clock DODGE RAM 2003 Service User Guide

CONDITION POSSIBLE CAUSES CORRECTION
CLOCK WILL NOT KEEP
SET TIME1. Fuse faulty. 1. Check Ignition-Off Draw (IOD) fuse in the
Integrated Power Module (IPM). Replace fuse, if
required.
2. Radio connector faulty. 2. Check for loose or corroded radio connector.
Repair, if required.
3. Wiring faulty. 3. Check for battery voltage at radio connector.
Repair wiring, if required.
4. Radio ground faulty. 4. Check for continuity between radio chassis and
a known good ground. There should be
continuity. Repair ground, if required.
5. Radio faulty. 5. Refer to appropriate Diagnostic Service
Manual.
POOR RADIO RECEPTION 1. Antenna faulty. 1. (Refer to 8 - ELECTRICAL/AUDIO/ANTENNA
BODY & CABLE - DIAGNOSIS AND TESTING).
2. Radio ground faulty. 2. Check for continuity between radio chassis and
a known good ground. There should be
continuity. Repair ground, if required.
3. Radio noise suppression
faulty.3. Repair or replace ground strap as necessary.
4. Radio faulty. 4. Refer to appropriate Diagnostic Service
Manual.
NO/POOR TAPE
OPERATION1. Faulty tape. 1. Insert known good tape and test operation.
2. Foreign objects behind
tape door.2. Remove foreign objects and test operation.
3. Dirty cassette tape head. 3. Clean head with Mopar Cassette Head
Cleaner.
4. Faulty tape deck. 4. Exchange or replace radio, if required.
NO COMPACT DISC
OPERATION1. Faulty CD. 1. Insert known good CD and test operation.
2. Foreign material on CD. 2. Clean CD and test operation.
3. Condensation on CD or
optics.3. Allow temperature of vehicle interior to stabilize
and test operation.
4. Faulty CD player. 4. Refer to appropriate Diagnostic Service
Manual.
AMPLIFIER
DESCRIPTION
The optional Infinity premium speaker system
includes a separate Infinity audio power amplifier.
The amplifier is a six channel unit and is rated at
240 total output watts. The amplifier is located
behind the glove box.
OPERATION
The power amplifier electronically increases the
frequency response of the normal audio signal output
from the radio amplifier in order to improve the
acoustic performance of the speakers. On vehiclesequipped with an amplifier, the amplifier section of
the radio becomes a pre-amplifier.
The amplifier receives audio signal inputs for
speaker channels from the radio, then sends ampli-
fied audio outputs through six separate channels
with dedicated feed and return circuits to the indi-
vidual speakers.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove glove box (Refer to 23 - BODY/IN-
STRUMENT PANEL/GLOVE BOX - REMOVAL).
DRAUDIO 8A - 3
AUDIO (Continued)

INSTALLATION
(1) Install antenna cable to instrument panel by
pressing retaining fasteners into position.
(2) Connect instrument panel antenna cable to
antenna body and cable.
(3) Install radio (Refer to 8 - ELECTRICAL/AU-
DIO/RADIO - INSTALLATION).
(4) Install the instrument panel lower right center
bezel (Refer to 23 - BODY/INSTRUMENT PANEL/IP
LOWER RIGHT CENTER BEZEL - INSTALLA-
TION).
(5) Install the instrument panel center bezel (Refer
to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL CENTER BEZEL - INSTALLATION).
(6) Install the glove box (Refer to 23 - BODY/IN-
STRUMENT PANEL/GLOVE BOX - INSTALLA-
TION).
(7) Connect the battery negative cable.
RADIO
DESCRIPTION
Available factory-installed radio receivers for this
model include:
²AM/FM/cassette with CD changer control fea-
ture (RBB sales code)
²AM/FM/cassette/CD/graphic equalizer with CD
changer control feature (RAZ sales code)
²AM/FM/CD with CD changer control feature
(RBK sales code)
²AM/FM/CD with 6 CD changer (RBQ sales code)
²AM/FM/cassette/CD (RBY sales code) - export
only
All factory-installed radio receivers can communi-
cate on the Programmable Communications Interface(PCI) data bus network. All factory-installed receiv-
ers are stereo Electronically Tuned Radios (ETR) and
include an electronic digital clock function.
