brake DODGE RAM 2003 Service Repair Manual

POWERTRAIN CONTROL MODULE - C3 (DIESEL) - 32 WAY
CAV CIRCUIT FUNCTION
1- -
2- -
3- -
4 V36 18TN/RD SPEED CONTROL VACUUM SOLENOID CONTROL
5 V35 18LG/RD SPEED CONTROL VENT SOLENOID CONTROL
6- -
7- -
8- -
9- -
10 - -
11 V32 18YL/RD SPEED CONTROL SUPPLY
12 T16 14RD TRANSMISSION CONTROL RELAY OUTPUT
13 T6 18OR/WT OVERDRIVE OFF SWITCH SENSE
14 - -
15 - -
16 - -
17 - -
18 - -
19 - -
20 - -
21 - -
22 - -
23 - -
24 K29 18WT/PK BRAKE SWITCH SENSE
25 - -
26 - -
27 D15 18WT/DG SCI TRANSMIT
28 - -
29 D6 18PK/LB SCI RECEIVE
30 D25 18VT/BR PCI BUS
31 - -
32 V37 18RD/LG SPEED CONTROL SWITCH SIGNAL
8W - 80 - 86 8W-80 CONNECTOR PIN-OUTSDR

POWERTRAIN CONTROL MODULE C3 (JTEC) - GRAY 32 WAY
CAV CIRCUIT FUNCTION
1 C13 18DB/OR A/C CLUTCH RELAY CONTROL
2- -
3 K51 18DB/YL AUTO SHUT DOWN RELAY CONTROL
4 V36 18TN/RD SPEED CONTROL VACUUM SOLENOID CONTROL
5 V35 18LG/RD SPEED CONTROL VENT SOLENOID CONTROL
6- -
7 K73 18YL/BK (3.7L) KNOCK SENSOR NO. 1 SIGNAL
8 K199 18BR/VT OXYGEN SENSOR 1/1 HEATER CONTROL
9 K127 18DB/OR OXYGEN SENSOR DOWNSTREAM RELAY CONTROL
10 K106 18WT/DG LEAK DETECTION PUMP SWITCH SENSE
11 V32 18YL/RD SPEED CONTROL SUPPLY
12 A142 16DG/OR AUTO SHUT DOWN RELAY OUTPUT
13 T6 18OR/WT (5.9L) OVERDRIVE OFF SWITCH SENSE
13 T10 18YL/DG (5.9L DIESEL) TORQUE MANAGEMENT REQUEST SENSE
14 K107 18OR LEAK DETECTION PUMP SOLENOID CONTROL
15 K118 18PK/YL BATTERY TEMPERATURE SENSOR SIGNAL
16 K299 18BR/WT (CALIFORNIA) OXYGEN SENSOR 2/1 HEATER CONTROL
16 K299 18BR/WT (EXCEPT CALIFORNIA) OXYGEN SENSOR 1/2 HEATER CONTROL
17 - -
18 K74 18BR/VT (3.7L) KNOCK SENSOR NO. 2 SIGNAL
19 K31 18BR FUEL PUMP RELAY CONTROL
20 K52 18PK/BK EVAPORATIVE EMISSION SOLENOID CONTROL
21 - -
22 - -
23 - -
24 K29 18WT/PK BRAKE SWITCH SENSE
25 K125 18WT/DB GENERATOR SOURCE
26 G8 18LB/BK FUEL LEVEL SENSOR SIGNAL
27 D21 18PK SCI TRANSMIT
28 - -
29 D20 18LG SCI RECEIVE
30 D25 18VT/BR PCI BUS
31 - -
32 V37 18RD/LG SPEED CONTROL SWITCH SIGNAL
DR8W-80 CONNECTOR PIN-OUTS 8W - 80 - 91

POWERTRAIN CONTROL MODULE C3 (NGC) - WHITE 38 WAY
CAV CIRCUIT FUNCTION
1- -
2- -
3 K51 20DB.YL ASD RELAY CONTROL
4- -
5 V35 18LG/RD (4.7L) S/C VENT CONTROL
6 Y145 20DB/YL CONDENSER FAN RELAY CONTROL
7 V32 20YL/RD (4.7L) S/C POWER SUPPLY
8 K106 18WT/DG (4.7L) NVLD SOLENOID CONTROL
9 K199 18BR/VT O2 1/2 HEATER CONTROL
10 K399 18BR/GY (4.7L) O2 2/2 HEATER CONTROL
11 C13 20DB/OR A/C CLUTCH RELAY CONTROL
12 V36 18TN/RD (4.7L) S/C VACUUM CONTROL
13 - -
14 V32 20YL/RD (5.7L) BRAKE SWITCH NO.2 SIGNAL
15 Y215 20YL/PK (5.7L) S/C SWITCH RETURN
16 K223 18PK/DB (5.7L) APPS NO.1 RETURN
17 K981 18BR/DG (5.7L) APPS NO.2 RETURN
18 V38 20VT/OR (5.7L) S/C SWITCH NO.2 SIGNAL
