jump cable DODGE RAM 2002 Service Repair Manual

DESCRIPTION SPECIFICATION
Dry fill capacity Depending on type and size of
internal cooler, length and inside diameter of cooler
lines, or use of an auxiliary cooler, these figures may
vary. (Refer to 21 - TRANSMISSION/TRANSAXLE/
AUTOMATIC/FLUID - STANDARD PROCEDURE)
MANUAL TRANSMISSION
NV4500 3.8 L (8.0 pts.)
NV5600 4.5 L (9.5 pts.)
TRANSFER CASE
NV241 2.18 L (4.61 pts.)
NV241 HD 3.08 L (6.51 pts.)
FRONT AXLE   .03 L (1 oz)
248-RBI (Model 60) 4.0 L (8.5 pts.)
REAR AXLE   .03 L (1 oz)
248-RBI (Model 60) 2WD 2.9 L (6.1 pts.)
248-RBI (Model 60) 4WD 3.4 L (7.2 pts.)
267-RBI (Model 70)
2WD3.3 L (7.0 pts.)
267-RBI (Model 70)
4WD3.6 L (7.6 pts.)
286-RBI (Model 80)
2WD3.2 L (6.8 pts.)
286-RBI (Model 80)
4WD4.8 L (10.1 pts.)
REAR AXLE - LIMITED SLIP DIFFERENTIAL   .03 L
(1 oz)
248-RBI (Model 60) 2WD 2.8 L (5.9 pts.)
248-RBI (Model 60) 4WD 3.2 L (6.8 pts.)
267-RBI (Model 70)
2WD3.1 L (6.5 pts.)
267-RBI (Model 70)
4WD3.4 L (7.2 pts.)
286-RBI (Model 80)
2WD3.0 L (6.3 pts.)
286-RBI (Model 80)
4WD4.5 L (9.5 pts.)
FRICTION MODIFIER   .03 L (1 oz)
248-RBI (Model 60) 2WD 0.15 L (5 oz)
248-RBI (Model 60) 4WD 0.18 L (6 oz)
267-RBI (Model 70)
2WD0.21 L (7 oz)DESCRIPTION SPECIFICATION
267-RBI (Model 70)
4WD0.24 L (8 oz)
286-RBI (Model 80)
2WD0.21 L (7 oz)
286-RBI (Model 80)
4WD0.30 L (10 oz)
**** Includes 0.9L (1.0 qts.) for coolant reservoir.
*****Nominal refill capacities are shown. A variation
may be observed from vehicle to vehicle due to
manufacturing tolerance and refill procedure.
MAINTENANCE SCHEDULES
DESCRIPTION
9Maintenance Schedule Information not included in
this section, is located in the appropriate Owner's
Manual.9
JUMP STARTING
STANDARD PROCEDURE - JUMP STARTING
WARNING: REVIEW ALL SAFETY PRECAUTIONS
AND WARNINGS IN GROUP 8A, BATTERY/START-
ING/CHARGING SYSTEMS DIAGNOSTICS.
²DO NOT JUMP START A FROZEN BATTERY,
PERSONAL INJURY CAN RESULT.
²DO NOT JUMP START WHEN MAINTENANCE
FREE BATTERY INDICATOR DOT IS YELLOW OR
BRIGHT COLOR.
²DO NOT JUMP START A VEHICLE WHEN THE
BATTERY FLUID IS BELOW THE TOP OF LEAD
PLATES.
²DO NOT ALLOW JUMPER CABLE CLAMPS TO
TOUCH EACH OTHER WHEN CONNECTED TO A
BOOSTER SOURCE.
²DO NOT USE OPEN FLAME NEAR BATTERY.
²REMOVE METALLIC JEWELRY WORN ON
HANDS OR WRISTS TO AVOID INJURY BY ACCI-
DENTAL ARCING OF BATTERY CURRENT.
²WHEN USING A HIGH OUTPUT BOOSTING
DEVICE, DO NOT ALLOW BATTERY VOLTAGE TO
EXCEED 16 VOLTS. REFER TO INSTRUCTIONS
PROVIDED WITH DEVICE BEING USED.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY
RESULT IN PERSONAL INJURY.
CAUTION: When using another vehicle as a
booster, do not allow vehicles to touch. Electrical
systems can be damaged on either vehicle.
