2003 DODGE RAM app

CONNECTOR
REMOVAL
(1) Disconnect battery.
(2) Release Connector Lock (Fig. 10).
(3) Disconnect the connector being repaired from
its mating half/component.
(4) Remove the dress cover (if applicable) (Fig. 10).
(5) Release the Secondary Terminal Lock, if
required (Fig. 11).
(6) Position the connector locking finger away from
the terminal using the proper special tool. Pull on
the wire to remove the terminal from the connector
(Fig. 12).
INSTALLATION
(1) Insert the removed terminal in the same cavity
on the repair connector.
(2) Repeat steps for each terminal in the connec-
tor, being sure that all wires are inserted into the
proper cavities. For additional connector pin-out
identification, refer to the wiring diagrams.
(3) When the connector is re-assembled, the sec-
ondary terminal lock must be placed in the locked
position to prevent terminal push out.
(4) Replace dress cover (if applicable).
(5) Connect connector to its mating half/compo-
nent.
(6) Connect battery and test all affected systems.
Fig. 10 REMOVAL OF DRESS COVER
1 - DRESS COVER
2 - CONNECTOR LOCK
3 - CONNECTOR
DR8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 11

DIODE
REMOVAL
(1) Disconnect the battery.
(2) Locate the diode in the harness, and remove
the protective covering.
(3) Remove the diode from the harness, pay atten-
tion to the current flow direction (Fig. 13).
INSTALLATION
(1) Remove the insulation from the wires in the
harness. Only remove enough insulation to solder in
the new diode.
(2) Install the new diode in the harness, making
sure current flow is correct. If necessary, refer to the
appropriate wiring diagram for current flow (Fig. 13).
(3) Solder the connection together using rosin core
type solder only.Do not use acid core solder.
(4) Tape the diode to the harness using electrical
tape. Make sure the diode is completely sealed from
the elements.
(5) Re-connect the battery and test affected sys-
tems.
TERMINAL
REMOVAL
(1) Follow steps for removing terminals described
in the connector removal section.
(2) Cut the wire 6 inches from the back of the con-
nector.
INSTALLATION
(1) Select a wire from the terminal repair kit that
best matches the color and gage of the wire being
repaired.
(2) Cut the repair wire to the proper length and
remove one±half (1/2) inch of insulation.
(3) Splice the repair wire to the wire harness (see
wire splicing procedure).
(4) Insert the repaired wire into the connector.
(5) Install the connector locking wedge, if required,
and reconnect the connector to its mating half/compo-
nent.
(6) Re-tape the wire harness starting at 1±1/2
inches behind the connector and 2 inches past the
repair.
(7) Connect battery and test all affected systems.
Fig. 13 DIODE IDENTIFICATION
1 - CURRENT FLOW
2 - BAND AROUND DIODE INDICATES CURRENT FLOW
3 - DIODE AS SHOWN IN THE DIAGRAMS
8W - 01 - 14 8W-01 WIRING DIAGRAM INFORMATIONDR

WIRE
STANDARD PROCEDURE - WIRE SPLICING
When splicing a wire, it is important that the cor-
rect gage be used as shown in the wiring diagrams.
(1) Remove one-half (1/2) inch of insulation from
each wire that needs to be spliced.
(2) Place a piece of adhesive lined heat shrink tub-
ing on one side of the wire. Make sure the tubing will
be long enough to cover and seal the entire repair
area.
(3) Place the strands of wire overlapping each
other inside of the splice clip (Fig. 14).
(4) Using crimping tool, Mopar p/n 05019912AA,
crimp the splice clip and wires together (Fig. 15).(5) Solder the connection together using rosin core
type solder only (Fig. 16).
CAUTION: DO NOT USE ACID CORE SOLDER.
(6) Center the heat shrink tubing over the joint
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing (Fig. 17).
Fig. 14 SPLICE BAND
1 - SPLICE BAND
Fig. 15 CRIMPING TOOL
1 - CRIMPING TOOL
Fig. 16 SOLDER SPLICE
1 - SOLDER
2 - SPLICE BAND
3 - SOLDERING IRON
Fig. 17 HEAT SHRINK TUBE
1 - SEALANT
2 - HEAT SHRINK TUBE
DR8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 15

