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step. If test light is dim or not illuminated, go to step 7).
2) Turn ignition off. Using an ohmmeter, check resistance of
ground circuit at S/C servo connector terminal No. 4 (Black wire). If
resistance is 5 ohms or more, repair open ground circuit. Perform TEST
VER-4A under VERIFICATION TESTS. If resistance is less than 5 ohms, go
to next step.
3) Disconnect PCM. Inspect connectors. Clean or repair as
necessary. Using an ohmmeter, measure resistance of S/C vacuum
solenoid control circuit between PCM connector C3, terminal No. 4 and
S/C servo connector terminal No. 1 (Tan/Red wire). If resistance is 5
ohms or more, repair open circuit. Perform TEST VER-4A under
VERIFICATION TESTS. If resistance is less than 5 ohms, go to next
step.
4) Using an ohmmeter, check resistance between ground and S/C
vacuum solenoid control circuit at S/C servo connector terminal No. 1
(Tan/Red wire). If resistance is less than 5 ohms, repair short to
ground. Perform TEST VER-4A under VERIFICATION TESTS. If resistance is
5 ohms or more, go to next step.
5) Using an ohmmeter, check resistance of S/C vent solenoid
control circuit between PCM connector C3, terminal No. 5 and S/C servo
connector terminal No. 2 (Light Green/Red wire). If resistance is 5
ohms or more, repair open circuit. Perform TEST VER-4A under
VERIFICATION TESTS. If resistance is less than 5 ohms, go to next
step.
6) Using an ohmmeter, check resistance between ground and S/C
vent solenoid control circuit at S/C servo connector terminal No. 2
(Light Green/Red wire). If resistance is less than 5 ohms, repair
short to ground. Perform TEST VER-4A under VERIFICATION TESTS. If
resistance is 5 ohms or more, replace S/C servo. Perform TEST VER-4A
under VERIFICATION TESTS.
7) Turn ignition off. Disconnect brake switch connector.
Inspect connectors. Clean or repair as necessary. Turn ignition on.
Using scan tool, actuate S/C solenoid. Using a 12-volt test light,
probe S/C power supply circuit at brake switch connector terminal No.
4 (Yellow/Red wire). If test light is illuminated and bright, go to
next step. If test light is not illuminated or dim, go to step 10).
8) Check brake switch adjustment. See BRAKE SWITCH under
REMOVAL & INSTALLATION. Adjust as necessary. Perform TEST VER- 4A
under VERIFICATION TESTS. If brake switch adjustment is okay, go to
next step.
9) Using an ohmmeter, check resistance of brake switch output
circuit between brake switch connector terminal No. 3 and S/C servo
connector terminal No. 3 (Dark Blue/Red wire). If resistance is more
than 5 ohms, repair open circuit. Perform TEST VER-4A under
VERIFICATION TESTS. If resistance is 5 ohms or less, replace brake
switch. Perform TEST VER-4A under VERIFICATION TESTS.
10) Turn ignition off. Using an ohmmeter, check resistance
between ground and S/C brake switch output circuit at S/C servo
connector terminal No. 3 (Dark Blue/Red wire). If resistance is less
than 5 ohms, repair short to ground. Perform TEST VER-4A under
VERIFICATION TESTS. If resistance is 5 ohms or more, go to next step.
11) Disconnect PCM. Inspect connectors. Clean or repair as
necessary. Using an ohmmeter, check resistance of S/C power supply
circuit between PCM connector C3, terminal No. 11 and brake switch
connector terminal No. 4 (Yellow/Red wire). If resistance is 5 ohms or\
more, repair open circuit. Perform TEST VER-4A under VERIFICATION
TESTS. If resistance is less than 5 ohms, replace PCM. Perform TEST
VER-4A under VERIFICATION TESTS.
FTC P1899: PARK/NEUTRAL POSITION (PNP) SWITCH STUCK IN PARK
OR IN GEAR (A/T MODELS)
Possible Causes:
Page 397 of 1691
next step. If scan tool does not display brake pedal PRESSED and
RELEASED, go to NTC-1: BRAKE SWITCH SENSE.
4) Turn S/C on. On A/T models, move gear selector to Drive.
If scan tool displays park neutral switch D/R, go to next step. If
scan tool does not display park neutral switch D/R, go to FTC P1899:
PARK/NEUTRAL POSITION SWITCH STUCK IN PARK OR IN GEAR under DIAGNOSTIC
TESTS.
5) On all models, using scan tool, actuate S/C vent solenoid.