BR/BELUBRICATION & MAINTENANCE 0 - 7
FLUID CAPACITIES (Continued)

TO JUMP START A DISABLED VEHICLE:
(1) Raise hood on disabled vehicle and visually
inspect engine compartment for:
²Battery cable clamp condition, clean if necessary.
²Frozen battery.
²Yellow or bright color test indicator, if equipped.
²Low battery fluid level.
²Generator drive belt condition and tension.
²Fuel fumes or leakage, correct if necessary.
CAUTION: If the cause of starting problem on dis-
abled vehicle is severe, damage to booster vehicle
charging system can result.
(2) When using another vehicle as a booster
source, park the booster vehicle within cable reach.
Turn off all accessories, set the parking brake, place
the automatic transmission in PARK or the manual
transmission in NEUTRAL and turn the ignition
OFF.
(3) On disabled vehicle, place gear selector in park
or neutral and set park brake. Turn off all accesso-
ries.
(4) Connect jumper cables to booster battery. RED
clamp to positive terminal (+). BLACK clamp to neg-
ative terminal (-). DO NOT allow clamps at opposite
end of cables to touch, electrical arc will result.
Review all warnings in this procedure.
(5) On disabled vehicle, connect RED jumper cable
clamp to positive (+) terminal. Connect BLACK
jumper cable clamp to engine ground as close to the
ground cable attaching point as possible (Fig. 7)and
(Fig. 8).
(6) Start the engine in the vehicle which has the
booster battery, let the engine idle a few minutes,
then start the engine in the vehicle with the dis-
charged battery.
CAUTION: Do not crank starter motor on disabled
vehicle for more than 15 seconds, starter will over-
heat and could fail.
(7) Allow battery in disabled vehicle to charge to
at least 12.4 volts (75% charge) before attempting to
start engine. If engine does not start within 15 sec-
onds, stop cranking engine and allow starter to cool
(15 min.), before cranking again.
DISCONNECT CABLE CLAMPS AS FOLLOWS:
²Disconnect BLACK cable clamp from engine
ground on disabled vehicle.²When using a Booster vehicle, disconnect
BLACK cable clamp from battery negative terminal.
Disconnect RED cable clamp from battery positive
terminal.
²Disconnect RED cable clamp from battery posi-
tive terminal on disabled vehicle.
Fig. 7 Jumper Cable Clamp ConnectionsÐGas
Engine
1 - NEGATIVE OR GROUND CABLE CONNECTION
2 - POSITIVE CABLE CONNECTION
3 - BATTERY
Fig. 8 Jumper Cable Clamp ConnectionsÐDiesel
Engine
1 - POSITIVE CABLE CONNECTION
2 - BATTERY
3 - NEGATIVE OR GROUND CABLE CONNECTION
0 - 8 LUBRICATION & MAINTENANCEBR/BE
JUMP STARTING (Continued)

²Battery- The storage battery provides a reli-
able means of storing a renewable source of electrical
energy within the vehicle.
²Battery Cable- The battery cables connect the
battery terminal posts to the vehicle electrical sys-
tem.
²Battery Holddown- The battery holddown
hardware secures the battery in the battery tray in
the engine compartment.
²Battery Tray- The battery tray provides a
secure mounting location in the vehicle for the bat-
tery and an anchor point for the battery holddown
hardware.
For battery system maintenance schedules and
jump starting procedures, see the owner's manual in
the vehicle glove box. Optionally, refer to Lubrication
and Maintenance for the recommended battery main-
tenance schedules and for the proper battery jump
starting procedures. While battery charging can be
considered a maintenance procedure, the battery
charging procedures and related information are
located in the standard procedures section of this ser-
vice manual. This was done because the battery must
be fully-charged before any battery system diagnosis
or testing procedures can be performed. Refer to
Standard procedures for the proper battery charging
procedures.
OPERATION
The battery system is designed to provide a safe,
efficient, reliable and mobile means of delivering and
storing electrical energy. This electrical energy is
required to operate the engine starting system, as
well as to operate many of the other vehicle acces-
sory systems for limited durations while the engine
and/or the charging system are not operating. The
battery system is also designed to provide a reserve
of electrical energy to supplement the charging sys-
tem for short durations while the engine is running
and the electrical current demands of the vehicle
exceed the output of the charging system. In addition
to delivering, and storing electrical energy for the
vehicle, the battery system serves as a capacitor and
voltage stabilizer for the vehicle electrical system. It
absorbs most abnormal or transient voltages caused
by the switching of any of the electrical components
or circuits in the vehicle.
