2001 DODGE RAM lock

SPECIAL TOOLS
POWER DISTRIBUTION SYSTEMS
CIGAR LIGHTER OUTLET
DESCRIPTION
A cigar lighter is standard equipment on this
model. The cigar lighter is installed in the instru-
ment panel next to the ash receiver, which is located
near the center of the instrument panel, below the
radio. The cigar lighter base is secured by a snap fit
within the instrument panel.
The cigar lighter knob and heating element unit,
and the cigar lighter receptacle unit are available for
service. These components cannot be repaired and, if
faulty or damaged, they must be replaced.
OPERATION
The cigar lighter consists of two major components:
a knob and heating element unit, and the cigar
lighter base or receptacle shell. The receptacle shell
is connected to ground, and an insulated contact in
the bottom of the shell is connected to battery cur-
rent. The cigar lighter receives battery voltage from a
fuse in the junction block only when the ignition
switch is in the Accessory or On positions.
The knob and heating element are encased within
a spring-loaded housing, which also features a sliding
protective heat shield. When the knob and heating
element are inserted in the receptacle shell, the heat-
ing element resistor coil is grounded through its
housing to the receptacle shell. If the cigar lighter
knob is pushed inward, the heat shield slides up
toward the knob exposing the heating element, and
the heating element extends from the housing toward
the insulated contact in the bottom of the receptacle
shell.
Two small spring-clip retainers are located on
either side of the insulated contact inside the bottomof the receptacle shell. These clips engage and hold
the heating element against the insulated contact
long enough for the resistor coil to heat up. When the
heating element is engaged with the contact, battery
current can flow through the resistor coil to ground,
causing the resistor coil to heat.
When the resistor coil becomes sufficiently heated,
excess heat radiates from the heating element caus-
ing the spring-clips to expand. Once the spring-clips
expand far enough to release the heating element,
the spring-loaded housing forces the knob and heat-
ing element to pop back outward to their relaxed
position. When the cigar lighter knob and element
are pulled out of the receptacle shell, the protective
heat shield slides downward on the housing so that
the heating element is recessed and shielded around
its circumference for safety.
DIAGNOSIS & TESTING - CIGAR LIGHTER
For complete circuit diagrams, refer toCigar
Lighterin Wiring Diagrams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Check the fused ignition switch output (run/ac-
cessory) fuse in the junction block. If OK, go to Step
2. If not OK, repair the shorted circuit or component
as required and replace the faulty fuse.
(2) Turn the ignition switch to the On position.
Check for battery voltage at the fused ignition switch
output (run/accessory) fuse in the junction block. If
OK, go to Step 3. If not OK, repair the open fused
ignition switch output (run/accessory) circuit to the
ignition switch as required.
(3) Turn the ignition switch to the Off position.
Remove the cigar lighter knob and element from the
cigar lighter receptacle. Check for continuity between
the inside circumference of the cigar lighter recepta-
cle and a good ground. There should be continuity. If
OK, go to Step 4. If not OK, go to Step 5.
(4) Turn the ignition switch to the On position.
Check for battery voltage at the insulated contact
located at the back of the cigar lighter receptacle. If
OK, replace the faulty cigar lighter knob and ele-
ment. If not OK, go to Step 5.
(5) Turn the ignition switch to the Off position.
Disconnect and isolate the battery negative cable.
Remove the cigar lighter receptacle from the instru-
ment panel and disconnect the wire harness connec-Terminal Pick Kit 6680
8W - 97 - 2 8W-97 POWER DISTRIBUTIONBR/BE

tor. Check for continuity between the ground circuit
cavity of the cigar lighter wire harness connector and
a good ground. There should be continuity. If OK, go
to Step 6. If not OK, repair the open ground circuit to
ground as required.
(6) Connect the battery negative cable. Turn the
ignition switch to the On position. Check for battery
voltage at the fused ignition switch output (run/ac-
cessory) circuit cavity of the cigar lighter wire har-
ness connector. If OK, replace the faulty cigar lighter
receptacle. If not OK, repair the open fused ignition
switch output (run/accessory) circuit to the junction
block fuse as required.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Pull the cigar lighter knob and element out of
the cigar lighter receptacle base, or unsnap the pro-
tective cap from the power outlet receptacle base
(Fig. 1).
