fuel type DODGE RAM 2003 Service Repair Manual

LUBRICATION & MAINTENANCE
TABLE OF CONTENTS
page page
INTERNATIONAL SYMBOLS
DESCRIPTION..........................1
FLUID TYPES
DESCRIPTION
DESCRIPTION - FUEL REQUIREMENTS -
DIESEL ENGINE.......................1
DESCRIPTION - ENGINE OIL AND
LUBRICANTS.........................2
DESCRIPTION - POWER STEERING FLUID . . 3
DESCRIPTION - ENGINE COOLANT........3
DESCRIPTION - TRANSFER CASE - NV241
GENII...............................4
DESCRIPTION - TRANSFER CASE - NV271 . . 4
DESCRIPTION - TRANSFER CASE - NV243 . . 4
DESCRIPTION - TRANSFER CASE - NV273 . . 4
DESCRIPTION - AXLE...................4DESCRIPTION - MANUAL TRANSMISSION . . . 4
DESCRIPTION - AUTOMATIC
TRANSMISSION FLUID..................4
OPERATION - AUTOMATIC TRANSMISSION
FLUID...............................5
FLUID CAPACITIES
SPECIFICATIONS
FLUID CAPACITIES.....................5
MAINTENANCE SCHEDULES
DESCRIPTION..........................6
JUMP STARTING
STANDARD PROCEDURE - JUMP STARTING...13
HOISTING
STANDARD PROCEDURE - HOISTING.......14
TOWING
STANDARD PROCEDURE - TOWING........15
INTERNATIONAL SYMBOLS
DESCRIPTION
DaimlerChrysler Corporation uses international
symbols to identify engine compartment lubricant
and fluid inspection and fill locations (Fig. 1).
FLUID TYPES
DESCRIPTION
DESCRIPTION - FUEL REQUIREMENTS -
DIESEL ENGINE
DESCRIPTION
WARNING: Do not use alcohol or gasoline as a fuel
blending agent. They can be unstable under certain
conditions and hazardous or explosive when mixed
with diesel fuel.
Use good quality diesel fuel from a reputable sup-
plier in your Dodge truck. For most year-round ser-
vice, number 2 diesel fuel meeting ASTM
specification D-975 will provide good performance. If
the vehicle is exposed to extreme cold (below 0ÉF/-
18ÉC), or is required to operate at colder-than-normal
conditions for prolonged periods, use climatized No. 2
diesel fuel or dilute the No. 2 diesel fuel with 50%
No. 1 diesel fuel. This will provide better protection
from fuel gelling or wax-plugging of the fuel filters.
Fig. 1 INTERNATIONAL SYMBOLS
DRLUBRICATION & MAINTENANCE 0 - 1

Diesel fuel is seldom completely free of water. To
prevent fuel system trouble, including fuel line freez-
ing in winter, drain the accumulated water from the
fuel/water separator using the fuel/water separator
drain provided. If you buy good-quality fuel and fol-
low the cold-weather advice above, fuel conditioners
should not be required in your vehicle. If available in
your area, a high cetane ªpremiumº diesel fuel may
offer improved cold starting and warm-up perfor-
mance.
DESCRIPTION - ENGINE OIL AND LUBRICANTS
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY. CONTACT YOUR DEALER OR GOVERN-
MENT AGENCY FOR LOCATION OF COLLECTION
CENTER IN YOUR AREA.
When service is required, DaimlerChrysler Corpo-
ration recommends that only Mopartbrand parts,
lubricants and chemicals be used. Mopartprovides
the best engineered products for servicing
DaimlerChrysler Corporation vehicles.
Only lubricants bearing designations defined by
the following organization should be used.
²Society of Automotive Engineers (SAE)
²American Petroleum Institute (API)
²National Lubricating Grease Institute (NLGI)
API SERVICE GRADE CERTIFIED
Use an engine oil that is API Certified. MOPARt
provides engine oils, that meet or exceed this
requirement.