19 A142 16DG/OR ASD RELAY OUTPUT
20 K108 18WT/TN EVAP PURGE SOL SIGNAL
21 T24 20BR/YL TRS T24 SENSE (P/N SENSE)
22 G113 18OR PTO SWITCH SENSE
23 K29 18WT/PK BRAKE SWITCH SIGNAL
24 - -
25 K255 18WT/DG (5.7L) APPS NO.1 SIGNAL
26 - -
27 - -
28 A142 16DG/OR ASD RELAY OUTPUT
29 K52 18PK/BK EVAP PURGE SOL CONTROL
30 S28 18YL/BK P/S SWITCH SIGNAL
31 - -
32 K118 18PK/YL BATT TEMP SIGNAL
33 G8 18LB/BK FUEL LEVEL SIGNAL
34 V37 18RD/LG S/C SWITCH NO.1 SIGNAL
35 K107 18OR NVLD SWITCH SIGNAL
36 K81 18DB/DG (5.7L) APPS NO.2 SIGNAL
37 K31 18BR FUEL PUMP RELAY CONTROL
38 T752 18DG/OR STARTER RELAY CONTROL
8W - 80 - 92 8W-80 CONNECTOR PIN-OUTSDR

SPEAKER-RIGHT FRONT DOOR - WHITE 3 WAY
CAV CIRCUIT FUNCTION
1 X80 18LB/BK RIGHT FRONT DOOR SPEAKER (-)
2- -
3 X82 18LB/VT RIGHT FRONT DOOR SPEAKER (+)
SPEAKER-RIGHT INSTRUMENT PANEL - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 X84 18OR/BK RIGHT INSTRUMENT PANEL SPEAKER (+)
2 X86 18OR/RD RIGHT INSTRUMENT PANEL SPEAKER (-)
SPEAKER-RIGHT REAR - WHITE 3 WAY
CAV CIRCUIT FUNCTION
1 X94 18TN/VT RIGHT REAR SPEAKER (+)
2- -
3 X92 18TN/BK RIGHT REAR SPEAKER (-)
SPEED CONTROL SERVO - BLACK 4 WAY
CAV CIRCUIT FUNCTION
1 V36 20TN/RD SPEED CONTROL VACUUM SOLENOID CONTROL
1 V36 20TN/RD (NGC) S/C VACUUM CONTROL
2 V35 20LG/RD (NGC) S/C VENT CONTROL
2 V35 20LG/RD SPEED CONTROL VENT SOLENOID CONTROL
3 V30 20DB/RD SPEED CONTROL BRAKE SWITCH OUTPUT
3 V30 20DB/RD (NGC) S/C BRAKE SWITCH OUTPUT
4 Z10 20BK/TN GROUND
DR8W-80 CONNECTOR PIN-OUTS 8W - 80 - 97

TRAILER TOW CONNECTOR-4WAY
CAV CIRCUIT FUNCTION
1 Z52 14BK GROUND
2 L76 18BK/OR PARK LAMP RELAY OUTPUT
3 Y141 18YL/PK TRAILER TOW LEFT TURN RELAY OUTPUT
4 Y140 18WT/PK TRAILER TOW RIGHT TURN RELAY OUTPUT
TRAILER TOW CONNECTOR-ADD ON - 10 WAY
CAV CIRCUIT FUNCTION
1- -
2 Y140 18WT/PK TRAILER TOW RIGHT TURN RELAY OUTPUT
3 L1 18VT/BK BACKUP LAMP FEED
4 Y133 14WT/RD FUSED B(+)
5 L76 18BK/OR PARK LAMP RELAY OUTPUT
6- -
7 B40 14LB TRAILER TOW BRAKE B(+)
8 Z52 14BK GROUND
9 Z52 14BK GROUND
10 Y141 18YL/PK TRAILER TOW LEFT TURN RELAY OUTPUT
TRANSFER CASE CONTROL MODULE C1 - BLACK 16 WAY
CAV CIRCUIT FUNCTION
A1 D25 20VT/DB PCI BUS
A2 - -
A3 - -
A4 Y122 20DG/BR 4WD LOW INDICATOR
A5 Y123 20DG/OR 4WD HIGH INDICATOR
A6 Y120 20YL/DG MODE SELECT
A7 Y116 20YL/GY MODE SENSOR GROUND
A8 Z366 18BK/RD GROUND
B1 - -
B2 - -
B3 - -
B4 Y121 20YL/LG NEUTRAL INDICATOR
B5 Y187 20RD 2WD/AWD INDICATOR
B6 Y112 20YL/BR MODE SENSOR D
B7 - -
B8 Z114 20LG/BK SENSOR GROUND
DR8W-80 CONNECTOR PIN-OUTS 8W - 80 - 101

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Blower Motor BK Behind Right Side of Instrument
PanelN/S
Blower Motor Resistor Block BK Behind Right Side of Instrument
