2003 DODGE RAM Service Repair Manual

rear entertainment bluetooth oil change fuel tank capacity brake light spare tire

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DODGE RAM 2003 Service Repair Manual (4) Move starter motor towards front of vehicle far
enough for nose of starter pinion housing to clear
housing. Always support starter motor during this
process. Do not let starter motor hang from wir

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DODGE RAM 2003 Service Repair Manual housing. Always support starter motor during this
process, do not let starter motor hang from wire har-
ness.
(8) Tilt nose downwards and lower starter motor
far enough to access and remove nut that s

housing. Always support starter motor during this
process, do not let starter motor hang from wire har-
ness.
(8) Tilt nose downwards and lower starter motor
far enough to access and remove nut that secures
battery positive cable wire harness connector eyelet
to solenoid battery terminal stud. Do not let starter
motor hang from wire harness.
(9) Remove battery positive cable wire harness
connector eyelet from solenoid battery terminal stud.
(10) Disconnect battery positive cable wire harness
connector from solenoid terminal connector recepta-
cle.
(11) Remove starter motor.
INSTALLATION
3.7L / 4.7L
(1) Connect solenoid wire to starter motor (snaps
on).
(2) Position battery cable to solenoid stud. Install
and tighten battery cable eyelet nut. Refer to Torque
Specifications. Do not allow starter motor to hang
from wire harness.
(3) Position starter motor to transmission.
(4) If equipped with automatic transmission, slide
cooler tube bracket into position.(5) Install and tighten both bolts (auto. trans.), or
1 nut and 1 bolt (man. trans.). Refer to Torque Spec-
ifications.
(6) Lower vehicle.
(7) Connect negative battery cable.
5.7L
(1) Connect solenoid wire to starter motor (snaps
on).
(2) Position battery cable to solenoid stud. Install
and tighten battery cable eyelet nut. Refer to Torque
Specifications. Do not allow starter motor to hang
from wire harness.
(3) Position starter motor to engine.
(4) If equipped with automatic transmission, slide
cooler tube bracket into position.
(5) Install and tighten both mounting bolts. Refer
to Torque Specifications.
(6) Lower vehicle.
(7) Connect negative battery cable.
5.9L Diesel
(1)If Equipped:Position and hold aluminum
spacer to rear of starter while positioning starter to
engine.
(2) Connect solenoid wire to starter motor. Tighten
nut.
(3) Position battery cable to starter stud. Install
and tighten battery cable nut. Refer to Torque Spec-
ifications. Do not allow starter motor to hang from
wire harness.
(4) Position starter motor to transmission.
(5) If equipped with automatic transmission, slide
cooler tube bracket into position.
(6) Install and tighten 3 starter mounting bolts.
Refer to Torque Specifications.
(7) Lower vehicle.
(8) Connect both negative battery cables to both
batteries.
5.9L Gas
(1) Connect solenoid wire to starter motor (snaps
on).
(2) Position battery cable to solenoid stud. Install
and tighten battery cable eyelet nut. Refer to Torque
Specifications. Do not allow starter motor to hang
from wire harness.
(3) Position starter motor to transmission.
(4) If equipped with automatic transmission, slide
cooler tube bracket into position.
(5) Install and tighten both bolts (auto. trans.), or
1 nut and 1 bolt (man. trans.). Refer to Torque Spec-
ifications.
(6) Lower vehicle.
(7) Connect negative battery cable.
Fig. 14 STARTER R/I - 5.9L GAS
1 - ENGINE
2 - STARTER MOUNTING FLANGE
3 - STUD
4 - STARTER MOTOR
5 - LOCK WASHER
6 - NUT
7 - BRACKET
8 - BOLT
9 - POSITIVE BATTERY CABLE WIRE HARNESS
10 - POSITIVE BATTERY CABLE WIRE HARNESS NUT
DRSTARTING 8F - 37
STARTER MOTOR (Continued)