Using a 12-volt test light, backprobe S/C brake switch output circuit
at S/C servo connector terminal No. 3 (Dark Blue/Red wire). If test
light is illuminated and bright, go to next step. If test light is dim
or is not illuminated, go to NTC-1: BRAKE SWITCH SENSE.
6) Start engine and let idle for one minute. Turn engine off.
Turn ignition on (engine off). Using scan tool, actuate S/C servo
solenoids. If throttle opens and closes, go to NTC-2: CHECKING FOR
SPEED CONTROL DENIED MESSAGE. If throttle does not open and close,
inspect throttle cable and linkage. Check vacuum supply. See VACUUM
SUPPLY under COMPONENT TESTS. Repair as necessary. Perform TEST VER-4A
under VERIFICATION TESTS.
7) While observing scan tool, press CANCEL switch several
times. If scan tool displays PRESSED and RELEASED, go to next step. If
scan tool does not display PRESSED and RELEASED, replace CANCEL
switch. Perform TEST VER-4A under VERIFICATION TESTS.
8) Turn ignition off. Disconnect S/C servo connector. Using
an ohmmeter, check resistance of ground circuit at S/C servo connector
terminal No. 4 (Black wire). If resistance is 5 ohms or more, repair
open ground circuit. Perform TEST VER-4A under VERIFICATION TESTS. If
resistance is less than 5 ohms, go to next step.
9) Reconnect S/C servo connector. Turn ignition and S/C on.
While observing scan tool, press SET switch several times. If scan
tool displays PRESSED and RELEASED, go to next step. If scan tool does
not display PRESSED and RELEASED, replace SET switch. Perform TEST
VER-4A under VERIFICATION TESTS.
10) Turn ignition off. Disconnect S/C servo connector.
Inspect terminals. If any terminal is damaged, pushed out or miswired,
repair as necessary. Perform TEST VER-4A under VERIFICATION TESTS. If
terminals are okay, go to next step.
11) Disconnect S/C servo connector. Disconnect PCM
connectors. Inspect connectors. Clean or repair as necessary. Using an
ohmmeter, check resistance of S/C vacuum solenoid control circuit
between PCM connector C3, terminal No. 4 and S/C servo connector
terminal No. 1 (Tan/Red wire). If resistance is 5 ohms or more, repair\
open circuit. Perform TEST VER-4A under VERIFICATION TESTS. If
resistance is less than 5 ohms, go to next step.
12) Turn S/C on. While observing scan tool, press COAST
switch several times. If scan tool displays PRESSED and RELEASED, go
to next step. If scan tool does not display PRESSED and RELEASED,
replace COAST switch. Perform TEST VER-4A under VERIFICATION TESTS.
13) Using an ohmmeter, check resistance of S/C vent solenoid
control circuit between PCM connector C3, terminal No. 5 and S/C servo
connector terminal No. 2 (Light Green/Red wire). If resistance is 5
ohms or more, repair open circuit. Perform TEST VER-4A under
VERIFICATION TESTS. If resistance is less than 5 ohms, replace S/C
servo. Perform TEST VER-4A under VERIFICATION TESTS.
NTC-1: BRAKE SWITCH SENSE
Possible Causes:
* Ground circuit open.
* Defective brake switch.
* Brake switch sense circuit open or shorted.
* Defective PCM.
Page 488 of 1691
not leaking ............ 2 . Suggest replacement of CV boot.
Cage broken ............. A ... Require repair or replacement
of CV joint.
Housing damaged to the
extent that it no longer
performs its intended
function ............... A ........... (1) Require repair or
replacement of CV joint.
Housing worn to the extent
that it no longer performs
its intended function .. A ........... ( 1) Require repair or
replacement of CV joint.
Holes elongated ......... A ............ Require replacement.
Internal parts binding .. A .. Require repair or replacement.
Internal parts worn ..... A .. Require repair or replacement.
Lubricant missing ....... C ... Require cleaning, inspection,
and repacking of CV joint.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
( 1) - Housing assembly may appear blue in color from normal
manufacturing process of heat-treating the housing.
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DIP STICK TUBES
DIP STICK TUBE INSPECTION \
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Condition Code Procedure
Broken .................. A .. Require repair or replacement.
Checkball missing ....... C .. Suggest repair or replacement.
Cracked ................. A .. Require repair or replacement.
Hold down bracket
broken ................. A .. Require repair or replacement.
Hold down bracket
missing ................ C ............ Require replacement.
Leaking ................. A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
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DIP STICKS (FLUID LEVEL INDICATORS)
DIP STICK (FLUID LEVEL INDICATOR) INSPECTION \
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Condition Code Procedure
Application incorrect ... B ............ Require replacement.
Broken .................. A ............ Require replacement.