PanelN/S
Brake Lamp Switch BK Top of Brake Pedal Arm 32, 37, 39
Brake Provision-Electric Rear of Engine 26, 27
Brake Transmission Shift Interlock
SolenoidBK Near Steering Column 33, 37, 39
C100 BK Near G107 21, 22, 23, 24, 25
C102 Near Integrated Power Module 28
C106 (5.7L) BK Left Rear Engine 5
C107 (5.7L) BK Left Rear Engine 5
C112 (Diesel) BK Near T/O for Water In Fuel Sensor N/S
C113 BK Left Side Engine 10
C114 BK Left side Engine 10
C115 (Diesel) BK Left Side Engine 10
C130 BK Left Rear of Engine 21, 22, 23, 24, 26
C200 GY Under Instrument Panel 40
C201 WT Near Left Instrument Panel
Speaker37, 39
C205 BK Left Rear Side of Engine
CompartmentN/S
C206 BK Right Instrument Panel 37, 40, 46
C216 BK Middle Left Frame 26, 28, 48
C217 BK Middle Left Frame 26, 28, 37, 48
C218 WT Left Side of Instrument Panel 26, 27, 41, 44
C219 GY Left Side of Instrument Panel 26, 27, 33, 37, 39, 41
C220 WT Left Side of Instrument Panel 37, 39, 41
C301 WT Right Kick Panel 41
C302 BK Left Front Door 41
C304 WT Left Side of Instrument Panel 42, 44, 45
C305 BK At Left Front Door 42, 44, 45
C306 WT Middle Front of Door 43, 45
C307 BK Near Right License Lamp 48, 49
C308 WT Under Instrument Panel 40, 41
C309 WT Left Side of Instrument Panel 39, 41, 44, 45
C310 BK Left Rear of Frame 48, 49
C311 BK Left Rear of Frame 44, 45
C312 WT Under Seat N/S
C313 DK GY At Driver Seat N/S
C314 DK GY At Driver Seat N/S
C315 DK GY At Driver Seat N/S
C316 BK At Passenger Seat N/S
8W - 91 - 2 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONDR
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
C317 BK At Passenger Seat N/S
C319 BK Bottom Left of Left Door N/S
C322 DK GY Left Rear of Frame N/S
C323 BK Left Side of Instrument Panel N/S
C327 BK Right Rear Fender 48, 49
C328 BK Left Rear Fender 48, 49, 50
Camshaft Position Sensor GY Right Front Side of Engine 3, 6, 8, 9
Capacitor Left Rear of Engine Compartment N/S
Center High Mounted Stop
Lamp/Cargo LampBK Rear of Cab 47
Cigar Lighter Outlet NAT Rear of Cigar Lighter 34, 37, 38
Clearance Lamp No. 1 BK Left Roof 46
Clearance Lamp No. 2 BK Left-Center Roof 46
Clearance Lamp No. 3 BK Center Roof 46
Clearance Lamp No. 4 BK Right-Center Roof 46
Clearance Lamp No. 5 BK Right Roof 46
Clockspring C1 BK Steering Column 33
Clockspring C2 YL Steering Column 33
Clockspring C3 BK Steering Column N/S
Clockspring C4 BK Steering Column N/S
Clutch Interlock Brake Switch BK At Clutch Pedal 26, 27
Coil On Plug No.1 BK Left Top Side of Intake Manifold 4
Coil On Plug No.2 BK Right Top Side of Intake Manifold 3
Coil On Plug No.3 BK Left Top Side of Intake Manifold 4
Coil On Plug No.4 BK Right Top Side of Intake Manifold 3