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DODGE RAM 2003 Service Repair Manual STARTER MOTOR RELAY
DESCRIPTION
The starter relay is an electromechanical device
that switches battery current to the pull-in coil of the
starter solenoid when ignition switch is turned to
Start posit

STARTER MOTOR RELAY
DESCRIPTION
The starter relay is an electromechanical device
that switches battery current to the pull-in coil of the
starter solenoid when ignition switch is turned to
Start position. The starter relay is located in the
Power Distribution Center (PDC) in the engine com-
partment. See PDC cover for relay identification and
location.
The starter relay is a International Standards
Organization (ISO) relay. Relays conforming to ISO
specifications have common physical dimensions, cur-
rent capacities, terminal patterns, and terminal func-
tions.
The starter relay cannot be repaired or adjusted. If
faulty or damaged, it must be replaced.
OPERATION
The ISO relay consists of an electromagnetic coil, a
resistor or diode, and three (two fixed and one mov-
able) electrical contacts. The movable (common feed)
relay contact is held against one of the fixed contacts
(normally closed) by spring pressure. When electro-
magnetic coil is energized, it draws the movable con-
tact away from normally closed fixed contact, and
holds it against the other (normally open) fixed con-
tact.
When electromagnetic coil is de-energized, spring
pressure returns movable contact to normally closed
position. The resistor or diode is connected in parallel
with electromagnetic coil within relay, and helps to
dissipate voltage spikes produced when coil is de-en-
ergized.
DIAGNOSIS AND TESTING - STARTER RELAY
The starter relay (Fig. 15) is located in Power Dis-
tribution Center (PDC). Refer to PDC cover for relay
identification and location. For complete starter relay
wiring circuit diagrams, refer to 8, Wiring Diagrams.
(1) Remove starter relay from PDC.
(2) A relay in de-energized position should have
continuity between terminals 87A and 30, and no
continuity between terminals 87 and 30. If OK, go to
Step 3. If not OK, replace faulty relay.
(3) Resistance between terminals 85 and 86 (elec-
tromagnet) should be 75 5 ohms. If OK, go to Step
4. If not OK, replace faulty relay.
(4) Connect 12V battery to terminals 85 and 86.
There should now be continuity between terminals
30 and 87, and no continuity between terminals 87A
and 30. If OK, perform Relay Circuit Test that fol-
lows. If not OK, replace faulty relay.RELAY CIRCUIT TEST
(1) The relay common feed terminal cavity (30) is
connected to battery voltage and should be hot at all
times. If OK, go to Step 2. If not OK, repair open cir-
cuit to fuse in PDC as required.
(2) The relay normally closed terminal (87A) is
connected to terminal 30 in the de-energized position,
but is not used for this application. Go to Step 3.
(3) The relay normally open terminal (87) is con-
nected to common feed terminal (30) in the energized
position. This terminal supplies battery voltage to
starter solenoid field coils. There should be continu-
ity between cavity for relay terminal 87 and starter
solenoid terminal at all times. If OK, go to Step 4. If
not OK, repair open circuit to starter solenoid as
required.
(4) The coil battery terminal (86) is connected to
electromagnet in relay. It is energized when ignition
switch is held in Start position. On vehicles with
manual transmission, clutch pedal must be fully
depressed for this test. Check for battery voltage at
cavity for relay terminal 86 with ignition switch in
Start position, and no voltage when ignition switch is
released to On position. If OK, go to Step 5. If not
OK with automatic transmission, check for open or
short circuit to ignition switch and repair, if required.
If circuit to ignition switch is OK, refer toIgnition
Switch and Key Lock Cylinder. If not OK with a
manual transmission, check circuit between relay
and clutch pedal position switch for open or a short.
If circuit is OK, refer toClutch Pedal Position
Switchin 6 , Clutch.
Fig. 15 TYPE 1 RELAY
TERMINAL LEGEND
NUMBER IDENTIFICATION
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
8F - 38 STARTINGDR