A/C-HEATER CONTROL C1 - BLACK 16 WAY
CAV CIRCUIT FUNCTION
1 F15 20DB FUSED IGNITION SWITCH OUTPUT (RUN)
2 Z120 20WT/BK GROUND
3 C57 20DB/GY SENSOR GROUND
4 C33 20DB/RD MODE DOOR 2 DRIVER
5- -
6 C12 20LG/BK EVAPORATOR TEMPERATURE SENSOR SIGNAL
7- -
8 Y165 20OR/YL PANEL LAMPS DRIVER
9 C62 20DB/PK BLEND DOOR DRIVER
10 C35 20DG/YL MODE DOOR 1 DRIVER
11 C34 20DB/WT COMMON DOOR DRIVER
12 C32 20GY/DB RECIRCULATION DOOR DRIVER
13 C46 20YL/LG PASSENGER BLEND DOOR DRIVER
14 - -
15 C16 20LB/YL HEATED MIRROR RELAY CONTROL
16 D25 20VT/LG PCI BUS
A/C-HEATER CONTROL C2 - BLACK 10 WAY
CAV CIRCUIT FUNCTION
1- -
2 C4 16TN BLOWER MOTOR LOW DRIVER
3 C6 14LB BLOWER MOTOR M2 DRIVER
4- -
5 Z37 10BK/DB GROUND
6- -
7 C5 16LG BLOWER MOTOR M1 DRIVER
8- -
9- -
10 C7 10BK/TN BLOWER MOTOR HIGH DRIVER
ACCELERATOR PEDAL POSITION SENSOR (5.7L/DIESEL M/T NORMAL BUILD)-6WAY
CAV CIRCUIT FUNCTION
1 K81 20DB/DG APPS NO. 2 SIGNAL
2 K6 20VT/WT 5-VOLT SUPPLY
3 K7 20OR 5-VOLT SUPPLY
4 K981 20BR/DG APPS NO. 2 RETURN
5 K255 20WT/DG APPS NO. 1 SIGNAL
6 K223 20PK/DB APPS NO. 1 RETURN
8W - 80 - 6 8W-80 CONNECTOR PIN-OUTSDR

ELECTRONIC THROTTLE CONTROL MODULE (5.7L) - BLACK 6 WAY
CAV CIRCUIT FUNCTION
1 K22 18OR/DB TP NO.1 SIGNAL
2 K7 18OR 5 VOLT SUPPLY
3 F888 18BR/PK ETC MOTOR(+)
4 K122 18DB/GY TP NO.2 SIGNAL
5 F855 18OR/PK ETC MOTOR(-)
6 K101 18WT TP SENSOR RETURN
ENGINE CONTROL MODULE - C1 (DIESEL) - 60 WAY
CAV CIRCUIT FUNCTION
1- -
2- -
3- -
4 D1 18VT/BR CCD BUS (+)
5 D2 18WT/BK CCD BUS (-)
6 K65 18OR/RD FUEL PUMP SUPPLY
7 K20 18DG GENERATOR FIELD CONTROL
8- -
9- -
10 - -
11 - -
12 K102 18PK/BK FUEL PRESSURE SENSOR SIGNAL
13 - -
14 K232 18YL APPS SIGNAL
15 K21 18BK/RD INTAKE AIR TEMPERATURE SENSOR SIGNAL
16 - -
17 K2 18TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
18 - -
19 K31 18BR FUEL PUMP RELAY CONTROL
20 - -
21 - -
22 G17 18WT/TN SPEEDOMETER SIGNAL
23 K104 18RD/WT SENSOR GROUND
24 K53 18DB/RD HALL EFFECT
25 Y501 18DB/YL 5 VOLT SUPPLY
26 C18 18DB A/C PRESSURE SIGNAL
27 K6 18VT/WT 5 VOLT SUPPLY
28 - -
29 Y502 18DG/YL INLET AIR TEMPERATURE/PRESSURE RETURN
30 K118 16WT/DB BATTERY TEMPERATURE SENSOR SIGNAL
31 G20 18VT/YL IGNITION SWITCH SENSE
32 K55 18LB/WT MASS AIR FLOW SENSOR SIGNAL
33 K56 18LG/OR APPS SENSOR RETURN
34 K49 18VT/BK APPS IDLE SWITCH
35 - -
36 K14 16RD/WT FUEL INJECTOR NO. 4 DRIVER
37 - -
8W - 80 - 54 8W-80 CONNECTOR PIN-OUTSDR