These radio receivers can only be serviced by an
authorized radio repair station. See the latest War-
ranty Policies and Procedures manual for a current
listing of authorized radio repair stations.
OPERATION
The radio receiver operates on ignition switched
battery current that is available only when the igni-
tion switch is in the On or Accessory positions. The
electronic digital clock function of the radio operates
on fused battery current supplied through the IOD
fuse, regardless of the ignition switch position.
For more information on the features, setting pro-
cedures, and control functions for each of the avail-
able factory-installed radio receivers, refer to the
owner's manual.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove center instrument panel bezel (Refer to
23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL CENTER BEZEL - REMOVAL).
(3) Remove radio mounting screws (Fig. 6).
(4) Disconnect electrical harness connector.
CAUTION: Pulling the antenna cable straight out of
the radio without pulling on the locking antenna
connector could damage the cable or radio.
(5) Disconnect the antenna cable by pulling the
locking antenna connector away from the radio (Fig.
7)
Fig. 5 INSTRUMENT PANEL ANTENNA CABLE
1 - INSTRUMENT PANEL ANTENNA CABLE
2 - ANTENNA BODY AND CABLE
Fig. 6 RADIO
DRAUDIO 8A - 7
INSTRUMENT PANEL ANTENNA CABLE (Continued)

INSTALLATION
BED TO CAB
(1) Install the ground strap and retaining bolts.
Tighten to 5 N´m (45 in. lbs.).
(2) Connect the battery negative cable.
ENGINE TO HEAT SHIELD
(1) Install the retaining nut and ground strap to
the plenum. Tighten to 8 N´m (70 in. lbs.).
(2) Install the retaining bolt and ground strap to
the engine cylinder heads. Tighten to 12 N´m (106 in.
lbs.).
(3) Connect the battery negative cable.
REMOTE SWITCHES
DESCRIPTION
A remote radio control switch option is available on
some models. Two rocker-type switches are mounted
on the back (instrument panel side) of the steering
wheel spokes (Fig. 13). The switch on the left spoke
is the seek switch and has seek up, seek down, and
preset station advance functions. The switch on the
right spoke is the volume control switch and has vol-
ume up, and volume down functions. The switch on
the right spoke also includes a ªmodeº control that
allows the driver to sequentially select AM radio, FM
radio, cassette player, CD player or CD changer (if
equipped).
OPERATION
The six switches in the two remote radio switch
units are normally open, resistor multiplexed
momentary switches that are hard wired to the Inte-
grated Power Module (IPM) through the clockspring.
The IPM sends a five volt reference signal to both
switch units on one circuit, and senses the status of
all of the switches by reading the voltage drop on a
second circuit.
When the IPM senses an input (voltage drop) from
any one of the remote radio switches, it sends the
proper switch status messages on the Programmable
Communication Interface (PCI) data bus network to
the radio receiver. The electronic circuitry within the
radio receiver is programmed to respond to these
remote radio switch status messages by adjusting the
radio settings as requested. For diagnosis of the IPM
or the PCI data bus, the use of a DRB IIItscan tool
and the proper Diagnostic Procedures manual are
recommended.
For more information on the features and control
functions for each of the remote radio switches, refer
to the owner's manual.
Fig. 12 ENGINE GROUND STRAP - 5.9L (8.0L
SIMILAR)
1 - GROUND STRAP
2 - MOUNTING BOLTS
Fig. 13 Remote Radio Switch Operational View
1 - PRESET SEEK
2 - SEEK UP
3 - VOLUME UP
4 - MODE
5 - VOLUME DOWN
6 - SEEK DOWN
8A - 10 AUDIODR
RADIO NOISE SUPPRESSION GROUND STRAP (Continued)

Turn on the headlamps for fifteen seconds, then
allow up to five minutes for the battery voltage to
stabilize.
(2) Disconnect and isolate both battery cables, neg-
ative cable first.
(3) Using a voltmeter connected to the battery
posts (see the instructions provided by the manufac-
turer of the voltmeter), measure the open-circuit volt-
age (Fig. 8).