Compressed .............. A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Modified ................ A ............ Require replacement.
Stretched ............... A .. Require repair or replacement.
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DOWEL PINS, GUIDES AND PILOT HOLES
DOWEL PIN, GUIDE AND PILOT HOLE INSPECTION \
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Page 676 of 1691
the old insert and machining an oversize insert bore. Replacement
oversize insert is usually chilled and the cylinder head is sometimes
warmed. Valve seat is pressed into the head. This operation requires
specialized machine shop equipment.
Valve Seat Concentricity
Using dial gauge, install gauge pilot in valve guide.
Position gauge arm on the valve seat. Adjust dial indicator to zero.
Rotate arm 360 degrees and note reading. Runout should not exceed
specification.
To check valve-to-valve seat concentricity, coat valve face
lightly with Prussian Blue dye. Install valve and rotate it on valve
seat. If pattern is even and entire seat is coated at valve contact
point, valve is concentric with the seat.
REASSEMBLY
Valve Stem Installed Height
Valve stem installed height must be checked when new valves
are installed or when valves or valve seats have been ground. Install
valve in valve guide. Measure distance from tip of valve stem to
spring seat. See Fig. 11. Distance must be within specifications.
Fig. 11: Measuring Valve Stem Installed Height - Typical
This Graphic For General Information Only
Remove valve and grind valve stem tip if height exceeds
specification. Valve tips are surface hardened. DO NOT remove more
Page 847 of 1691
HO W T O U SE S YSTE M W IR IN G D IA G RAM S
1999 D odge P ic ku p R 1500
GENERAL INFORMATION
Using Wiring Diagrams
All Models
INTRODUCTION
This CD obtains wiring diagrams and technical service
bulletins, containing wiring diagram changes from the domestic and
import manufacturers. These are checked for accuracy and are all
redrawn into a consistent format for easy use.
In the past, when cars were simpler, diagrams were simpler.
All components were connected by wires and diagrams seldom exceeded 4
pages in length. Today, some wiring diagrams require more than 16
pages. It would be impractical to expect a service technician to trace
a wire from page 1 across every page to page 16.
Removing some of the wiring maze reduces eyestrain and time
wasted searching across several pages. Today the majority of
these
diagrams follow a much improved format, which permits space for
internal switch details.
Wiring diagrams are drawn in a "top-down" format. The
diagrams are drawn with the power source at the top of the diagram and
the ground point at the bottom of the diagram. Components locations
are identified on the wiring diagrams. Any wires that don't connect
directly to a component are identified on the diagram to indicate
where they go.
COLOR ABBREVIATIONS
COLOR ABBREVIATIONS TABLE \
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Color Normal Optional
Black ................ BLK .......................... BK
Blue ................. BLU .......................... BU
Brown ................ BRN .......................... BN
Clear ................ CLR .......................... CR
Dark Blue .......... DK BLU ...................... DK BU
Dark Green ......... DK GRN ...................... DK GN
Green ................ GRN .......................... GN
Gray ................. GRY .......................... GY
Light Blue ......... LT BLU ...................... LT BU
Light Green ........ LT GRN ...................... LT GN
Orange ............... ORG .......................... OG
Pink ................. PNK .......................... PK
Purple ............... PPL .......................... PL
Red .................. RED .......................... RD
Tan .................. TAN .......................... TN
Violet ............... VIO .......................... VI
White ................ WHT .......................... WT
Yellow ............... YEL .......................... YL
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IDENTIFYING WIRING DIAGRAM ABBREVIATIONS
NOTE: Abbreviations used on these diagrams are normally
self-explanatory. If necessary see ABBREVIATIONS
Page 855 of 1691
systems may lose memory data. Driveability problems may exist
until computer systems have completed a relearn cycle. See
COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION
before disconnecting battery.
NOTE: Testing of instrument panel and gauges requires using a scan
tool to check circuits connected to Body Control Module
(BCM). See appropriate BODY CONTROL COMPUTER TESTS article.
PRELIMINARY DIAGNOSIS
NOTE: There are 2 instrument cluster connectors. These connectors
look identical. Identify connectors by wire color. See WIRING
DIAGRAMS.
Ram Pickup
1) If CCD bus controlled indicator lights and gauges do not
operate, go to step 4). If indicator lights operate and all gauges do
not operate, go to next step.
2) Check for battery voltage between ground and both sides of
fuse No. 14 in junction block. If battery voltage exists on both
sides, go to next step. If battery voltage exists on one side only,
repair short circuit and replace fuse. If battery voltage does not
exist on both sides, locate and repair open circuit. See WIRING
DIAGRAMS.