Coil On Plug No.5 BK Left Top Side of Intake Manifold 4
Coil On Plug No.6 BK Right Top Side of Intake Manifold 3
Coil On Plug No.7 BK Left Top Side of Intake Manifold 4
Coil On Plug No.8 BK Right Top Side of Intake Manifold 3
Compass/Mini-Trip Computer BK In Overhead Console N/S
Condenser Fan BK Near Condenser 26, 27
Controller Anti-Lock Brake C1 BK Left Fender Side Shield 26, 27, 28
Controller Anti-Lock Brake C2
(ABS)BK Left Fender Side Shield 26, 28
Crankshaft Position Sensor BK Right Rear of Engine Block 3, 6, 8, 9
Cylinder Lock Switch-Driver
(Premium)BK In Left Front Door 42
Cylinder Lock Switch-Passenger
(Premium)LT GY In Right Front Door N/S
Data Link Connector BK Left Bottom of Instrument Panel 37, 39
Data Link Connector - Engine
(Diesel)BK Near T/O for Water In Fuel Sensor N/S
Dome Lamp BK Center of Headliner N/S
DR8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 3
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Manifold Absolute Pressure Sensor
(5.9L)BK Left Front of Intake Manifold 8
Mode Door Actuator 1 BK Right Side of HVAC N/S
Mode Door Actuator 2 BK Right Side of HVAC N/S
Multi-Function Switch BK On Steering Column N/S
Natural Vacuum Leak Detection
AssemblyBK Rear of Transmission 18, 19
Output Speed Sensor DB Left Side of Transmission 11, 12, 14, 15
Overdrive Switch WT Center of Instrument Panel 37
Overhead Map/Reading Lamp
(Except Base)NAT Center of Headliner N/S
Oxygen Sensor 1/1 Upstream BK Left Front of Side of Transmission 11, 12, 14, 16
Oxygen Sensor 1/2 Downstream NAT Left Rear of Side of Transmission 11, 14, 16
Oxygen Sensor 2/1 Upstream BK Right Front Side of Transmission 11, 12, 14, 16, 17, 18,
19
Oxygen Sensor 2/2 Downstream BK Right Rear Side of Transmission 11, 12, 14, 16, 17, 18,
19
Park Brake Switch At Park Brake 26, 27
Park/Turn Signal Lamp-Left Front BK At Lamp 26, 30, 31
Park/Turn Signal Lamp-Right Front BK At Lamp 1, 25, 29
Passenger Airbag On/Off Switch Right Side of Instrument Panel 35, 37, 40
Passenger Blend Door Actuator
(Dual Zone)BK Right Side of HVAC N/S
Passenger Lumbar Switch At Passenger Seat N/S
Power Mirror-Left BK At Mirror 42
Power Mirror-Right BK At Mirror N/S
Power Outlet RD Center of Instrument Panel 37
Power Outlet-Console BK Center of Instrument Panel N/S
Power Seat Motor-Driver Front
VerticalRD At Driver Seat N/S
Power Seat Motor-Driver Horizontal BK At Driver Seat N/S
Power Seat Motor-Driver Rear
VerticalBK At Driver Seat N/S
Power Seat Switch-Driver BK At Driver Seat N/S
Power Seat Switch-Passenger BK At Passenger Seat N/S
Power Steering Pressure Switch BK Near Power Steering Pump 4, 5
Power Window Circuit Breaker Under Instrument Panel 33, 37, 39