SAE VISCOSITY
An SAE viscosity grade is used to specify the vis-
cosity of engine oil. Use only engine oils with multi-
ple viscosities such as 5W-30 or 10W-30. These are
specified with a dual SAE viscosity grade which indi-
cates the cold-to-hot temperature viscosity range.
Select an engine oil that is best suited to your par-
ticular temperature range and variation (Fig. 2).
ENERGY CONSERVING OIL
An Energy Conserving type oil is recommended for
gasoline engines. The designation of ENERGY CON-
SERVING is located on the label of an engine oil con-
tainer.
CONTAINER IDENTIFICATION
Standard engine oil identification notations have
been adopted to aid in the proper selection of engine
oil. The identifying notations are located on the front
label of engine oil plastic bottles and the top of
engine oil cans (Fig. 3).
This symbol means that the oil has been certified
by the American Petroleum Institute (API). Diamler-
Chrysler only recommend API Certified engine oils.
Use Mopartengine oil or equivalent.
GEAR LUBRICANTS
SAE ratings also apply to multigrade gear lubri-
cants. In addition, API classification defines the
lubricants usage. Such as API GL-5 and SAE 75W-
90.
LUBRICANTS AND GREASES
Lubricating grease is rated for quality and usage
by the NLGI. All approved products have the NLGI
symbol (Fig. 4) on the label. At the bottom of the
NLGI symbol is the usage and quality identification
letters. Wheel bearing lubricant is identified by the
letter ªGº. Chassis lubricant is identified by the letter
ªLº. The letter following the usage letter indicates
the quality of the lubricant. The following symbols
indicate the highest quality.
Fig. 2 TEMPERATURE/ENGINE OIL VISCOSITY
Fig. 3 API SYMBOL
0 - 2 LUBRICATION & MAINTENANCEDR
FLUID TYPES (Continued)

FLUID ADDITIVES
DaimlerChrysler strongly recommends against the
addition of any fluids to the transmission, other than
those automatic transmission fluids listed above.
Exceptions to this policy are the use of special dyes
to aid in detecting fluid leaks.
Various ªspecialº additives and supplements exist
that claim to improve shift feel and/or quality. These
additives and others also claim to improve converter
clutch operation and inhibit overheating, oxidation,
varnish, and sludge. These claims have not been sup-
ported to the satisfaction of DaimlerChrysler and
these additivesmust not be used.The use of trans-
mission ªsealersº should also be avoided, since they
may adversely affect the integrity of transmission
seals.
OPERATION - AUTOMATIC TRANSMISSION
FLUID
The automatic transmission fluid is selected based
upon several qualities. The fluid must provide a high
level of protection for the internal components by
providing a lubricating film between adjacent metal
components. The fluid must also be thermally stable
so that it can maintain a consistent viscosity through
a large temperature range. If the viscosity stays con-
stant through the temperature range of operation,
transmission operation and shift feel will remain con-
sistent. Transmission fluid must also be a good con-
ductor of heat. The fluid must absorb heat from the
internal transmission components and transfer that
heat to the transmission case.
FLUID CAPACITIES
SPECIFICATIONS
FLUID CAPACITIES
2DESCRIPTIONSPECIFICATION
FUEL TANK
Short Box (Lt. Duty) 98 L (26 gal.)*
Long Box (Lt. Duty) 132 L (35 gal.)*
ENGINE OIL WITH FILTER
3.7L 4.7 L (5.0 qts.)
4.7L 5.6 L (6.0 qts.)
5.7L 6.6 L (7.0 qts.)
5.9L 4.7 L (5.0 qts.)
8.0L 6.6 L (7.0 qts.)
5.9L DIESEL 10.4 L (11.0 qts.)
2DESCRIPTION SPECIFICATION
COOLING SYSTEM
3.7L 15.4 L (16.2 qts.)**
4.7L 15.4 L (16.2 qts.)**
5.7L 15.4L (16.2 qts.)**
5.9L 15.5 L (16.3 qts.)**
8.0L 24L (24.3 qts.)**
5.9L Diesel Engine 28L (29.5 qts.)**
POWER STEERING
Power steering fluid capacities are dependent on engine/
chassis options as well as steering gear/cooler options.