See the Open-Circuit Voltage Table. This voltage
reading will indicate the battery state-of-charge, but
will not reveal its cranking capacity. If a battery has
an open-circuit voltage reading of 12.4 volts or
greater, it may be load tested to reveal its cranking
capacity (Refer to 8 - ELECTRICAL/BATTERY SYS-
TEM/BATTERY - STANDARD PROCEDURE).
OPEN CIRCUIT VOLTAGE TABLE
Open Circuit Voltage Charge Percentage
11.7 volts or less 0%
12.0 volts 25%
12.2 volts 50%
12.4 volts 75%
12.6 volts or more 100%
STANDARD PROCEDURE - IGNITION-OFF
DRAW TEST
The term Ignition-Off Draw (IOD) identifies a nor-
mal condition where power is being drained from the
battery with the ignition switch in the Off position. A
normal vehicle electrical system will draw from five
to thirty-five milliamperes (0.005 to 0.035 ampere)
with the ignition switch in the Off position, and all
non-ignition controlled circuits in proper working
order. Up to thirty-five milliamperes are needed to
enable the memory functions for the Powertrain Con-
trol Module (PCM), digital clock, electronically tuned
radio, and other modules which may vary with the
vehicle equipment.
A vehicle that has not been operated for approxi-
mately twenty days, may discharge the battery to an
inadequate level. When a vehicle will not be used for
twenty days or more (stored), remove the IOD fuse
from the Integrated Power Module (IPM). This will
reduce battery discharging.
Excessive IOD can be caused by:
²Electrical items left on.
²Faulty or improperly adjusted switches.
²Faulty or shorted electronic modules and compo-
nents.
²An internally shorted generator.
²Intermittent shorts in the wiring.
If the IOD is over thirty-five milliamperes, the
problem must be found and corrected before replac-
ing a battery. In most cases, the battery can be
charged and returned to service after the excessive
IOD condition has been corrected.
(1) Verify that all electrical accessories are off.
Turn off all lamps, remove the ignition key, and close
all doors. If the vehicle is equipped with an illumi-
nated entry system or an electronically tuned radio,
allow the electronic timer function of these systems
to automatically shut off (time out). This may take
up to three minutes. See the Electronic Module Igni-
tion-Off Draw Table for more information.
ELECTRONIC MODULE IGNITION-OFF DRAW (IOD) TABLE
ModuleTime Out?
(If Yes, Interval And Wake-Up Input)IODIOD After Time
Out
Radio No1to3
milliamperesN/A
Audio Power
AmplifierNoup to 1
milliampereN/A
Powertrain Control
Module (PCM)No 0.95 milliampere N/A
Fig. 8 Testing Open-Circuit Voltage - Typical
DRBATTERY SYSTEM 8F - 11
BATTERY (Continued)

(3) Check condition of relay terminals and PDC
connector terminals for damage or corrosion. Repair
if necessary before installing relay.
(4) Check for pin height (pin height should be the
same for all terminals within the PDC connector).
Repair if necessary before installing relay.
INSTALLATION
The ASD relay is located in the Power Distribution
Center (PDC) (Fig. 5). Refer to label on PDC cover
for relay location.
(1) Install relay to PDC.
(2) Install cover to PDC.
CAMSHAFT POSITION
SENSOR
DESCRIPTION
3.7L V-6
The Camshaft Position Sensor (CMP) on the 3.7L
6-cylinder engine is bolted to the right-front side of
the right cylinder head.
4.7L V-8
The Camshaft Position Sensor (CMP) on the 4.7L
V-8 engine is bolted to the right-front side of the
right cylinder head.
5.7L V-8
The Camshaft Position Sensor (CMP) on the 5.7L
V-8 engine is located below the generator on the tim-
ing chain / case cover on the right/front side of
engine.
5.9L Diesel
The Camshaft Position Sensor (CMP) on the 5.9L
diesel engine is located below the fuel injection
pump. It is bolted to the back of the timing gear
cover.
5.9L V-8 Gas
The Camshaft Position Sensor (CMP) on the 5.9L
V-8 engine is located inside the distributor.
8.0L V±10
The Camshaft Position Sensor (CMP) on the 8.0L
V-10 engine is located on the timing chain / case
cover on the left/front side of engine.