(3) Look inside the cigar lighter or power outlet
receptacle base and note the position of the rectangu-
lar retaining bosses of the mount that secures the
receptacle base to the instrument panel (Fig. 2).
(4) Insert a pair of external snap ring pliers into
the cigar lighter or power outlet receptacle base and
engage the tips of the pliers with the retaining
bosses of the mount.
(5) Squeeze the pliers to disengage the mount
retaining bosses from the receptacle base and, usinga gentle rocking motion, pull the pliers and the
receptacle base out of the mount.
(6) Pull the receptacle base away from the instru-
ment panel far enough to access the instrument
panel wire harness connector.
(7) Disconnect the instrument panel wire harness
connector from the cigar lighter or power outlet
receptacle base connector receptacle.
(8) Remove the cigar lighter or power outlet mount
from the instrument panel.
INSTALLATION
(1) Install the cigar lighter or power outlet mount
into the instrument panel.
(2) Reconnect the instrument panel wire harness
connector to the cigar lighter or power outlet recep-
tacle base connector receptacle.
(3) Align the splines on the outside of the cigar
lighter or power outlet receptacle base connector
receptacle with the grooves on the inside of the
mount.
(4) Press firmly on the cigar lighter or power out-
let receptacle base until the retaining bosses of the
mount are fully engaged in their receptacles.
Fig. 1 Cigar Lighter and Power Outlet
1 - RECEPTACLE BASE
2 - KNOB & ELEMENT
3 - MOUNT
4 - WIRE HARNESS CONNECTOR
5 - POWER OUTLET
Fig. 2 Cigar Lighter and Power Outlet Remove/
Install
1 - KNOB AND ELEMENT
2 - RETAINING BOSSES-ENGAGE PLIERS HERE
3 - BASE
4 - PARTIALLY REMOVED
5 - EXTERNAL SNAP-RING PLIERS
6 - MOUNT
7 - BASE
BR/BE8W-97 POWER DISTRIBUTION 8W - 97 - 3
CIGAR LIGHTER OUTLET (Continued)

(5) Install the cigar lighter knob and element into
the cigar lighter receptacle base, or the protective cap
into the power outlet receptacle base.
(6) Reconnect the battery negative cable.
CIRCUIT BREAKER
DESCRIPTION
An automatic resetting circuit breaker in the junc-
tion block is used to protect the system from a short
circuit, or from an overload condition caused by an
obstructed or stuck seat adjuster.
The circuit breaker cannot be repaired and, if
faulty or damaged, it must be replaced.
DIAGNOSIS & TESTING - CIRCUIT BREAKER
For circuit descriptions and diagrams, refer to Wir-
ing Diagrams.
(1) Locate the correct circuit breaker in the junc-
tion block. Pull out the circuit breaker slightly, but
be certain that the circuit breaker terminals still con-
tact the terminals in the junction block cavities.
(2) Connect the negative lead of a 12-volt DC volt-
meter to a good ground.
(3) With the voltmeter positive lead, check both
terminals of the circuit breaker for battery voltage.
If only one terminal has battery voltage, the circuit
breaker is faulty and must be replaced. If neither ter-
minal has battery voltage, repair the open circuit
from the Power Distribution Center (PDC) as
required.
GENERATOR CARTRIDGE
FUSE
DESCRIPTION
A 140 ampere generator cartridge fuse is used on
this model. The generator cartridge fuse is similar to
other cartridge fuses found in the Power Distribution
Center (PDC). This fuse has a color-coded plastic
housing and a clear plastic fuse conductor inspection
cover like other cartridge fuses, but has a higher cur-
rent rating and is connected and secured with screws
instead of being pushed onto male spade-type termi-
nals. The generator cartridge fuse cannot be repaired
and, if faulty or damaged, it must be replaced.