Depending on type and size of internal cooler, length and
inside diameter of cooler lines, or use of an auxiliary cooler,
these capacities may vary. Refer to 19, Steering for proper
fill and bleed procedures.
AUTOMATIC TRANSMISSION
Service Fill - 46RE 3.8 L (4.0 qts.)
O-haul - 46RE 9-9.5L (19-20 pts.)L
Service Fill - 45RFE/
545RFE4X2 - 5.2 L (11.0 pts.)
4X4 - 6.2 L (13.0 pts.)
O-haul - 45RFE/545RFE 14-16 L (29-33 pts.)L
LDry 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
NV3500 4X2 2.3 L (4.8 pts.)
NV3500 4X4 2.0 L (4.2 pts.)
NV4500 3.8 L (8.0 pts.)
NV5600 4.5 L (9.5 pts.)
TRANSFER CASE
NV241 GENII 1.6 L (3.4 pts.)
NV243 1.6 L (3.4 pts.)
NV271 1.89 L (4.0 pts.)
NV273 1.89 L (4.0 pts.)
FRONT AXLE   .03 L (1 oz)
C205F 1.66 L (3.5 pts.)
9 1/4 AA 2.25 L (4.75 pts.)
REAR AXLE   .03 L (1 oz)
9 1/4 2.32 L (4.9 pts.)***
10 1/2 AA 2.25 L (4.75 pts.)
11 1/2 AA 3.62 L (7.65 pts)
*** With Trac-Lok add 118 ml (4 oz.) of Limited Slip Additive.
** 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.
DRLUBRICATION & MAINTENANCE 0 - 5
FLUID TYPES (Continued)

HOISTING
STANDARD PROCEDURE - HOISTING
Refer to the Owner's Manual for emergency vehicle
lifting procedures.
WARNING: THE HOISTING AND JACK LIFTING
POINTS PROVIDED ARE FOR A COMPLETE VEHI-
CLE. WHEN A CHASSIS OR DRIVETRAIN COMPO-
NENT IS REMOVED FROM A VEHICLE, THE
CENTER OF GRAVITY IS ALTERED MAKING SOME
HOISTING CONDITIONS UNSTABLE. PROPERLY
SUPPORT (Fig. 5) OR SECURE VEHICLE TO HOIST-
ING DEVICE WHEN THESE CONDITIONS EXIST.
FLOOR JACK
When properly positioned, a floor jack can be used
to lift a vehicle (Fig. 6). Support the vehicle in the
raised position with jack stands at the front and rear
ends of the frame rails (Fig. 5).
CAUTION: Do not lift vehicle with a floor jack posi-
tioned under:
²An axle tube.
²A body side sill.
²A steering linkage component.²A drive shaft.
²The engine or transmission oil pan.
²The fuel tank.
²A front suspension arm.
NOTE: Use the correct frame rail lifting locations
only (Fig. 7) and (Fig. 8).
HOIST
A vehicle can be lifted with:
²A single-post, frame-contact hoist.
²A twin-post, chassis hoist.
²A ramp-type, drive-on hoist.
NOTE: When a frame-contact type hoist is used,
verify that the lifting pads are positioned properly
(Fig. 6). The forward lifting pads should be posi-
tioned against the forward flange of the transmis-
sion crossmember brackets at the bottom of the
frame rail (Fig. 7). The real lifting pads should be
wedged between the forward flange of the leaf
spring bracket and the frame rail (Fig. 8). Safety
stands should be placed under the frame rails at
the front and rear ends (Fig. 5).
Fig. 5 Safety Stands
1 - SAFETY STANDS
Fig. 6 Vehicle Lifting Locations
0 - 14 LUBRICATION & MAINTENANCEDR

TOWING
STANDARD PROCEDURE - TOWING
A vehicle equipped with SAE approved sling-type
towing equipment can be used to tow all vehicles.