OPERATION
3.7L V-6
The Camshaft Position Sensor (CMP) sensor on the
3.7L V-6 engine contains a hall effect device referred
to as a sync signal generator. A rotating target wheel
(tonewheel) for the CMP is located at the front of the
camshaft for the right cylinder head (Fig. 6). This
sync signal generator detects notches located on a
tonewheel. As the tonewheel rotates, the notches
pass through the sync signal generator. The signal
from the CMP sensor is used in conjunction with the
Crankshaft Position Sensor (CKP) to differentiate
between fuel injection and spark events. It is also
used to synchronize the fuel injectors with their
respective cylinders.
When the leading edge of the tonewheel notch
enters the tip of the CMP, the interruption of mag-
netic field causes the voltage to switch high, result-
ing in a sync signal of approximately 5 volts.
When the trailing edge of the tonewheel notch
leaves then tip of the CMP, the change of the mag-
netic field causes the sync signal voltage to switch
low to 0 volts.
4.7L V-8
The CMP sensor on the 4.7L engine contains a hall
effect device called a sync signal generator to gener-
ate a fuel sync signal. This sync signal generator
detects notches located on a tonewheel. The tone-
wheel is located at the front of the camshaft for the
right cylinder head (Fig. 7). As the tonewheel rotates,
the notches pass through the sync signal generator.
The pattern of the notches (viewed counter-clockwise
from front of engine) is: 1 notch, 2 notches, 3 notches,
Fig. 5 PDC LOCATION
1 - BATTERY
2 - PDC (POWER DISTRIBUTION CENTER)
8I - 8 IGNITION CONTROLDR
AUTOMATIC SHUT DOWN RELAY (Continued)

REMOVAL
CAUTION: Base ignition timing is not adjustable on
any engine. Distributors do not have built in centrif-
ugal or vacuum assisted advance. Base ignition
timing and timing advance are controlled by the
Powertrain Control Module (PCM). Because a con-
ventional timing light can not be used to adjust dis-
tributor position after installation, note position of
distributor before removal.
(1) Disconnect negative cable from battery.
(2) Remove air cleaner tubing.
(3) Remove distributor cap from distributor (two
screws).
(4) Mark the position of distributor housing in
relationship to engine or dash panel. This is done to
aid in installation.
(5) Before distributor is removed, the number one
cylinder must be brought to the Top Dead Center
(TDC) firing position.
(6) Attach a socket to the Crankshaft Vibration
Damper mounting bolt.
(7) Slowly rotate engine clockwise, as viewed from
front, until indicating mark on crankshaft vibration
damper is aligned to 0 degree (TDC) mark on timing
chain cover (Fig. 24).
(8) The distributor rotor should now be aligned to
the CYL. NO. 1 alignment mark (stamped) into the
camshaft position sensor (Fig. 25). If not, rotate the
crankshaft through another complete 360 degree
turn. Note the position of the number one cylinder
spark plug cable (on the cap) in relation to rotor.
Rotor should now be aligned to this position.(9) Disconnect camshaft position sensor wiring
harness from main engine wiring harness.
(10) Remove distributor rotor from distributor
shaft.
(11) Remove distributor holddown clamp bolt and
clamp (Fig. 26). Remove distributor from vehicle.
CAUTION: Do not crank engine with distributor
removed. Distributor/crankshaft relationship will be
lost.
Fig. 24 DAMPER-TO-COVER ALIGNMENT MARKS Ð
TYPICAL
1 - ALIGNMENT MARK
2 - TIMING CHAIN COVER MARKS
3 - CRANKSHAFT VIBRATION DAMPER
Fig. 25 ROTOR ALIGNMENT MARK
1 - CAMSHAFT POSITION SENSOR ALIGNMENT MARK
2 - ROTOR
3 - DISTRIBUTOR
Fig. 26 DISTRIBUTOR HOLDDOWN CLAMP
1 - CLAMP BOLT
2 - HOLDDOWN CLAMP
3 - DISTRIBUTOR HOUSING
DRIGNITION CONTROL 8I - 17
DISTRIBUTOR (Continued)

INSTALLATION
If engine has been cranked while distributor is
removed, establish the relationship between distribu-
tor shaft and number one piston position as follows:
Rotate crankshaft in a clockwise direction, as
viewed from front, until number one cylinder piston
is at top of compression stroke (compression should
be felt on finger with number one spark plug
removed). Then continue to slowly rotate engine
clockwise until indicating mark (Fig. 24) is aligned to
0 degree (TDC) mark on timing chain cover.