OPERATION
The generator cartridge fuse is secured between
the two B(+) terminal stud connection bus bars
within the Power Distribution Center (PDC). This
fuse protects the vehicle electrical system from dam-
age that could be caused by excessive charging sys-
tem output and/or excessive electrical system currentlevels resulting from a faulty generator or faulty
charging system control circuits. If the current rating
of the fuse is exceeded, the fuse conductor melts to
open the generator output circuit connection to the
PDC. If a generator cartridge fuse fails, be certain to
completely inspect and test the vehicle charging sys-
tem before replacing the fuse and returning the vehi-
cle to service. Refer toCharging Systemin the
index of this service manual for the charging system
diagnostic procedures. Refer toPower Distribution
in the index of this service manual for the location of
complete PDC circuit diagrams.
REMOVAL
If a generator cartridge fuse fails, be certain to
inspect and test the vehicle charging system before
replacing the cartridge fuse and returning the vehicle
to service. Refer toCharging Systemin the index of
this service manual for the charging system diagnos-
tic procedures.
(1) Disconnect and isolate the battery negative
cable.
(2) Unlatch and remove the cover from the Power
Distribution Center (PDC).
(3) Remove the two screws that secure the genera-
tor cartridge fuse to the two B(+) terminal stud bus
bars within the PDC.
(4) Remove the generator cartridge fuse from the
PDC.
INSTALLATION
If a generator cartridge fuse fails, be certain to
inspect and test the vehicle charging system before
replacing the cartridge fuse and returning the vehicle
to service. Refer toCharging Systemin the index of
this service manual for the charging system diagnos-
tic procedures.
(1) Position the generator cartridge fuse onto the
two B(+) terminal stud bus bars within the PDC.
(2) Install and tighten the two screws that secure
the generator cartridge fuse to the two B(+) terminal
stud bus bars within the PDC. Tighten the screws to
3.4 N´m (30 in. lbs.).Be certain that both screws
are tightened to the proper torque value.
(3) Install and latch the cover onto the PDC.
(4) Reconnect the battery negative cable.
IOD FUSE
DESCRIPTION
All vehicles are equipped with an Ignition-Off
Draw (IOD) fuse (Fig. 3) that is disconnected within
the Junction Block (JB) when the vehicle is shipped
from the factory. Dealer personnel are to reconnect
the IOD fuse in the JB as part of the preparation
8W - 97 - 4 8W-97 POWER DISTRIBUTIONBR/BE
CIGAR LIGHTER OUTLET (Continued)

procedures performed just prior to new vehicle deliv-
ery.
The left end of the instrument panel cover has a
snap-fit fuse access panel that can be removed to pro-
vide service access to the fuses in the JB. A finger
recess is molded into the access panel for easy
removal. An adhesive-backed fuse layout map is
secured to the instrument panel side of the access
panel to ensure proper fuse identification. The IOD
fuse is a 10 ampere mini blade-type fuse. The fuse is
secured within a black molded plastic fuse holder
and puller unit that serves both as a tool for discon-
necting and reconnecting the fuse in its JB cavity,
and as a fuse holder that conveniently stores the fuse
in the same JB cavity after it has been disconnected.
OPERATION
The term ignition-off draw identifies a normal con-
dition where power is being drained from the battery
with the ignition switch in the Off position. The IOD
fuse feeds the memory and sleep mode functions for
some of the electronic modules in the vehicle as well
as various other accessories that require battery cur-
rent when the ignition switch is in the Off position,
including the clock. The only reason the IOD fuse is
disconnected is to reduce the normal IOD of the vehi-
cle electrical system during new vehicle transporta-
tion and pre-delivery storage to reduce battery
depletion, while still allowing vehicle operation sothat the vehicle can be loaded, unloaded and moved
as needed by both vehicle transportation company
and dealer personnel.
The IOD fuse is disconnected from JB fuse cavity
12 when the vehicle is shipped from the assembly
plant. Dealer personnel must reconnect the IOD fuse
when the vehicle is being prepared for delivery in
order to restore full electrical system operation. Once
the vehicle is prepared for delivery, the IOD function
of this fuse becomes transparent and the fuse that
has been assigned the IOD designation becomes only
another Fused B(+) circuit fuse. The IOD fuse serves
no useful purpose to the dealer technician in the ser-
vice or diagnosis of any vehicle system or condition,
other than the same purpose as that of any other
standard circuit protection device.