When towing a 4WD vehicle using a wheel-lift towing
device, use tow dollies under the opposite end of the
vehicle. A vehicle with flat-bed device can also be
used to transport a disabled vehicle (Fig. 9).
A wooden crossbeam may be required for proper
connection when using the sling-type, front-end tow-
ing method.
SAFETY PRECAUTIONS
CAUTION: The following safety precautions must be
observed when towing a vehicle:
²Secure loose and protruding parts.
²Always use a safety chain system that is inde-
pendent of the lifting and towing equipment.
²Do not allow towing equipment to contact the
disabled vehicle's fuel tank.
²Do not allow anyone under the disabled vehicle
while it is lifted by the towing device.
²Do not allow passengers to ride in a vehicle
being towed.
²Always observe state and local laws regarding
towing regulations.
²Do not tow a vehicle in a manner that could
jeopardize the safety of the operator, pedestrians or
other motorists.
²Do not attach tow chains, T-hooks, J-hooks, or a
tow sling to a bumper, steering linkage, drive shafts
or a non-reinforced frame hole.
²Do not tow a heavily loaded vehicle. Damage to
the cab, cargo box or frame may result. Use a flatbed
device to transport a loaded vehicle.
GROUND CLEARANCE
CAUTION: If vehicle is towed with wheels removed,
install lug nuts to retain brake drums or rotors.
Fig. 7 FRONT LIFT PAD LOCATION
1 - BODY MOUNT BRACKET
2 - FRONT LIFT PAD
3 - TRANSMISSION CROSSMEMBER BRACKET
4 - FRAME RAIL
Fig. 8 REAR LIFT PAD LOCATION
1 - FRAME RAIL
2 - REAR LIFT PAD
3 - LEAF SPRING MOUNTING BRACKET
4 - BOX MOUNTING BRACKET
Fig. 9 Tow Vehicles With Approved Equipment
1 - SLING TYPE2 - WHEEL LIFT3 - FLAT BED
DRLUBRICATION & MAINTENANCE 0 - 15
HOISTING (Continued)

INSTALLATION
(1) Install antenna cable to radio.
(2) Connect electrical harness connector to radio.
(3) Install radio to instrument panel.
(4) Install instrument panel center bezel (Refer to
23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL CENTER BEZEL - INSTALLATION).
(5) Connect battery negative cable.
RADIO NOISE SUPPRESSION
GROUND STRAP
DESCRIPTION
Radio noise suppression devices are factory-in-
stalled standard equipment on this vehicle. Radio
Frequency Interference (RFI) and ElectroMagnetic
Interference (EMI) can be produced by any on-board
or external source of electromagnetic energy. These
electromagnetic energy sources can radiate electro-
magnetic signals through the air, or conduct them
through the vehicle electrical system.
When the audio system converts RFI or EMI to an
audible acoustic wave form, it is referred to as radio
noise. This undesirable radio noise is generally man-
ifested in the form of ªbuzzing,º ªhissing,º ªpopping,º
ªclicking,º ªcrackling,º and/or ªwhirringº sounds. In
most cases, RFI and EMI radio noise can be sup-
pressed using a combination of vehicle and compo-
nent grounding, filtering and shielding techniques.
This vehicle is equipped with factory-installed radio
noise suppression devices that were designed to min-
imize exposure to typical sources of RFI and EMI;
thereby, minimizing radio noise complaints.Factory-installed radio noise suppression is accom-
plished primarily through circuitry or devices that
are integral to the factory-installed radios, audio
power amplifiers and other on-board electrical com-
ponents such as generators, wiper motors, blower
motors, and fuel pumps that have been found to be
potential sources of RFI or EMI. External radio noise
suppression devices that are used on this vehicle to
control RFI or EMI, and can be serviced, include the
following:
²Engine-to-body ground strap- This length of
braided ground strap has an eyelet terminal connec-
tor crimped to each end. One end is secured to the
engine cylinder head(s). The other is secured to the
plenum at the exhaust heat shield forward/outer
attaching stud.
²Resistor-type spark plugs- This type of spark
plug has an internal resistor connected in series
between the spark plug terminal and the center elec-
trode to help reduce the production of electromag-
netic radiation that can result in radio noise.