(1) Clean top of cylinder block for a good seal
between distributor base and block.
(2) Lightly oil the rubber o-ring seal on the distrib-
utor housing.
(3) Install rotor to distributor shaft.
(4) Position distributor into engine to its original
position. Engage tongue of distributor shaft with slot
in distributor oil pump drive gear. Position rotor to
the number one spark plug cable position.
(5) Install distributor holddown clamp and clamp
bolt. Do not tighten bolt at this time.
(6) Rotate the distributor housing until rotor is
aligned to CYL. NO. 1 alignment mark on the cam-
shaft position sensor (Fig. 25).
(7) Tighten clamp holddown bolt (Fig. 26) to 22.5
N´m (200 in. lbs.) torque.
(8) Connect camshaft position sensor wiring har-
ness to main engine harness.
(9) Install distributor cap. Tighten mounting
screws.
(10) Refer to the following, Checking Distributor
Position.
Checking Distributor Position
To verify correct distributor rotational position, the
DRB scan tool must be used.
WARNING: WHEN PERFORMING THE FOLLOWING
TEST, THE ENGINE WILL BE RUNNING. BE CARE-
FUL NOT TO STAND IN LINE WITH THE FAN
BLADES OR FAN BELT. DO NOT WEAR LOOSE
CLOTHING.
(1) Connect DRB scan tool to data link connector.
The data link connector is located in passenger com-
partment, below and to left of steering column.
(2) Gain access to SET SYNC screen on DRB.
(3) Follow directions on DRB screen and start
engine. Bring to operating temperature (engine must
be in ªclosed loopº mode).
(4) With engine running atidle speed, the words
IN RANGE should appear on screen along with 0É.
This indicates correct distributor position.(5) If a plus (+) or a minus (-) is displayed next to
degree number, and/or the degree displayed is not
zero, loosen but do not remove distributor holddown
clamp bolt. Rotate distributor until IN RANGE
appears on screen. Continue to rotate distributor
until achieving as close to 0É as possible. After
adjustment, tighten clamp bolt to 22.5 N´m (200 in.
lbs.) torque.
Do not attempt to adjust ignition timing using this
method. Rotating distributor will have no effect on
ignition timing. All ignition timing values are con-
trolled by Powertrain Control Module (PCM).
After testing, install air cleaner tubing.
DISTRIBUTOR CAP
DIAGNOSIS AND TESTING - DISTRIBUTOR
CAP - 5.9L V-8
Remove the distributor cap and wipe it clean with
a dry lint free cloth. Visually inspect the cap for
cracks, carbon paths, broken towers or damaged
rotor button (Fig. 27) or (Fig. 28). Also check for
white deposits on the inside (caused by condensation
entering the cap through cracks). Replace any cap
that displays charred or eroded terminals. The
machined surface of a terminal end (faces toward
rotor) will indicate some evidence of erosion from
normal operation. Examine the terminal ends for evi-
dence of mechanical interference with the rotor tip.
Fig. 27 CAP INSPECTIONÐEXTERNALÐTYPICAL
1 - BROKEN TOWER
2 - DISTRIBUTOR CAP
3 - CARBON PATH
4 - CRACK
8I - 18 IGNITION CONTROLDR
DISTRIBUTOR (Continued)

WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, SEAT BELT TENSIONER,
SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. DISCON-
NECT AND ISOLATE THE BATTERY NEGATIVE
(GROUND) CABLE, THEN WAIT TWO MINUTES FOR
THE SYSTEM CAPACITOR TO DISCHARGE BEFORE
PERFORMING FURTHER DIAGNOSIS OR SERVICE.
THIS IS THE ONLY SURE WAY TO DISABLE THE
SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO
TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
CLUSTER BULB
This procedure applies to each of the incandescent
cluster illumination lamp bulb and bulb holder units.
If the vehicle is equipped with the optional Remote
Keyless Entry (RKE) system, the RKE receiver mod-
ule must be removed from the instrument cluster
rear cover to access the lower center cluster illumi-
nation lamp, which is located on the circuit board
directly behind the RKE module. (Refer to 8 - ELEC-
TRICAL/POWER LOCKS/REMOTE KEYLESS
ENTRY MODULE - REMOVAL).