The IOD fuse can be used by the vehicle owner as
a convenient means of reducing battery depletion
when a vehicle is to be stored for periods not to
exceed about thirty days. However, it must be
remembered that disconnecting the IOD fuse will not
eliminate IOD, but only reduce this normal condition.
If a vehicle will be stored for more than about thirty
days, the battery negative cable should be discon-
nected to eliminate normal IOD; and, the battery
should be tested and recharged at regular intervals
during the vehicle storage period to prevent the bat-
tery from becoming discharged or damaged. Refer to
Batteryin the index of this service manual for the
location of additional service information covering
the battery.
REMOVAL
The Ignition-Off Draw (IOD) fuse is disconnected
from Junction Block (JB) fuse cavity 12 when the
vehicle is shipped from the assembly plant. Dealer
personnel must reconnect the IOD fuse when the
vehicle is being prepared for delivery in order to
restore full electrical system operation.
(1) Turn the ignition switch to the Off position.
(2) Remove the fuse access panel by unsnapping it
from the left outboard end of the instrument panel.
(3) Grasp the upper and lower tabs of the IOD
fuse holder unit in fuse cavity 12 of the JB between
the thumb and forefinger and pull the unit firmly
outward.
(4) Install the fuse access panel by snapping it
onto the left outboard end of the instrument panel.
INSTALLATION
The Ignition-Off Draw (IOD) fuse is disconnected
from Junction Block (JB) fuse cavity 12 (Fig. 4) when
the vehicle is shipped from the assembly plant.
Dealer personnel must reconnect the IOD fuse when
the vehicle is being prepared for delivery in order to
restore full electrical system operation.
Fig. 3 Ignition-Off Draw Fuse
1 - JUNCTION BLOCK
2 - IGNITION-OFF DRAW FUSE AND HOLDER
3 - LEFT INSTRUMENT PANEL END BRACKET
BR/BE8W-97 POWER DISTRIBUTION 8W - 97 - 5
IOD FUSE (Continued)

(1) Turn the ignition switch to the Off position.
(2) To install the IOD fuse, use a thumb to press
the IOD fuse holder unit in fuse cavity 12 firmly into
the JB.
(3) Install the fuse access panel by snapping it
onto the left outboard end of the instrument panel.
JUNCTION BLOCK
DESCRIPTION
An electrical Junction Block (JB) is concealed
behind the left outboard end of the instrument panel
cover (Fig. 5). The JB combines the functions previ-
ously provided by a separate fuseblock module and
relay center, serves to simplify and centralize numer-
ous electrical components, and to distribute electrical
current to many of the accessory systems in the vehi-
cle. It also eliminates the need for numerous splice
connections and serves in place of a bulkhead connec-
tor between many of the engine compartment, instru-
ment panel, and body wire harnesses. The JB houses
up to nineteen blade-type fuses (two standard-type
and seventeen mini-type), up to two blade-type auto-
matic resetting circuit breakers, the electronic combi-
nation turn signal and hazard warning flasher, and
one International Standards Organization (ISO)
micro-relay.The molded plastic JB housing has integral mount-
ing brackets that are secured with two screws to the
left instrument panel end bracket. The left end of the
instrument panel cover has a snap-fit fuse access
panel that can be removed for service of the JB. A
fuse puller and spare fuse holders are located on the
back of the fuse access cover, as well as an adhesive-
backed fuse layout map to ensure proper fuse identi-
fication.
The JB unit cannot be repaired and is only ser-
viced as an assembly. If any internal circuit or the JB
housing is faulty or damaged, the entire JB unit
must be replaced.
OPERATION
All of the circuits entering and leaving the JB do
so through up to nine wire harness connectors, which
are connected to the JB through integral connector
receptacles molded into the JB housing. Internal con-
nection of all of the JB circuits is accomplished by an
intricate combination of hard wiring and bus bars.