OPERATION
There are two common strategies that can be used
to suppress Radio Frequency Interference (RFI) and
ElectroMagnetic Interference (EMI) radio noise. The
first suppression strategy involves preventing the
production of RFI and EMI electromagnetic signals
at their sources. The second suppression strategy
involves preventing the reception of RFI and EMI
electromagnetic signals by the audio system compo-
nents.
The use of braided ground straps in key locations
is part of the RFI and EMI prevention strategy.
These ground straps ensure adequate ground paths,
particularly for high current components such as
many of those found in the starting, charging, igni-
tion, engine control and transmission control sys-
tems. An insufficient ground path for any of these
high current components may result in radio noise
caused by induced voltages created as the high cur-
rent seeks alternative ground paths through compo-
nents or circuits intended for use by, or in close
proximity to the audio system components or circuits.
Preventing the reception of RFI and EMI is accom-
plished by ensuring that the audio system compo-
nents are correctly installed in the vehicle. Loose,
corroded or improperly soldered wire harness connec-
tions, improperly routed wiring and inadequate audio
system component grounding can all contribute to
the reception of RFI and EMI. A properly grounded
antenna body and radio chassis, as well as a shielded
antenna coaxial cable with clean and tight connec-
tions will each help reduce the potential for reception
of RFI and EMI.
Fig. 7 ANTENNA TO RADIO
1 - RADIO
2 - LOCKING ANTENNA CONNECTOR
3 - INSTRUMENT PANEL ANTENNA CABLE
8A - 8 AUDIODR
RADIO (Continued)

DIAGNOSIS AND TESTING - ASD AND FUEL
PUMP RELAYS
The following description of operation and
tests apply only to the Automatic Shutdown
(ASD) and fuel pump relays. The terminals on the
bottom of each relay are numbered. Two different
types of relays may be used, (Fig. 3) or (Fig. 4).
²Terminal number 30 is connected to battery volt-
age. For both the ASD and fuel pump relays, termi-
nal 30 is connected to battery voltage at all times.
²The PCM grounds the coil side of the relay
through terminal number 85.²Terminal number 86 supplies voltage to the coil
side of the relay.
²When the PCM de-energizes the ASD and fuel
pump relays, terminal number 87A connects to termi-
nal 30. This is the Off position. In the off position,
voltage is not supplied to the rest of the circuit. Ter-
minal 87A is the center terminal on the relay.
²When the PCM energizes the ASD and fuel
pump relays, terminal 87 connects to terminal 30.
This is the On position. Terminal 87 supplies voltage
to the rest of the circuit.
The following procedure applies to the ASD and
fuel pump relays.
(1) Remove relay from connector before testing.
(2) With the relay removed from the vehicle, use
an ohmmeter to check the resistance between termi-
nals 85 and 86. The resistance should be 75 ohms +/-
5 ohms.
(3) Connect the ohmmeter between terminals 30
and 87A. The ohmmeter should show continuity
between terminals 30 and 87A.
(4) Connect the ohmmeter between terminals 87
and 30. The ohmmeter should not show continuity at
this time.
(5) Connect one end of a jumper wire (16 gauge or
smaller) to relay terminal 85. Connect the other end
of the jumper wire to the ground side of a 12 volt
power source.
(6) Connect one end of another jumper wire (16
gauge or smaller) to the power side of the 12 volt
power source.Do not attach the other end of the
jumper wire to the relay at this time.
WARNING: DO NOT ALLOW OHMMETER TO CON-
TACT TERMINALS 85 OR 86 DURING THIS TEST.
DAMAGE TO OHMMETER MAY RESULT.
(7) Attach the other end of the jumper wire to
relay terminal 86. This activates the relay. The ohm-
meter should now show continuity between relay ter-
minals 87 and 30. The ohmmeter should not show
continuity between relay terminals 87A and 30.
(8) Disconnect jumper wires.