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the instrument cluster from the instru-
ment panel. (Refer to 8 - ELECTRICAL/INSTRU-
MENT CLUSTER - REMOVAL).
(3) Turn the bulb holder counterclockwise about
sixty degrees on the cluster electronic circuit board
(Fig. 6).(4) Pull the bulb and bulb holder unit straight
back to remove it from the bulb mounting hole in the
cluster electronic circuit board.
CLUSTER LENS, HOOD, AND MASK
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the instrument cluster from the instru-
ment panel. (Refer to 8 - ELECTRICAL/INSTRU-
MENT CLUSTER - REMOVAL).
(3) From the back of the instrument cluster,
remove the eight screws around the outer perimeter
of the rear cover that secure the lens, hood, and
mask unit to the cluster housing (Fig. 7).
(4) Remove the lens, hood, and mask unit from the
face of the instrument cluster.
ASSEMBLY
Some of the components for the instrument cluster
used in this vehicle are serviced individually. The
serviced components include the incandescent instru-
ment cluster illumination lamp bulbs (including the
integral bulb holders), and the cluster lens, hood and
mask unit. Following are the procedures for assem-
bling these components to the instrument cluster
unit.
Fig. 6 Cluster Bulb Remove/Install
1 - INSTRUMENT CLUSTER
2 - BULB & HOLDER (11)
Fig. 7 Instrument Cluster Components
1 - SCREW (9)
2 - REAR COVER
3 - CLUSTER HOUSING
4 - LENS, HOOD & MASK
DRINSTRUMENT CLUSTER 8J - 15
INSTRUMENT CLUSTER (Continued)

WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, SEAT BELT TENSIONER,
SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. DISCON-
NECT AND ISOLATE THE BATTERY NEGATIVE
(GROUND) CABLE, THEN WAIT TWO MINUTES FOR
THE SYSTEM CAPACITOR TO DISCHARGE BEFORE
PERFORMING FURTHER DIAGNOSIS OR SERVICE.
THIS IS THE ONLY SURE WAY TO DISABLE THE
SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO
TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
CLUSTER BULB
This procedure applies to each of the incandescent
cluster illumination lamp bulb and bulb holder units.
If the vehicle is equipped with the optional Remote
Keyless Entry (RKE) system, and the RKE receiver
module was removed from the instrument cluster
rear cover to access the lower center cluster illumi-
nation lamp, reinstall the RKE module after the bulb
is replaced on the circuit board. (Refer to 8 - ELEC-
TRICAL/POWER LOCKS/REMOTE KEYLESS
ENTRY MODULE - INSTALLATION).
CAUTION: Always use the correct bulb size and
type for replacement. An incorrect bulb size or type
may overheat and cause damage to the instrument
cluster, the electronic circuit board and/or the
gauges.
(1) Insert the bulb and bulb holder unit straight
into the correct bulb mounting hole in the cluster
electronic circuit board (Fig. 6).
(2) With the bulb holder fully seated against the
cluster electronic circuit board, turn the bulb holder
clockwise about sixty degrees to lock it into place.
(3) Reinstall the instrument cluster onto the
instrument panel. (Refer to 8 - ELECTRICAL/IN-
STRUMENT CLUSTER - INSTALLATION).
(4) Reconnect the battery negative cable.CLUSTER LENS, HOOD, AND MASK
(1) Position the cluster lens, hood, and mask unit
over the face of the instrument cluster (Fig. 7). Be
certain that the odometer/trip odometer switch but-
ton is inserted through the proper clearance holes in
the mask and the lens.
(2) From the back of the instrument cluster, install
and tighten the eight screws around the outer perim-
eter of the rear cover that secure the lens, hood, and
mask unit to the cluster housing. Tighten the screws
to 1 N´m (10 in. lbs.).
(3) Reinstall the instrument cluster onto the
instrument panel. (Refer to 8 - ELECTRICAL/IN-
STRUMENT CLUSTER - INSTALLATION).
(4) Reconnect the battery negative cable.