Power Window Motor-Driver BK In Driver Door at Motor 42
Power Window Motor-Left Rear BK In Door at Motor 43
Power Window Motor-Passenger BK In Passenger Door at Motor N/S
Power Window Motor-Right Rear BK In Door at Motor 43
Power Window Switch-Left Rear BL In Door 43
Power Window Switch-Right Rear BL In Door 43
Powertrain Control Module C1 BK Right Rear Engine Compartment 21, 22, 23, 24
8W - 91 - 6 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONDR
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Powertrain Control Module C2 WT Right Rear Engine Compartment 21, 22, 23, 24
Powertrain Control Module C3 GY Right Rear Engine Compartment 21, 22, 23, 24
Powertrain Control Module C4 GN Right Rear Engine Compartment 21
PTO Sense Near G107 21, 22, 24
Radio (Base) GY Rear of Radio 37, 38
Radio (Premium) BK Rear of Radio 37, 38
Recirculation Door Actuator BK Right Side of HVAC N/S
Red Brake Warning Indicator
SwitchBK Near Master Cylinder 26, 28, 31
Remote Radio Switch-Left BK At Steering Wheel N/S
Remote Radio Switch-Right BK At Steering Wheel N/S
Seat Belt Pretensioner-Left YL Left B-Pillar 44, 45
Seat Belt Pretensioner-Right YL Right B-Pillar N/S
Seat Belt Switch-Driver DK GY Left B-Pillar N/S
Seat Belt Tension Reducer
(Standard Cab)YL Left B-Pillar 44
Seat Heater Interface Module GN Under Driver Seat N/S
Sentry Key Immobilizer Module BK On Steering Column 32
Side Marker - Left Front (Dual
Wheels)BK Front of Left Rear Fender 50
Side Marker - Left Rear (Dual
Wheels)BK Rear of Left Rear Fender 50
Side Marker - Right Front (Dual
Wheels)BK Front of Right Rear Fender 50
Side Marker - Right Rear (Dual
Wheels)BK Rear of Right Rear Fender 50
Speaker-Center Instrument Panel WT Center of Instrument Panel 37, 38
Speaker-Left Front Door WT In Left Front Door 42
Speaker-Left Instrument Panel BK Left Side of Instrument Panel 37, 39
Speaker-Left Rear (Standard Cab) WT In Lower Left B-Pillar 44
Speaker-Left Rear Door (Quad
Cab)WT In Left Rear Door 43
Speaker-Right Front Door WT In Right Front Door N/S
Speaker-Right Instrument Panel BK Right Side of Instrument Panel 37, 40
Speaker-Right Rear (Standard
Cab)BK In Lower Right B-Pillar N/S
Speaker-Right Rear Door (Quad
Cab)BK In Right Rear Door 43
Speed Control Servo BK Left Front Side of Engine
Compartment26, 28
Speed Control Switch - Left
(Except ETC)GN Steering Wheel N/S
Speed Control Switch - Right
(Except ETC)GN Steering Wheel N/S
Speed Control Switch-Left (ETC) WT At Steering Wheel N/S
DR8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 7
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

(12) Disconnect heater hoses from heater core and
remove hose assembly.