(9) Replace the relay if it did not pass the continu-
ity and resistance tests. If the relay passed the tests,
it operates properly. Check the remainder of the ASD
and fuel pump relay circuits. Refer to 8, Wiring Dia-
grams.
REMOVAL
The ASD relay is located in the Power Distribution
Center (PDC) (Fig. 5). Refer to label on PDC cover
for relay location.
(1) Remove PDC cover.
(2) Remove relay from PDC.
Fig. 3 TYPE 1 RELAY (ISO MICRO RELAY)
Fig. 4 ASD AND FUEL PUMP RELAY TERMINALSÐ
TYPE 2
TERMINAL LEGEND
NUMBER IDENTIFICATION
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
DRIGNITION CONTROL 8I - 7
AUTOMATIC SHUT DOWN RELAY (Continued)

NOTE: Over or under tightening the sensor mount-
ing bolts will affect knock sensor performance, pos-
sibly causing improper spark control. Always use
the specified torque when installing the knock sen-
sors. The torque for the knock senor bolt is rela-
tively light for an 8mm bolt.
NOTE: Note foam strip on bolt threads. This foam is
used only to retain the bolts to sensors for plant
assembly. It is not used as a sealant. Do not apply
any adhesive, sealant or thread locking compound
to these bolts.
(3) Install and tighten mounting bolts. Refer to
torque specification.
(4) Install intake manifold. Refer to Engine sec-
tion.
(5) Connect knock sensor wiring harness to engine
harness at rear of intake manifold.
5.7L V-8
(1) Thoroughly clean knock sensor mounting hole.
(2) Install sensor into cylinder block.
NOTE: Over or under tightening the sensor mount-
ing bolts will affect knock sensor performance, pos-
sibly causing improper spark control. Always use
the specified torque when installing the knock sen-
sors. The torque for the knock senor bolt is rela-
tively light for an 8mm bolt.
NOTE: Note foam strip on bolt threads. This foam is
used only to retain the bolts to sensors for plant
assembly. It is not used as a sealant. Do not apply
any adhesive, sealant or thread locking compound
to these bolts.
(3) Install and tighten mounting bolt. Refer to
torque specification.
(4) Install electrical connector to sensor.
SPARK PLUG
DESCRIPTION
Resistor type spark plugs are used on all engines.
Sixteen spark plugs (2 per cylinder) are used with
5.7L V-8 engines.
DIAGNOSIS AND TESTING - SPARK PLUG
CONDITIONS
To prevent possible pre-ignition and/or mechanical
engine damage, the correct type/heat range/number
spark plug must be used.
Always use the recommended torque when tighten-
ing spark plugs. Incorrect torque can distort the
spark plug and change plug gap. It can also pull the
plug threads and do possible damage to both the
spark plug and the cylinder head.
Remove the spark plugs and examine them for
burned electrodes and fouled, cracked or broken por-
celain insulators. Keep plugs arranged in the order
in which they were removed from the engine. A sin-
gle plug displaying an abnormal condition indicates
that a problem exists in the corresponding cylinder.
Replace spark plugs at the intervals recommended in
the Lubrication and Maintenance section.
Spark plugs that have low mileage may be cleaned
and reused if not otherwise defective, carbon or oil
fouled.
CAUTION: Never use a motorized wire wheel brush
to clean the spark plugs. Metallic deposits will
remain on the spark plug insulator and will cause
plug misfire.
Spark plug resistance values range from 6,000 to
20,000 ohms (when checked with at least a 1000 volt
spark plug tester).Do not use an ohmmeter to
check the resistance values of the spark plugs.
Inaccurate readings will result.
NORMAL OPERATING
The few deposits present on the spark plug will
probably be light tan or slightly gray in color. This is
evident with most grades of commercial gasoline
(Fig. 42). There will not be evidence of electrode
burning. Gap growth will not average more than
approximately 0.025 mm (.001 in) per 3200 km (2000
miles) of operation. Spark plugs that have normal
wear can usually be cleaned, have the electrodes
filed, have the gap set and then be installed.