Refer toJunction Blockin the index of this service
manual for the location of complete JB circuit dia-
grams.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
Fig. 4 Ignition-Off Draw Fuse
1 - JUNCTION BLOCK
2 - IGNITION-OFF DRAW FUSE AND HOLDER
3 - LEFT INSTRUMENT PANEL END BRACKET
Fig. 5 Junction Block Location
1 - JUNCTION BLOCK
2 - FUSE ACCESS PANEL
8W - 97 - 6 8W-97 POWER DISTRIBUTIONBR/BE
IOD FUSE (Continued)

(2) Roll down the instrument panel from the dash
panel, but do not remove it from the vehicle. Refer to
Instrument Panel Assemblyin the index of this
service manual for the instrument panel assembly
removal procedures.
(3) Reach through the outboard side of the instru-
ment panel steering column opening to access and
disconnect all of the wire harness connectors from
the Junction Block (JB) connector receptacles (Fig.
6).
(4) Reach through the outboard side of the instru-
ment panel steering column opening to access and
remove the two screws that secure the JB to the left
instrument panel end bracket.
(5) Reach through the outboard side of the instru-
ment panel steering column opening to remove the
JB from the left instrument panel end bracket.
INSTALLATION
NOTE: If the Junction Block (JB) is being replaced
with a new unit, be certain to transfer each of the
fuses, circuit breakers and relays from the faulty JB
to the proper cavities of the replacement JB. Refer
to Junction Block in the index of this service man-
ual for the location of complete circuit diagrams
and cavity assignments for the JB.(1) Reach through the outboard side of the instru-
ment panel steering column opening to position the
JB onto the left instrument panel end bracket.
(2) Reach through the outboard side of the instru-
ment panel steering column opening to install and
tighten the two screws that secure the JB to the left
instrument panel end bracket. Tighten the screws to
2.85 N´m (25 in. lbs.).
(3) Reach through the outboard side of the instru-
ment panel steering column opening to access and
reconnect all of the wire harness connectors to the
JB connector receptacles.
(4) Install the instrument panel onto the dash
panel. Refer toInstrument Panel Assemblyin the
index of this service manual for the location of the
instrument panel assembly installation procedures.
(5) Reconnect the battery negative cable.
POWER DISTRIBUTION
CENTER
DESCRIPTION
All of the electrical current distributed throughout
this vehicle is directed through the standard equip-
ment Power Distribution Center (PDC) (Fig. 7). The
molded plastic PDC housing is located in the left
front corner of the engine compartment, just behind
the battery. The PDC houses the generator cartridge
fuse and up to twelve maxi-type cartridge fuses,
Fig. 6 Junction Block Remove/Install
1 - END BRACKET
2 - JUNCTION BLOCK
3 - SCREWS
Fig. 7 Power Distribution Center Location
1 - POWER DISTRIBUTION CENTER
BR/BE8W-97 POWER DISTRIBUTION 8W - 97 - 7
JUNCTION BLOCK (Continued)

ENGINE
TABLE OF CONTENTS
page page
ENGINE 3.9L.............................. 1
ENGINE 5.2L............................. 59
ENGINE 5.9L............................ 116ENGINE 8.0L............................ 171
ENGINE 5.9L DIESEL..................... 229
ENGINE 3.9L
TABLE OF CONTENTS
page page
ENGINE 3.9L
DESCRIPTION............................3
DIAGNOSIS AND TESTING..................3
ENGINE DIAGNOSIS - INTRODUCTION.......3
PERFORMANCE........................4
MECHANICAL..........................6
LUBRICATION..........................8
CYLINDER COMPRESSION PRESSURE......9
CYLINDER COMBUSTION PRESSURE
LEAKAGE..............................9
REAR SEAL AREA LEAKS................10
STANDARD PROCEDURE..................10
CYLINDER BORE HONING...............10
HYDROSTATIC LOCK....................11
REPAIR DAMAGED OR WORN THREADS....11
FORM-IN-PLACE GASKETS AND SEALERS . . . 11
REMOVAL..............................12
INSTALLATION...........................13
SPECIFICATIONS........................14
SPECIAL TOOLS.........................19
AIR CLEANER ELEMENT
REMOVAL..............................21
INSTALLATION...........................21
CYLINDER HEAD
DESCRIPTION...........................22
OPERATION.............................22
DIAGNOSIS AND TESTING.................22
CYLINDER HEAD GASKET FAILURE........22
REMOVAL..............................23
CLEANING..............................23
INSPECTION............................23
INSTALLATION...........................23
CYLINDER HEAD COVER(S)
REMOVAL..............................24