DIAGNOSIS AND TESTING - BATTERY SYSTEM
The battery, starting, and charging systems in the
vehicle operate with one another and must be tested
as a complete system. In order for the engine to start
and the battery to maintain its charge properly, all of
the components that are used in these systems must
perform within specifications. It is important that
the battery, starting, and charging systems be thor-
oughly tested and inspected any time a battery needs
to be charged or replaced. The cause of abnormal bat-
tery discharge, overcharging or early battery failure
must be diagnosed and corrected before a battery is
replaced and before a vehicle is returned to service.
The service information for these systems has been
separated within this service manual to make it eas-
ier to locate the specific information you are seeking.
However, when attempting to diagnose any of these
systems, it is important that you keep their interde-
pendency in mind.
The diagnostic procedures used for the battery,
starting, and charging systems include the most
basic conventional diagnostic methods, to the more
sophisticated On-Board Diagnostics (OBD) built into
the Powertrain Control Module (PCM). Use of an
induction-type milliampere ammeter, a volt/ohmme-
ter, a battery charger, a carbon pile rheostat (load
tester) and a 12-volt test lamp may be required. All
OBD-sensed systems are monitored by the PCM.
Each monitored circuit is assigned a Diagnostic Trou-
ble Code (DTC). The PCM will store a DTC in elec-
tronic memory for any failure it detects. Refer to
Charging System for the proper charging system on-
board diagnostic test procedures.
MIDTRONICS ELECTRICAL SYSTEM TESTER
The Midtronicstautomotive battery and charging
system tester is designed to help the dealership tech-
nicians diagnose the cause of a defective battery or
charging system. Follow the instruction manual sup-
plied with the tester to properly diagnose a vehicle. If
the instruction manual is not available refer to the
standard procedure in this section, which includes
the directions for using the midtronics electrical sys-
tem tester.
8F - 2 BATTERY SYSTEMBR/BE
BATTERY SYSTEM (Continued)

thirty-five milliamperes, isolate each circuit using the
fuse and circuit breaker remove-and-replace process
in Step 5. The multi-meter reading will drop to
within the acceptable limit when the source of the
excessive current draw is disconnected. Repair this
circuit as required; whether a wiring short, incorrect
switch adjustment, or a component failure is at fault.
STANDARD PROCEDURE - USING
MIDTRONICS ELECTRICAL TESTER
Always use the Midtronics Instruction Manual that
was supplied with the tester as a reference. If the
Instruction Manual is not available the following pro-
cedure can be used:
WARNING: ALWAYS WEAR APPROPRIATE EYE
PROTECTION AND USE EXTREME CAUTION WHEN
WORKING WITH BATTERIES.
BATTERY TESTING
(1) If testing the battery OUT-OF-VEHICLE, clean
the battery terminals with a wire brush before test-
ing. If the battery is equipped with side post termi-
nals, install and tighten the supplied lead terminal
stud adapters. Do not use steel bolts. Failure to prop-
erly install the stud adapters, or using stud adapters
that are dirty or worn-out may result in false test
readings.
(2) If testing the battery IN-THE-VEHICLE, make
certain all of the vehicle accessory loads are OFF,
including the ignition.The preferred test positionis at the battery terminal. If the battery is not
accessible, you may test using both the positive and
negative jumper posts. Select TESTING AT JUMPER
POST when connecting to that location.
(3) Connect the tester to (Fig. 14) the battery or
jumper posts, the red clamp to positive (+) and the
black clamp to negative (±).
NOTE: Multiple batteries connected in parallel must
have the ground cable disconnected to perform a
battery test. Failure to disconnect may result in
false battery test readings.
NOTE: When testing the battery in a PT Cruiser,
always test at the battery terminals
(4) Using the ARROW key selectinoroutof vehi-
cle testing and press ENTER to make a selection.
(5) If not selected, choose the Cold Cranking Amp
(CCA) battery rating. Or select the appropriate bat-
tery rating for your area (see menu). The tester will
then run its self programmed test of the battery and
display the results. Refer to the test result table
noted below.
CAUTION: If REPLACE BATTERY is the result of the
test, this may mean a poor connection between the
vehicle's cables and battery exists. After discon-
necting the vehicle's battery cables from the bat-
tery, retest the battery using the OUT-OF-VEHICLE
test before replacing.