Some fuel refiners in several areas of the United
States have introduced a manganese additive (MMT)
for unleaded fuel. During combustion, fuel with MMT
causes the entire tip of the spark plug to be coated
with a rust colored deposit. This rust color can be
misdiagnosed as being caused by coolant in the com-
bustion chamber. Spark plug performance may be
affected by MMT deposits.
DRIGNITION CONTROL 8I - 27
KNOCK SENSOR (Continued)

the vehicle speed remains greater than about twenty-
four kilometers-per-hour (fifteen miles-per-hour).
²Vacuum Fluorescent Display Synchroniza-
tion- The EMIC transmits electronic panel lamp
dimming level messages which allows all other elec-
tronic modules on the PCI data bus with Vacuum
Fluorescent Display (VFD) units to coordinate their
illumination intensity with that of the EMIC VFD
units.
²Vehicle Theft Security System- The EMIC
monitors inputs from the door cylinder lock switch-
(es), the door ajar switches, the ignition switch, and
the Remote Keyless Entry (RKE) receiver module,
then provides electronic horn and lighting request
messages to the Front Control Module (FCM) located
on the Integrated Power Module (IPM) for the appro-
priate VTSS alarm output features.
²Wiper/Washer System Control- The EMIC
provides electronic wiper and/or washer request mes-
sages to the Front Control Module (FCM) located on
the Integrated Power Module (IPM) for the appropri-
ate wiper and washer system features. (Refer to 8 -
ELECTRICAL/WIPERS/WASHERS - DESCRIP-
TION).
The EMIC houses six analog gauges and has pro-
visions for up to twenty-three indicators (Fig. 3) or
(Fig. 4). The EMIC includes the following analog
gauges:
²Coolant Temperature Gauge
²Fuel Gauge
²Oil Pressure Gauge
²Speedometer
²Tachometer
²Voltage Gauge
Some of the EMIC indicators are automatically
configured when the EMIC is connected to the vehi-
cle electrical system for compatibility with certain
optional equipment or equipment required for regula-
tory purposes in certain markets. While each EMIC
may have provisions for indicators to support every
available option, the configurable indicators will not
be functional in a vehicle that does not have the
equipment that an indicator supports. The EMIC
includes provisions for the following indicators (Fig.
3) or (Fig. 4):
²Airbag Indicator (with Airbag System only)
²Antilock Brake System (ABS) Indicator
(with ABS or Rear Wheel Anti-Lock [RWAL]
brakes only)
²Brake Indicator
²Cargo Lamp Indicator
²Check Gauges Indicator
²Cruise Indicator (with Speed Control only)
²Door Ajar Indicator
²Electronic Throttle Control (ETC) Indicator
(with 5.7L Gasoline Engine only)²Gear Selector Indicator (with Automatic
Transmission only)
²High Beam Indicator
²Lamp Out Indicator
²Low Fuel Indicator
²Malfunction Indicator Lamp (MIL)
²Overdrive-Off Indicator (with Automatic
Transmission only)
²Seatbelt Indicator
²Security Indicator (with Sentry Key Immo-
bilizer & Vehicle Theft Security Systems only)
²Service Four-Wheel Drive Indicator (with
Four-Wheel Drive only)
²Transmission Overtemp Indicator (with
Automatic Transmission only)
²Turn Signal (Right and Left) Indicators
²Upshift Indicator (with Manual Transmis-
sion only)
²Washer Fluid Indicator
²Wait-To-Start Indicator (with Diesel Engine
only)
²Water-In-Fuel Indicator (with Diesel Engine
only)
Each indicator in the EMIC, except those located
within one of the VFD units, is illuminated by a ded-
icated LED that is soldered onto the EMIC electronic
circuit board. The LED units are not available for
service replacement and, if damaged or faulty, the
entire EMIC must be replaced. Cluster illumination
is accomplished by dimmable incandescent back
lighting, which illuminates the gauges for visibility
when the exterior lighting is turned on. Each of the
incandescent bulbs is secured by an integral bulb
holder to the electronic circuit board from the back of
the cluster housing.