CLEANING..............................24INSPECTION............................24
INSTALLATION...........................24
INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION...........................25
STANDARD PROCEDURE..................25
VALVES, GUIDES AND SPRINGS...........25
REMOVAL..............................27
CLEANING..............................27
INSPECTION............................27
INSTALLATION...........................28
ENGINE BLOCK
CLEANING..............................28
INSPECTION............................28
CAMSHAFT & BEARINGS (IN BLOCK)
REMOVAL..............................29
INSTALLATION...........................29
CONNECTING ROD BEARINGS
STANDARD PROCEDURE..................31
CONNECTING ROD BEARING FITTING......31
CRANKSHAFT
DESCRIPTION...........................31
OPERATION.............................31
REMOVAL..............................31
INSTALLATION...........................32
CRANKSHAFT MAIN BEARINGS
DESCRIPTION...........................32
OPERATION.............................32
STANDARD PROCEDURE..................33
MAIN BEARING FITTING.................33
REMOVAL..............................33
INSTALLATION...........................34
CRANKSHAFT OIL SEAL - FRONT
DESCRIPTION...........................34
OPERATION.............................34
REMOVAL..............................34
BR/BEENGINE 9 - 1

INSTALLATION...........................34
CRANKSHAFT OIL SEAL - REAR
DESCRIPTION...........................34
OPERATION.............................34
REMOVAL..............................35
INSTALLATION...........................35
DISTRIBUTOR BUSHING
REMOVAL..............................37
INSTALLATION...........................37
HYDRAULIC LIFTERS (CAM IN BLOCK)
DIAGNOSIS AND TESTING.................38
HYDRAULIC TAPPETS...................38
REMOVAL..............................39
CLEANING..............................39
INSTALLATION...........................39
PISTON & CONNECTING ROD
DESCRIPTION...........................40
STANDARD PROCEDURE..................40
PISTON FITTING.......................40
REMOVAL..............................40
CLEANING..............................41
INSPECTION............................41
INSTALLATION...........................41
PISTON RINGS
STANDARD PROCEDURE..................41
PISTON RING FITTING..................41
VIBRATION DAMPER
REMOVAL..............................42
INSTALLATION...........................42
FRONT MOUNT
REMOVAL..............................43
INSTALLATION...........................43
REAR MOUNT
REMOVAL..............................44
INSTALLATION...........................44
LUBRICATION
DESCRIPTION...........................45
OPERATION.............................45
DIAGNOSIS AND TESTING.................47
ENGINE OIL PRESSURE.................47
ENGINE OIL LEAKS.....................47
OIL
STANDARD PROCEDURE..................47
ENGINE OIL...........................47OIL FILTER
REMOVAL..............................48
INSTALLATION...........................48
OIL PAN
REMOVAL..............................48
CLEANING..............................49
INSPECTION............................49
INSTALLATION...........................49
OIL PRESSURE SENSOR/SWITCH
DESCRIPTION...........................49
OPERATION.............................49
OIL PUMP
REMOVAL..............................50
DISASSEMBLY...........................50
CLEANING..............................50
INSPECTION............................50
ASSEMBLY.............................51
INSTALLATION...........................52
INTAKE MANIFOLD
DESCRIPTION...........................52
OPERATION.............................52
DIAGNOSIS AND TESTING.................53
INTAKE MANIFOLD LEAKAGE.............53
REMOVAL..............................53
CLEANING..............................53
INSPECTION............................53
INSTALLATION...........................53
EXHAUST MANIFOLD
DESCRIPTION...........................55
OPERATION.............................55
REMOVAL..............................55
CLEANING..............................55
INSPECTION............................55
INSTALLATION...........................55
TIMING BELT / CHAIN COVER(S)
REMOVAL..............................56
INSTALLATION...........................56
TIMING BELT/CHAIN TENSIONER
DESCRIPTION...........................57
OPERATION.............................57
TIMING BELT/CHAIN AND SPROCKETS
REMOVAL..............................57
INSPECTION............................58
INSTALLATION...........................58
9 - 2 ENGINE 3.9LBR/BE