3) Disconnect negative battery cable. Remove instrument
cluster. See INSTRUMENT CLUSTER under REMOVAL & INSTALLATION. Connect
negative battery cable. Measure voltage between ground and terminal
No. 6 (Yellow wire) of instrument cluster connector C1. See Fig. 1. If
battery voltage is present, reinstall instrument cluster and go to
SELF-DIAGNOSTICS. If battery voltage is not present, repair open
circuit between fuse No. 14 in junction block and instrument cluster
connector C1.
4) Turn ignition on. Measure voltage between ground and both
sides of fuse No. 17 (10-amp) in junction block. If battery voltage
exists on both sides, go to next step. If battery voltage exists on
one side only, repair short circuit and replace fuse. If battery
voltage does not exist on both sides, repair open Dark Blue wire
between ignition switch and junction block.
5) Turn ignition off. Disconnect negative battery cable.
Reconnect instrument cluster. See INSTRUMENT CLUSTER under REMOVAL &
INSTALLATION. Connect negative battery cable. Turn ignition on. Set
parking brake and observe instrument cluster brake warning light. If
brake warning light is off, go to step 7). If brake warning light is
on, go to next step.
6) Turn ignition off. Turn parking lights on and adjust
instrument panel lights dimmer rheostat to full bright position. If
instrument panel lights are on, go to step 8). If instrument panel
lights are off, repair open ground circuit to instrument cluster
connector C1 terminal No. 4 (Black/Light Green wire) or No. 5
(Black/Orange wire). See WIRING DIAGRAMS.
7) Turn ignition off and disconnect negative battery cable.
Remove instrument cluster. See INSTRUMENT CLUSTER under REMOVAL &
INSTALLATION. Connect negative battery cable. Turn ignition on.
Measure voltage between ground and instrument cluster connector C1
terminal No. 2 (Dark Blue/White wire). If battery voltage exists, go
to SELF-DIAGNOSTICS. If battery voltage does not exist, repair open
Dark Blue/White wire.
8) Turn ignition off. Disconnect negative battery cable.
Remove instrument cluster. See INSTRUMENT CLUSTER under REMOVAL &
INSTALLATION. Using an ohmmeter, check continuity between ground and
instrument cluster connector C1 terminals No. 4 (Black/Light Green
wire) and No. 5 (Black/Orange wire). If continuity exists, go to SELF\
-
Page 857 of 1691
cluster. See INSTRUMENT CLUSTER under REMOVAL & INSTALLATION.
Reconnect negative battery cable. Measure voltage between ground and
terminal No. 6 (Pink/White wire) of instrument cluster connector C1.
See Fig. 1 . If battery voltage is present, reinstall instrument
cluster and go to SELF- DIAGNOSTICS. If battery voltage is not
present, repair open circuit between fuse No. 12 (15-amp) in junction
block and instrument cluster connector C1 and go to next step.
5) Remove and inspect fuse No. 11 (10-amp) in junction block\
.
If fuse is okay, go to next step. If fuse is blown, locate and repair
cause of blown fuse. Install new fuse and recheck system operation.
6) Turn ignition on. Measure voltage between ground and power
side (Dark Blue/White wire) of fuse No. 11 (10-amp) in junction bloc\
k.
If battery voltage is present, go to step 8). If battery voltage is
not present, locate and repair open circuit to fuse No. 11. See WIRING
DIAGRAMS.
7) Turn ignition off and disconnect negative battery cable.
Install instrument cluster. Connect negative battery cable. Turn
ignition on. Set parking brake and observe instrument cluster brake
warning light. If brake warning light is on, go to next step. If brake
warning light is off, go to step 9).
8) Turn ignition off. Turn parking lights on and adjust
instrument panel lights dimmer rheostat to full bright position. If
instrument panel lights are on, go to step 10). If instrument panel
lights are off, repair instrument cluster illumination ground circuit
between instrument cluster connector C2 terminal No. 7 (Black wire)
and ground. See WIRING DIAGRAMS.
9) Turn ignition off and disconnect negative battery cable.
Remove instrument cluster. See INSTRUMENT CLUSTER under REMOVAL &
INSTALLATION. Connect negative battery cable. Turn ignition on.
Measure voltage between ground and terminal No. 2 (Dark Blue/White
wire) at instrument cluster connector C1. If battery voltage is
present, go to SELF-DIAGNOSTICS. If battery voltage is not present,
repair open circuit between junction block fuse No. 11 and instrument
cluster.
10) Turn ignition off and disconnect negative battery cable.