(6) While viewing the battery test result, press the
CODE button and the tester will prompt you for the
last 4 digits of the VIN. Use the UP/DOWN arrow
buttons to scroll to the correct character; then press
ENTER to select and move to the next digit. Then
press the ENTER button to view the SERVICE
CODE. Pressing the CODE button a second time will
return you to the test results.
BATTERY TEST RESULTS
GOOD BATTERY Return to service
GOOD - RECHARGE Fully charge battery and
return to service
CHARGE & RETEST Fully charge battery and
retest battery
REPLACE BATTERY Replace the battery and
retest complete system
BAD-CELL REPLACE Replace the battery and
retest complete system
NOTE: The SERVICE CODE is required on every
warranty claim submitted for battery replacement.
Fig. 14 MIDTRONICS BATTERY AND CHARGING
SYSTEM TESTER - Micro420
BR/BEBATTERY SYSTEM 8F - 15
BATTERY (Continued)

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, and
the 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 AND 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-
rosion or foreign material, then reassembled.
Following reassembly, check the voltage drop for the
battery cable connection and the battery cable again
to confirm repair.
When performing the voltage drop test, it is impor-
tant to remember that the voltage drop is giving an
indication of the resistance between the two points at
which the voltmeter probes are attached.EXAM-
PLE:When testing the resistance of the battery pos-
itive cable, touch the voltmeter leads to the battery
positive cable terminal clamp and to the battery pos-
itive cable eyelet terminal at the starter solenoid
B(+) terminal stud. If you probe the battery positive
terminal post and the battery positive cable eyelet
terminal at the starter solenoid B(+) terminal stud,
you are reading the combined voltage drop in the
battery positive cable terminal clamp-to-terminal
post connection and the battery positive cable.
BR/BEBATTERY SYSTEM 8F - 19
BATTERY CABLE (Continued)

(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
ENGINE
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.
INSTALLATION
POSITIVE CABLE INSTALLATION - GASOLINE
ENGINE
(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.
NEGATIVE CABLE INSTALLATION - GASOLINE
ENGINE
(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 chas-
sis grease to the exposed surfaces of the battery cable
terminal clamps and the battery terminal posts.
8F - 22 BATTERY SYSTEMBR/BE
BATTERY CABLE (Continued)

the feed of battery voltage to the starter motor, also
engaging and disengaging the starter pinion gear
with the starter ring gear.
All starter motors use an overrunning clutch and
starter pinion gear unit to engage and drive a starter
ring gear that is integral to the flywheel (manual
transmission), torque converter or torque converter
drive plate (automatic transmission) mounted on the
rear crankshaft flange.
DIAGNOSIS AND TESTING - STARTER MOTOR
Correct starter motor operation can be confirmed
by performing the following free running bench test.
This test can only be performed with starter motor
removed from vehicle. Refer to Starter Specifications
for starter motor specifications.
(1) Remove starter motor from vehicle. Refer to
Starter MotorRemoval and Installation.
(2) Mount starter motor securely in a soft-jawed
bench vise. The vise jaws should be clamped on
mounting flange of starter motor. Never clamp on
starter motor by field frame.
(3) Connect suitable volt-ampere tester and 12-volt
battery to starter motor in series, and set ammeter to
100 ampere scale (250 ampere scale for diesel engine
starters). See instructions provided by manufacturer
of volt-ampere tester being used.
(4) Install jumper wire from solenoid terminal to
solenoid battery terminal. The starter motor should
operate. If starter motor fails to operate, replace
faulty starter motor assembly.
(5) Adjust carbon pile load of tester to obtain free
running test voltage. Refer to Specifications for the
starter motor free running test voltage specifications.
(6) Note reading on ammeter and compare this
reading to free running test maximum amperage
draw. Refer to Specifications for starter motor free
running test maximum amperage draw specifica-
tions.
(7) If ammeter reading exceeds maximum amper-
age draw specification, replace faulty starter motor
assembly.
STARTER MOTOR SOLENOID
This test can only be performed with starter motor
removed from vehicle.
(1) Remove starter motor. Refer toStarter Motor
Removal and Installation.
(2) Disconnect wire from solenoid field coil termi-
nal.
(3) Check for continuity between solenoid terminal
and solenoid field coil terminal with continuity tester
(Fig. 7). There should be continuity. If OK, go to Step
4. If not OK, replace faulty starter motor assembly.(4) Check for continuity between solenoid terminal
and solenoid case (Fig. 8). There should be continuity.