(13) Disconnect throttle and speed control cables.
(14) Remove upper radiator hose from engine.
(15) Remove lower radiator hose from engine.
(16) Remove radiator/cooling module assembly.
(17) Disconnect the engine to body ground straps
at the left side of cowl.
(18) Disconnect the engine wiring harness at the
following points:
²Intake air temperature (IAT) sensor
²Fuel Injectors
²Throttle Position (TPS) Switch
²Idle Air Control (IAC) Motor
²Engine Oil Pressure Switch
²Engine Coolant Temperature (ECT) Sensor
²Manifold Absolute Pressure MAP) Sensor
²Camshaft Position (CMP) Sensor
²Coil Over Plugs
²Crankshaft Position Sensor
(19) Remove coil over plugs.
(20) Release fuel rail pressure.
(21) Remove fuel rail and secure away from
engine.
NOTE: It is not necessary to release the quick con-
nect fitting from the fuel supply line for engine
removal.
(22) Remove the PCV hose.
(23) Remove the breather hoses.
(24) Remove the vacuum hose for the power brake
booster.
(25) Disconnect knock sensors.
(26) Remove engine oil dipstick tube.
(27) Remove intake manifold.
(28) Install engine lifting fixture,special tool#8247,
using original fasteners from the removed intake
manifold, and fuel rail. Torque to factory specifica-
tions.
NOTE: Recheck bolt torque for engine lift plate
before removing engine.
(29) Secure the left and right engine wiring har-
nesses away from engine.
(30) Raise vehicle.
(31) Disconnect oxygen sensor wiring.
(32) Disconnect crankshaft postion sensor.
(33) Disconnect the engine block heater power
cable, if equipped.
(34) Disconnect the front propshaft at the front
differential and secure out of way.
NOTE: It is necessary to disconnect the front prop-
shaft for access to the starter and left side exhaust
flange.(35) Remove the starter.
(36) Remove the ground straps from the left and
right side of the block.
(37) Disconnect the right and left exhaust pipes at
the manifolds and from the crossover, and remove
from the vehicle.
NOTE: The exhaust clamps at the manifolds cannot
be reused. New clamps must be used or leaks may
occur.
(38) Remove the structural cover.
(39) Remove torque convertor bolts, and mark
location for reassembly.
(40) Remove transmission bellhousing to engine
bolts.
(41) Remove left and right engine mount thru
bolts.
(42) Lower the vehicle.
(43) Support the transmission with a suitable jack.
(44) Connect a suitable engine hoist to the engine
lift plate.
(45) Remove engine from vehicle.
INSTALLATION
(1) Position the engine in the vehicle.
(2) Install both left and right side engine mounts
onto engine.
(3) Raise the vehicle.
(4) Install the transmission bellhousing to engine
mounting bolts. Tighten the bolts to 41 N´m (30ft.
lbs.).
(5) Tighten the engine mount thru bolts.
(6) Install the torque convertor bolts.
(7) Connect the ground straps on the left and right
side of the engine.
(8) Install the starter.
(9) Connect the crankshaft position sensor.
(10) Install the engine block heater power cable, if
equipped.
CAUTION: The structural cover requires a specific
torque sequence. Failure to follow this sequence
may cause severe damage to the cover.
(11) Install the structural cover.
NOTE: New clamps must be used on exhaust man-
ifold flanges. Failure to use new clamps may result
in exhaust leaks.
(12) Install the left and right exhaust pipes.
(13) Connect the left and right oxygen sensors.
(14) Lower vehicle.
(15) Remove the engine lift plate.
(16) Connect the knock sensors.
DRENGINE - 3.7L 9 - 11
ENGINE - 3.7L (Continued)