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, SEAT BELT TENSIONER,
SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. DISCON-
NECT AND ISOLATE THE BATTERY NEGATIVE
(GROUND) CABLE, THEN WAIT TWO MINUTES FOR
THE SYSTEM CAPACITOR TO DISCHARGE BEFORE
PERFORMING FURTHER DIAGNOSIS OR SERVICE.
THIS IS THE ONLY SURE WAY TO DISABLE THE
SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO
TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Position the instrument cluster to the instru-
ment panel.
(2) Reconnect the instrument panel wire harness
connectors for the cluster to the connector receptacles
on the back of the cluster housing.
(3) Position the instrument cluster into the instru-
ment panel.
(4) Install and tighten the four screws that secure
the instrument cluster to the instrument panel struc-
tural support (Fig. 5). Tighten the screws to 4 N´m
(31 in. lbs.).
(5) Reinstall the cluster bezel onto the instrument
panel. (Refer to 23 - BODY/INSTRUMENT PANEL/
CLUSTER BEZEL - INSTALLATION).
(6) Reconnect the battery negative cable.
8J - 16 INSTRUMENT CLUSTERDR
INSTRUMENT CLUSTER (Continued)

Vehicles equipped with the speed control option use
a dual function brake lamp switch. The PCM moni-
tors the state of the dual function brake lamp switch.
The brake switch is equipped with three sets of
contacts, one normally open and the other two nor-
mally closed (brakes disengaged). The PCM sends a
12 volt signal to one of the normally closed contacts
in the brake switch, which is returned to the PCM as
a brake switch state signal. With the contacts closed,
the 12 volt signal is pulled to ground causing the sig-
nal to go low. The low voltage signal, monitored by
the PCM, indicates that the brakes are not applied.
When the brakes are applied, the contacts open,
causing the PCM's output brake signal to go high,
disengaging the speed control, cutting off PCM power
to the speed control solenoids.
The second set of normally closed contacts supplies
12 volts from the PCM any time speed control is
turned on. Through the brake switch, voltage is
routed to the speed control servo solenoids. The
speed control solenoids (vacuum, vent and dump) are
provided this voltage any time the speed control is
ON and the brakes are disengaged.
When the driver applies the brakes, the contacts
open and voltage is interrupted to the solenoids. The
normally open contacts are fed battery voltage. When
the brakes are applied, battery voltage is supplied to
the brake lamps.
The brake lamp switch can only be adjusted once.
That is at the initial installation of the switch. If the
switch is not adjusted properly or has been removed,
a new switch must be installed and adjusted.
DIAGNOSIS AND TESTING - BRAKE LAMP
SWITCH
The brake lamp switch can be tested with an ohm-
meter. The ohmmeter is used to check continuity
between the pin terminals (Fig. 2).
SWITCH CIRCUIT IDENTIFICATION
²Terminals 1 and 2: brake lamp circuit
²Terminals 3 and 4: RWAL/ABS module and Pow-
ertrain Control Module (PCM) circuit
²Terminals 5 and 6: speed control circuit
SWITCH CONTINUITY TEST
NOTE: Disconnect switch harness before testing
switch continuity.
With switch plunger extended, attach test leads to
pins 1 and 2. Replace switch if meter indicates no
continuity.
With switch plunger retracted, attach test leads to
pins 3 and 4. Replace switch if meter indicates no
continuity.With switch plunger retracted, attach test leads to
pins 5 and 6. Replace switch if meter indicates no
continuity.
REMOVAL
(1) Disconnect the switch harness (Fig. 3).
(2) Press and hold the brake pedal in applied posi-
tion.
(3) Rotate the switch counterclockwise about 30É to
align the switch lock tab with the notch in bracket.
(4) Pull the switch rearward out of the mounting
bracket and release the brake pedal.
Fig. 2 Brake Lamp Switch Terminal Identification
1 - TERMINAL PINS
2 - PLUNGER TEST POSITIONS
Fig. 3 Brake Lamp Switch & Bracket
1 - RELEASE LEVER
2 - BRACKET
3 - BRAKE PEDAL SUPPORT
4 - BRAKE LAMP SWITCH
DRLAMPS/LIGHTING - EXTERIOR 8L - 9
BRAKE LAMP SWITCH (Continued)