If not OK, replace faulty starter motor assembly.
REMOVAL
5.9L GASOLINE ENGINE
(1) Disconnect and isolate negative battery cable.
(2) Raise and support vehicle.
(3) Remove nut and lock washer securing starter
motor to mounting stud (Fig. 9).
(4) While supporting starter motor, remove upper
mounting bolt from starter motor.
(5) If equipped with automatic transmission, slide
cooler tube bracket forward on tubes far enough for
starter motor mounting flange to be removed from
lower mounting stud.
(6) Move starter motor towards front of vehicle far
enough for nose of starter pinion housing to clear
housing. Always support starter motor during this
process, do not let starter motor hang from wire har-
ness.
(7) Tilt nose downwards and lower starter motor
far enough to access and remove nut that secures
battery positive cable wire harness connector eyelet
Fig. 7 Continuity Test Between Solenoid Terminal
and Field Coil Terminal - Typical
1 - OHMMETER
2 - SOLENOID TERMINAL
3 - FIELD COIL TERMINAL
Fig. 8 Continuity Test Between Solenoid Terminal
and Solenoid Case - Typical
1 - SOLENOID TERMINAL
2 - OHMMETER
3 - SOLENOID
8F - 38 STARTINGBR/BE
STARTER MOTOR (Continued)

CAUTION: Do not leave any one spark plug cable
disconnected for longer than necessary during test-
ing. This may cause possible heat damage to the
catalytic converter. Total test time must not exceed
ten minutes.
With the engine running, remove spark plug cable
from spark plug (one at a time) and hold next to a
good engine ground. If the cable and spark plug are
in good condition, the engine rpm should drop and
the engine will run poorly. If engine rpm does not
drop, the cable and/or spark plug may not be operat-
ing properly and should be replaced. Also check
engine cylinder compression.
With the engine not running, connect one end of a
test probe to a good ground. Start the engine and run
the other end of the test probe along the entire
length of all spark plug cables. If cables are cracked
or punctured, there will be a noticeable spark jump
from the damaged area to the test probe. The cable
running from the ignition coil to the distributor cap
can be checked in the same manner. Cracked, dam-
aged or faulty cables should be replaced with resis-
tance type cable. This can be identified by the words
ELECTRONIC SUPPRESSION printed on the cable
jacket.
Use an ohmmeter to test for open circuits, exces-
sive resistance or loose terminals. If equipped,
remove the distributor cap from the distributor.Do
not remove cables from cap.Remove cable from
spark plug. Connect ohmmeter to spark plug termi-
nal end of cable and to corresponding electrode in
distributor cap. Resistance should be 250 to 1000
Ohms per inch of cable. If not, remove cable from dis-
tributor cap tower and connect ohmmeter to the ter-
minal ends of cable. If resistance is not within
specifications as found in the SPARK PLUG CABLE
RESISTANCE chart, replace the cable. Test all spark
plug cables in this manner.
SPARK PLUG CABLE RESISTANCE
MINIMUM MAXIMUM
250 Ohms Per Inch 1000 Ohms Per Inch
3000 Ohms Per Foot 12,000 Ohms Per Foot
To test ignition coil-to-distributor cap cable, do not
remove the cable from the cap. Connect ohmmeter to
rotor button (center contact) of distributor cap and
terminal at ignition coil end of cable. If resistance is
not within specifications as found in the Spark Plug
Cable Resistance chart, remove the cable from the
distributor cap. Connect the ohmmeter to the termi-
nal ends of the cable. If resistance is not within spec-
ifications as found in the Spark Plug CableResistance chart, replace the cable. Inspect the igni-
tion coil tower for cracks, burns or corrosion.
REMOVAL
CAUTION: When disconnecting a high voltage cable
from a spark plug or from the distributor cap, twist
the rubber boot slightly (1/2 turn) to break it loose
(Fig. 37). Grasp the boot (not the cable) and pull it
off with a steady, even force.
INSTALLATION
Install cables into the proper engine cylinder firing
order (Fig. 38) or (Fig. 39).
