
Driver Heated Seat Switch.............. 8W-63
Driver Lumbar Motor.................. 8W-63
Driver Power Seat Front Vertical Motor.... 8W-63
Driver Power Seat Horizontal Motor....... 8W-63
Driver Power Seat Rear Vertical Motor..... 8W-63
Driver Power Seat Switch............... 8W-63
Driver Power Window Motor............. 8W-60
Electric Brake Provision................ 8W-54
Engine Control Module................. 8W-30
Engine Coolant Temperature Sensor....... 8W-30
Engine Oil Pressure Sensor.............. 8W-30
Engine Starter Motor Relay.............. 8W-21
Engine Starter Motor................... 8W-21
EVAP/Purge Solenoid................... 8W-30
Fender Lamp......................... 8W-51
Fog Lamp Relay....................... 8W-50
Fog Lamp............................ 8W-50
Fuel Heater Relay..................... 8W-30
Fuel Heater........................ 8W-30-36
Fuel Injection Pump................... 8W-30
Fuel Injectors......................... 8W-30
Fuel Pump Module.................... 8W-30
Fuel Pump Relay...................... 8W-30
Fuel Tank Module..................... 8W-30
Fuel Transfer Pump.................... 8W-30
Fuses (JB)........................... 8W-12
Fuses (PDC).......................... 8W-10
Fusible Link....................... 8W-20, 30
Grounds............................. 8W-15
Generator............................ 8W-20
Glove Box Lamp And Switch............. 8W-44
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 Relay..................... 8W-12
High Note Horn....................... 8W-41
Horn Relay.......................... 8W-41
Horn Switch.......................... 8W-41
Idle Air Control Motor.................. 8W-30
Ignition Coils......................... 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, 34, 35,
40, 44, 45, 51, 53, 54, 70
Junction Block........................ 8W-12
Leak Detection Pump.................. 8W-30
BR/BE8W-02 COMPONENT INDEX 8W - 02 - 1

Component Page
License Lamp......................... 8W-51
Low Note Horn....................... 8W-41
Manifold Absolute Pressure Sensor........ 8W-30
Outboard Clearance Lamps.............. 8W-50
Outboard Headlamps................... 8W-50
Outboard Identification Lamps........... 8W-50
Output Speed Sensor................... 8W-31
Overdrive Switch...................... 8W-31
Overhead Console..................... 8W-49
Oxygen Sensors....................... 8W-30
Oxygen Sensor Downstream Relay........ 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
Passenger Cylinder Lock Switch.......... 8W-39
Passenger Door Ajar Switch.............. 8W-45
Passenger Door Lock Motor.............. 8W-61
Passenger Door Window/Lock Switch.... 8W-60, 61
Passenger Heated Seat Cushion.......... 8W-63
Passenger Heated Seat Switch........... 8W-63
Passenger Lumbar Motor................ 8W-63
Passenger Power Seat Front Vertical
Motor............................. 8W-63
Passenger Power Seat Horizontal Motor.... 8W-63
Passenger Power Seat Rear Vertical Motor . . 8W-63
Passenger Power Seat Switch............ 8W-63
Passenger Power Window Motor.......... 8W-60
Power Distribution Center............... 8W-10
Power Mirror Switch................... 8W-62Component Page
Power Mirror......................... 8W-62
Power Outlet......................... 8W-41
Powertrain Control Module.............. 8W-30
PTO Switch.......................... 8W-30
Quad High Beam Relay................. 8W-50
Radio Choke Relay..................... 8W-47
Radio............................... 8W-47
Rear Wheel Speed Sensor............ 8W-34, 35
Remote Radio Switch................... 8W-47
Splices.............................. 8W-70
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 Switches................. 8W-33
Tail/Stop/Turn Signal Lamp.............. 8W-51
Tailgate Lamps....................... 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 Lamps.................... 8W-44
Washer Fluid Level Switch.............. 8W-40
Water In Fuel Sensor................... 8W-30
Wheel Speed Sensor.................... 8W-35
Windshield Washer Pump............... 8W-53
Wiper Motor Relay..................... 8W-53
8W - 02 - 2 8W-02 COMPONENT INDEXBR/BE

8W-10 POWER DISTRIBUTION
Component Page
A/C Compressor Clutch................ 8W-10-27
A/C Compressor Clutch Relay......... 8W-10-9, 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....................... 8W-10-23
Blower Motor Relay................. 8W-10-8, 23
Brake Lamp Switch................. 8W-10-8, 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.............. 8W-10-22, 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................. 8W-10-23
Engine Starter Motor Relay........... 8W-10-8, 23
Fog Lamp Relay..................... 8W-10-25
Fuel Heater........................ 8W-10-20
Fuel Heater Relay.................. 8W-10-8, 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-10-8, 10
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-10-8, 13
Fuse 5 (PDC)...................... 8W-10-8, 13
Fuse 6 (PDC)................... 8W-10-8, 14, 20
Fuse 7 (PDC)...................... 8W-10-8, 20
Fuse 8 (PDC)...................... 8W-10-8, 21
Fuse 9 (PDC)...................... 8W-10-8, 23
Fuse 10 (PDC)..................... 8W-10-8, 22
Fuse 11 (PDC)..................... 8W-10-8, 23
Fuse 12 (JB)........................ 8W-10-10
Fuse 12 (PDC)................... 8W-10-8, 9, 23
Fuse 13 (JB)........................ 8W-10-10
Component Page
Fuse 14 (JB)........................ 8W-10-10
Fuse B (PDC)................... 8W-10-8, 9, 24
Fuse C (PDC)..................... 8W-10-9, 24
Fuse E (PDC)..................... 8W-10-9, 24
Fuse F (PDC)..................... 8W-10-9, 24
Fuse G (PDC)..................... 8W-10-9, 25
Fuse H (PDC)..................... 8W-10-9, 26
Fuse I (PDC)...................... 8W-10-9, 26
Fuse J (PDC)...................... 8W-10-9, 27
Fuse K (PDC)............. 8W-10-9, 14, 17, 18, 19
Fuse L (PDC)..................... 8W-10-9, 27
Fuse Gen (PDC)................... 8W-10-8, 27
G201............................. 8W-10-22
Generator........................ 8W-10-8, 27
Headlamp Beam Select Switch........... 8W-10-25
Headlamp Switch.................. 8W-10-9, 24
High Note Horn..................... 8W-10-26
Horn Relay....................... 8W-10-9, 26
Ignition Coil........................ 8W-10-15
Ignition Coil 4 Pack................... 8W-10-16
Ignition Coil 6 Pack................... 8W-10-16
Ignition Switch................. 8W-10-8, 10, 22
Joint Connector No. 1.............. 8W-10-25, 26
Joint Connector No. 2........ 8W-10-8, 9, 11, 12, 14,
15, 16, 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-10-8, 10, 13
Left Fog Lamp...................... 8W-10-25
Left Headlamp...................... 8W-10-24
Left Outboard Headlamp.......... 8W-10-9, 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-10-8, 9, 10, 11, 12,
13, 14, 2, 20, 21, 22, 23, 24, 25, 26, 27
Power Outlet...................... 8W-10-9, 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-10-9, 24, 25
Security Relay..................... 8W-10-9, 25
Trailer Tow Connector................. 8W-10-21
Trailer Tow Relay.................... 8W-10-21
Transmission Control Relay........... 8W-10-9, 26
Transmission Solenoid Assembly......... 8W-10-26
Turn Signal/Hazard Switch............. 8W-10-13
BR/BE8W-10 POWER DISTRIBUTION 8W - 10 - 1