Hard wired circuitry connects the EMIC to the
electrical system of the vehicle. These hard wired cir-
cuits are integral to several wire harnesses, which
are routed throughout the vehicle and retained by
many different methods. These circuits may be con-
nected to each other, to the vehicle electrical system
and to the EMIC through the use of a combination of
soldered splices, splice block connectors, and many
different types of wire harness terminal connectors
and insulators. Refer to the appropriate wiring infor-
mation. The wiring information includes wiring dia-
grams, proper wire and connector repair procedures,
further details on wire harness routing and reten-
tion, as well as pin-out and location views for the
various wire harness connectors, splices and grounds.
The EMIC modules for this model are serviced only
as complete units. The EMIC module cannot be
adjusted or repaired. If a gauge, an LED indicator, a
VFD unit, the electronic circuit board, the circuit
board hardware, the cluster overlay, or the EMIC
housing are damaged or faulty, the entire EMIC mod-
DRINSTRUMENT CLUSTER 8J - 5
INSTRUMENT CLUSTER (Continued)

WIPER MODULE
DESCRIPTION
The wiper motor bracket is secured with two
screws below the wiper motor through two rubber
insulators to the bottom of the cowl plenum panel
beneath the cowl plenum cover/grille panel (Fig. 25).
Two screws secure the top of the wiper module
bracket to the cowl plenum panel through rubber
insulators located on the outboard end of each pivot
bracket. The ends of the wiper pivot shafts that pro-
trude through dedicated openings in the cowl plenum
cover/grille panel to drive the wiper arms and blades
are the only visible components of the wiper module.
The wiper module consists of the following major
components:
²Bracket- The wiper module bracket consists of
a long tubular steel main member that has a die castpivot bracket formation near each end where the two
wiper pivots are secured. A stamped steel clamp
secures the center of the tubular member to the die
cast bracket integral to the wiper motor with two
screws.
²Crank Arm- The wiper motor crank arm is a
stamped steel unit with a slotted hole on the driven
end that is secured to the wiper motor output shaft
with a nut, and has a ball stud secured to the drive
end.
²Linkage- Two stamped steel drive links con-
nect the wiper motor crank arm to the wiper pivot
lever arms. The left side drive link has a plastic sock-
et-type bushing on each end. The right side drive
link has a plastic socket-type bushing on one end,
and a plastic sleeve-type bushing on the other end.
The socket-type bushing on one end of each drive
link is snap-fit over the ball stud on the lever arm of
its respective pivot. The right side drive link sleeve-
type bushing end is then fit over the motor crank
arm ball stud, and the other socket-type bushing of
the left side drive link is snap-fit over the exposed
end of the wiper motor crank arm ball stud.
Fig. 24 Integrated Power Module
1 - 15 - CARTRIDGE FUSE
16 - 53 - BLADE FUSE
54 - HEATED MIRROR RELAY
55 - WIPER ON/OFF RELAY
56 - A/C CONDENSER FAN RELAY
57 - ENGINE CONTROL RELAY
58 - FUEL PUMP RELAY
59 - TRANSMISSION RELAY
60 - WIPER HIGH/LOW RELAY
61 - SPARE
62 - FOG LAMP RELAY
63 - ADJUSTABLE PEDAL RELAY
64 - A/C CLUTCH RELAY
65 - SPARE
66 - O2 RELAY
67 - SPARE
68 - SPARE
69 - SPARE
70 - SPARE
71 - SPARE
72 - STARTER RELAY
73 - PARK LAMP RELAY
Fig. 25 Wiper Module
1 - PIVOT BRACKET (2)
2 - TUBE
3 - CLAMP
4 - PIVOT SHAFT (2)
5 - INSULATOR (4)
6 - LINKAGE BUSHING (4)
7 - DRIVE LINK (2)
8 - PIVOT CRANK ARM (2)
9 - PIGTAIL WIRE CONNECTOR
10 - MOTOR CRANK ARM
11 - WIPER MOTOR
8R - 22 WIPERS/WASHERSDR
WIPER HIGH/LOW RELAY (Continued)