Fig. 37 Cable Removal
1 - SPARK PLUG CABLE AND BOOT
2 - SPARK PLUG BOOT PULLER
3 - TWIST AND PULL
4 - SPARK PLUG
Fig. 38 Engine Firing OrderÐ5.9L V-8 Engines
BR/BEIGNITION CONTROL 8I - 21
SPARK PLUG CABLE (Continued)

disconnect mechanism, (Refer to 3 - DIFFERENTIAL
& DRIVELINE/FRONT AXLE/AXLE VACUUM
MOTOR - OPERATION). The four-wheel drive switch
input to the instrument cluster circuitry can be diag-
nosed using conventional diagnostic tools and meth-
ods.
DIAGNOSIS AND TESTING - FOUR-WHEEL
DRIVE INDICATOR
The diagnosis found here addresses an inoperative
four-wheel drive indicator condition. If the problem
being diagnosed is related to indicator accuracy, be
certain to confirm that the problem is with the indi-
cator and not with a damaged or inoperative front
axle disconnect mechanism. (Refer to 3 - DIFFEREN-
TIAL & DRIVELINE/FRONT AXLE/AXLE VACUUM
MOTOR - DIAGNOSIS AND TESTING). If no front
axle disconnect problem is found, the following proce-
dure will help locate a short or open in the four-
wheel drive switch input to the instrument cluster.
Refer to the appropriate wiring information. The wir-
ing information includes wiring diagrams, proper
wire and connector repair procedures, details of wire
harness routing and retention, connector pin-out
information and location views for the various wire
harness connectors, splices and grounds.
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.
INDICATOR DOES NOT ILLUMINATE WITH FOUR-WHEEL
DRIVE MODE SELECTED
(1) Disconnect and isolate the battery negative
cable. Disconnect the engine wire harness connector
for the four-wheel drive switch from the switch con-
nector receptacle. Check for continuity between the
ground circuit cavity of the engine wire harness con-
nector for the four-wheel drive switch and a good
ground. There should be continuity. If OK, go to Step
2. If not OK, repair the open ground circuit to ground
(G100) as required.
(2) Reconnect the battery negative cable. Turn the
ignition switch to the On position. Install a jumper
wire between the 4WD switch sense circuit cavity ofthe engine wire harness connector for the four-wheel
drive switch and a good ground. The four-wheel drive
indicator should light. If OK, replace the faulty four-
wheel drive switch. If not OK, go to Step 3.
(3) Turn the ignition switch to the Off position.
Disconnect and isolate the battery negative cable.
Remove the instrument cluster from the instrument
panel. Check for continuity between the 4WD switch
sense circuit cavities of the instrument panel wire
harness connector (Connector C2) for the instrument
cluster and the engine wire harness connector for the
four-wheel drive switch. There should be continuity.
If OK, replace the faulty instrument cluster. If not
OK, repair the open 4WD switch sense circuit
between the instrument cluster and the four-wheel
drive switch as required.
INDICATOR STAYS ILLUMINATED WITH FOUR-WHEEL DRIVE
MODE NOT SELECTED
(1) Disconnect and isolate the battery negative
cable. Disconnect the engine wire harness connector
for the four-wheel drive switch from the switch con-
nector receptacle. Check for continuity between the
ground circuit terminal and the 4WD switch sense
circuit terminal in the four-wheel drive switch con-
nector receptacle. There should be no continuity. If
OK, repair the shorted 4WD switch sense circuit
between the four-wheel drive switch and the instru-
ment cluster as required. If not OK, replace the
faulty four-wheel drive switch.
SPEEDOMETER
DESCRIPTION
A speedometer is standard equipment on all instru-
ment clusters. The speedometer is located just to the
right of the tachometer near the center of the instru-
ment cluster. The speedometer consists of a movable
gauge needle or pointer controlled by the instrument
cluster circuitry and a fixed 210 degree primary scale
on the gauge dial face that reads left-to-right either
from 0 to 120 mph, or from 0 to 200 km/h, depending
upon the market for which the vehicle is manufac-
tured. Each version also has a secondary inner scale
on the gauge dial face that provides the equivalent
opposite units from the primary scale. Text appearing
on the cluster overlay just below the hub of the
speedometer needle abbreviates the unit of measure
for the primary scale in all upper case letters (i.e.:
MPH or KM/H), followed by the unit of measure for
the secondary scale in all lower case letters (i.e.: mph
or km/h). The speedometer graphics are white (pri-
mary scale) and red (secondary scale) against a black
field, making them clearly visible within the instru-
ment cluster in daylight. When illuminated from
behind by the panel lamps dimmer controlled cluster
BR/BEINSTRUMENT CLUSTER 8J - 29
SHIFT INDICATOR (TRANSFER CASE) (Continued)

AMBIENT TEMP SENSOR
DESCRIPTION
Ambient air temperature is monitored by the com-
pass mini-trip computer module through the ambient
temperature sensor. The ambient temperature sensor
is a variable resistor mounted to a bracket that is
secured with a screw to the underside of the hood
panel near the hood latch striker in the engine com-
partment (Fig. 8).