ENGINE CONTROL MODULE - C1 (DIESEL) - 60 WAY
CAV CIRCUIT FUNCTION
38 - -
39 - -
40 K13 16TN FUEL INJECTOR NO. 3 DRIVER
41 - -
42 K900 18DB/DG 5 VOLT SUPPLY
43 K9 18LB 5 VOLT SUPPLY
44 K101 18WT APPS NOT IDLE SWITCH
45 K62 18BR/DB LETF PUMP
46 K58 16BR/DB FUEL INJECTOR NO. 6 DRIVER
47 - -
48 - -
49 - -
50 K12 16YL/WT FUEL INJECTOR NO. 2 DRIVER
51 - -
52 K167 18BR/YL ACCELERATOR PEDAL POSITION SENSOR GROUND
NO. 1
53 G910 18VT/RD FUEL PRESSURE SENSOR SIGNAL RETURN
54 K72 18DG/OR MAP SENSOR SIGNAL
55 - -
56 K38 16GY FUEL INJECTOR NO. 5 DRIVER
57 K92 16TN/PK COIL ON PLUG DRIVER NO. 2
58 - -
59 K91 16TN/RD COIL ON PLUG DRIVER NO. 1
60 - -
ENGINE CONTROL MODULE - C2 (DIESEL) - 50 WAY
CAV CIRCUIT FUNCTION
1 K22 18DR/DB THROTTLE POSITION SENSOR SIGNAL
2 K24 18WT/DG CRANKSHAFT POSITION SENSOR SIGNAL
3 K69 18 BR/LB INJECTOR CONTROL SIGNAL NO.1
4- -
5 K154 18GY GLOW PLUG RELAY NO. 1 OUTPUT
6 K152 18WT GLOW PLUG RELAY NO. 1 CONTROL
7- -
8- -
9- -
10 Y5 18OR FAN SPEED SENSOR
11 G7 18WT/OR VEHICLE SPEED SIGNAL
12 G60 18GY/YL ENGINE OIL PRESSURE SWITCH SENSE
13 - -
14 - -
15 - -
16 D21 18PK SCI TRANSMIT
17 - -
18 - -
19 D20 18LG SCI RECEIVE
20 A140 16DG/WT FUSED B(+)
21 Z816 16BK/TN GROUND
22 - -
23 Y3 18WT -
24 K4 18BK/LB SENSOR GROUND
25 - -
26 G8 18 LB/BK FUEL LEVEL SENSOR SIGNAL
27 K77 18 BR/WT TRANSFER CASE POSITION SENSOR INPUT
DR8W-80 CONNECTOR PIN-OUTS 8W - 80 - 55

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

POWERTRAIN CONTROL MODULE C4 (NGC) - GREEN 38 WAY
CAV CIRCUIT FUNCTION
1 T60 18BR (4.7L) OVERDRIVE SOLENOID CONTROL
2 T159 18DG/WT (4.7L) 4C SOLENOID CONTROL
3 Y207 18RD/WT (5.7L) TPS NO. 1 OUTPUT
4 T140 18VT/LG (4.7L) PRESSURE CONTROL SOLENOID CONTROL
5 Y208 18DB/YL (5.7L) APPS NO. 1 OUTPUT
6 T119 18WT/DB (4.7L) 2C SOLENOID CONTROL
7 T10 18YL/DG (5.7L) TORQUE MANAGEMENT REQUEST SENSE
8 T59 18PK (4.7L) UNDERDRIVE SOLENOID CONTROL
9 Y209 18TN/BK (5.7L) SENSOR GROUND
10 T120 18LG (4.7L) LR SOLENOID CONTROL
11 T118 18YL/DB (4.7L) PRESSURE CONTROL SOLENOID CONTROL
11 Y210 18YL/RD (5.7L EATX) RPM SIGNAL
12 Z13 16BK/RD (4.7L) GROUND
13 Z13 16BK/RD (4.7L) GROUND
14 Z13 16BK/RD (4.7L) GROUND
15 T1 18LG/BK (4.7L) TRS T1 SENSE
16 T3 18VT (4.7L) TRS T3 SENSE
17 T6 18OR/WT (4.7L) OVERDRIVE OFF SWITCH SENSE
18 K30 18PK (4.7L) TRANSMISSION CONTROL RELAY CONTROL
19 T16 16RD (4.7L) TRANSMISSION CONTROL RELAY OUTPUT
20 T48 18DB (4.7L) 4C PRESSURE SWITCH SENSE
21 T29 18GY (4.7L) UNDERDRIVE PRESSURE SWITCH SENSE
22 T9 18OR/BK (4.7L) OVERDRIVE PRESSURE SWITCH SENSE
23 - -
24 - -
25 - -
26 T4 18PK/OR (4.7L) TRS T2 SENSE
27 - -
28 T16 16RD (4.7L) TRANSMISSION CONTROL RELAY OUTPUT
29 T50 18DG (4.7L) LOW/REVERSE PRESSURE SWITCH SENSE
30 T147 18LB (4.7L) 2C PRESSURE SWITCH SENSE
31 T38 18VT/TN (4.7L) LINE PRESSURE SENSOR SIGNAL
32 T14 18LG/WT (4.7L) OUTPUT SPEED SENSOR SIGNAL
33 T52 18RD/BK (4.7L) INPUT SPEED SENSOR SIGNAL
34 T13 18DB/BK (4.7L) SPEED SENSOR GROUND
35 T54 18VT (4.7L) TRANSMISSION TEMPERATURE SENSOR SIGNAL
36 - -
37 T42 18VT/WT (4.7L) TRS T42 SENSE
38 T16 16RD (4.7L) TRANSMISSION CONTROL RELAY OUTPUT
DR8W-80 CONNECTOR PIN-OUTS 8W - 80 - 93