Remove instrument cluster. See INSTRUMENT CLUSTER under REMOVAL &
INSTALLATION. Check continuity between ground and terminal No. 4
(Black/Dark Green wire) at instrument cluster connector C1. If
continuity exists, go to SELF-DIAGNOSTICS. If continuity does not
exist, locate and repair open in ground circuit.
SELF-DIAGNOSTICS
1) With ignition off, press and hold trip odometer RESET
button while turning ignition switch to ON position. Continue to hold
RESET button until odometer window displays CHEC (about 10 seconds).
Release RESET button. If problem exists, system will display
Diagnostic Trouble Codes (DTC). See DIAGNOSTIC CODE CHART table. For
repairs of DTCs, see appropriate BODY CONTROL COMPUTER TESTS article.
DIAGNOSTIC TROUBLE (DTC) CODE CHART
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DTC Description Correction
\b\
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110 Cluster CPU, RAM Or EEPROM Fault Replace Cluster
\b\
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900 CCD Bus Inoperative Check CCD Bus Connections At
Cluster; Check Cluster
Fuses; Check CCD Bus Bias;
Check CCD Bus Voltage;
Check CCD Bus Terminations
\b\
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920 Not Receiving VSS Message From PCM Check PCM Software Level;
Page 860 of 1691
3) Turn ignition off. Disconnect washer fluid level sensor
connector. Install jumper wire between washer fluid level sensor
connector terminals. Turn ignition on. Low washer fluid level light
should illuminate. Disconnect jumper wire and light should go off. If
light performs as specified, replace washer fluid level sensor. If
light does not perform as specified, go to next step.
4) Turn ignition off. Check continuity between ground and
washer fluid level sensor connector Black wire. If continuity does not
exist, repair open Black wire between washer fluid level sensor and
ground. If continuity exists, go to next step.
5) Ensure washer fluid level sensor is still disconnected.
Turn ignition off. Remove instrument cluster. See INSTRUMENT CLUSTER
under REMOVAL & INSTALLATION. Check continuity between ground and
instrument cluster connector C2 terminal No. 2 (Black/White wire) on
Ram Pickup and terminal No. 9 (Black/Gray wire) on Ram Van and Ram
Wagon. If continuity does not exist, go to next step. If continuity
exists, repair short to ground in White/Black or Black/Gray wire
between instrument cluster and washer fluid level sensor.
6) Check continuity of Black/White wire on Ram Pickup or
Black/Gray wire on Ram Van and Ram Wagon between washer fluid level
sensor connector and instrument cluster connector C2 terminal No. 2 on
Ram Pickup or terminal No. 9 on Ram Van and Ram Wagon. See Fig. 1. If
continuity does not exist, repair open Black/White wire on Ram Pickup
or Black/Gray wire on Ram Van and Ram Wagon. If continuity exists,
replace bulb.
WAIT-TO-START LIGHT INOPERATIVE (RAM PICKUP - DIESEL)
1) Remove and inspect fuse No. 17 (10-amp) in junction block\
.
Junction block is located at left end cover of instrument panel. If
fuse is okay, go to next step. If fuse is blown, locate and repair
cause of blown fuse. Install new fuse and recheck system operation.
2) Turn ignition on. Measure voltage between ground and power
side of fuse No. 17. If battery voltage is present, go to next step.
If battery voltage is not present, locate and repair open circuit
between Power Distribution Center (PDC) and junction block.
3) Disconnect negative battery cable. Remove instrument
cluster. See INSTRUMENT CLUSTER under REMOVAL & INSTALLATION. Check
for battery voltage between ground and instrument cluster connector C1
terminal No. 2 (Dark Blue/White wire). See Fig. 1. Turn ignition on.
If battery voltage exists, go to next step. If battery voltage does
not exist, repair open Dark Blue/White wire between junction block and
instrument cluster.
4) Turn ignition off. Disconnect Powertrain Control Module
(PCM) White connector C2. PCM is located at firewall in right side of
engine compartment. Connector C2 is center connector. Check continuity
between ground and instrument cluster connector C1 terminal No. 8
(Orange/Black wire). If continuity does not exist, go to next step. If\
continuity exists, repair short to ground in Orange/Black wire between
instrument cluster and ground.
5) Install instrument cluster. Connect battery cable. Install
jumper wire between PCM White connector C2 terminal No. 20
(Orange/Black wire) and ground. See Fig. 2. Turn ignition on. Wait-to-
start light should illuminate. If wait-to-start light illuminates, see
appropriate SELF-DIAGNOSTICS article in ENGINE PERFORMANCE section. If
wait-to-start light does not illuminate, see SELF-DIAGNOSTICS.