For complete circuit diagrams, refer toOverhead
Consolein the Contents of Wiring Diagrams. The
ambient temperature sensor cannot be adjusted or
repaired and, if faulty or damaged, it must be
replaced.
OPERATION
The ambient temperature sensor is a variable
resistor that operates on a five-volt reference signal
sent to it by the compass mini-trip computer module.
The resistance in the sensor changes as temperature
changes, changing the return circuit voltage to the
compass mini-trip computer module. Based upon the
resistance in the sensor, the compass mini-trip com-
puter module senses a specific voltage on the return
circuit, which it is programmed to correspond to a
specific temperature.
DIAGNOSIS AND TESTING - AMBIENT
TEMPERATURE SENSOR
The thermometer function is supported by the
ambient temperature sensor, a wiring circuit, and a
portion of the compass mini-trip computer module. If
any portion of the ambient temperature sensor cir-
cuit fails, the compass/thermometer display function
will self-diagnose the circuit. If 55É C (131É F)
appears in the display, the sensor is being exposed to
temperatures above 55É C (131É F), or the sensor cir-
cuit is shorted. If ±40É C (±40É F) appears in the dis-
play, the sensor is being exposed to temperatures
below ±40É C (±40É F), or the sensor circuit is open.
The ambient temperature sensor circuit can also be
diagnosed using the following Sensor Test, and Sen-
sor Circuit Test. If the temperature sensor and cir-
cuit are confirmed to be OK, but the temperature
display is inoperative or incorrect, refer toDiagnosis
and Testing the Compass Mini-Trip Computer.
For complete circuit diagrams, refer toWiring Dia-
grams.
SENSOR TEST
(1) Turn the ignition switch to the Off position.
Disconnect and isolate the battery negative cable.
Disconnect the ambient temperature sensor wire har-
ness connector.(2) Measure the resistance of the ambient temper-
ature sensor. At ±40É C (±40É F), the sensor resis-
tance is 336 kilohms. At 55É C (131É F), the sensor
resistance is 2.488 kilohms. The sensor resistance
should read between these two values. If OK, refer to
theSensor Circuit Test below. If not OK, replace
the faulty ambient temperature sensor.
SENSOR CIRCUIT TEST
(1) Turn the ignition switch to the Off position.
Disconnect and isolate the battery negative cable.
Disconnect the ambient temperature sensor wire har-
ness connector and the overhead console wire har-
ness connector.
(2) Connect a jumper wire between the two termi-
nals in the body half of the ambient temperature sen-
sor wire harness connector.
(3) Check for continuity between the sensor return
circuit and the ambient temperature sensor signal
circuit cavities of the roof wire harness overhead con-
sole connector. There should be continuity. If OK, go
to Step 4. If not OK, repair the open sensor return
circuit or ambient temperature sensor signal circuit
to the ambient temperature sensor as required.
(4) Remove the jumper wire from the body half of
the ambient temperature sensor wire harness con-
nector. Check for continuity between the sensor
return circuit cavity of the roof wire harness over-
head console connector and a good ground. There
should be no continuity. If OK, go to Step 5. If not
OK, repair the shorted sensor return circuit as
required.
(5) Check for continuity between the ambient tem-
perature sensor signal circuit cavity of the roof wire
harness overhead console connector and a good
ground. There should be no continuity. If OK, refer to
Diagnosis and Testing the Compass Mini-Trip
Computerin this section. If not OK, repair the
shorted ambient temperature sensor signal circuit as
required.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Locate the ambient temperature sensor, on the
underside of the hood near the hood latch striker
(Fig. 8).
(3) Disconnect the wire harness connector from the
ambient temperature sensor connector receptacle.
(4) Remove the one screw that secures the ambient
temperature sensor bracket to the inner hood rein-
forcement.
(5) Remove the ambient temperature sensor from
the inner hood reinforcement.
8M - 12 MESSAGE SYSTEMSBR/BE