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DODGE RAM 2003 Service Repair Manual (5) The coil ground terminal (85) is connected to
the electromagnet in the relay. On vehicles with
manual transmission, it is grounded at all times. On
vehicles with automatic transmission, it is grou

Page 445 of 2895

Page 446 of 2895

DODGE RAM 2003 Service Repair Manual HEATED SYSTEMS
TABLE OF CONTENTS
page page
HEATED MIRRORS......................... 1 HEATED SEATSYSTEM..................... 3
HEATED MIRRORS
TABLE OF CONTENTS
page page
HEATED MIRRORS
DESCRIPTION - HE

HEATED SYSTEMS
TABLE OF CONTENTS
page page
HEATED MIRRORS......................... 1 HEATED SEATSYSTEM..................... 3
HEATED MIRRORS
TABLE OF CONTENTS
page page
HEATED MIRRORS
DESCRIPTION - HEATED MIRROR SYSTEM . . . 1
OPERATION - HEATED MIRROR SYSTEM.....1DIAGNOSIS AND TESTING - HEATED
MIRROR SYSTEM......................2
HEATED MIRRORS
DESCRIPTION - HEATED MIRROR SYSTEM
Electrically heated outside rear view mirrors are
an additional factory-installed option on models that
are equipped with factory-installed dual power mir-
rors. Vehicles with this option can be visually identi-
fied by the International Control and Display Symbol
icon for rear window defogger, which appears on thelower inboard corner of each outside mirror glass
(Fig. 1); or, by the heated mirror switch that is
located in the lower left corner of the a/c heater con-
trol unit face plate. The heated mirror system helps
the vehicle operator maintain outside rear view mir-
ror visibility during inclement operating conditions
by keeping both outside mirror glasses clear of ice,
snow, or fog. The heated mirror system for this vehi-
cle includes the following major components:
²The heated mirror switch, including the heated
mirror system solid state electronic control logic and
timer circuitry, the heated mirror relay and the
heated mirror system indicator lamp. All of these
components are integral to the a/c heater control unit
on the instrument panel.
²The two outside mirror heating grids, which are
integral to the power outside mirror units.
Following are general descriptions of the major
components in the heated mirror system. See the
owner's manual in the vehicle glove box for more
information on the features, use and operation of the
heated mirror system.
OPERATION - HEATED MIRROR SYSTEM
The solid state electronic control logic and timer
circuitry for the heated mirror system receives bat-
tery current from a fuse in the Junction Block (JB)
only when the ignition switch is in the On or Start
positions. After the heated mirror system is turned
On, the electronic control logic and timer circuitry
will automatically turn the system off after a pro-
grammed time interval of about fifteen minutes.
After the initial time interval has expired, if the
Fig. 1 HEATED MIRROR- typical
1 - POWER HEATED OUTSIDE REAR VIEW MIRROR
2 - REAR WINDOW DEFOGGER ICON
DRHEATED SYSTEMS 8G - 1

Page 447 of 2895

DODGE RAM 2003 Service Repair Manual heated mirror switch is depressed and released a sec-
ond time during the same ignition cycle, the elec-
tronic control logic and timer circuitry will
automatically turn the heated mirror system off a

heated mirror switch is depressed and released a sec-
ond time during the same ignition cycle, the elec-
tronic control logic and timer circuitry will
automatically turn the heated mirror system off after
a programmed time interval of about five minutes.
The heated mirror system will be shut off automati-
cally if the ignition switch is turned to the Off or
Accessory positions. After the heated mirror system
is turned On, it can also be turned off manually by
depressing and releasing the heated mirror switch a
second time.
When the heated mirror system is turned On, the
heated mirror system control logic and timer cir-
cuitry energizes the heated mirror system indicator
lamp and the heated mirror relay. When energized,
the heated mirror relay supplies fused ignition
switch output (run/start) current from a fuse in the
JB to the outside mirror heating grids located behind
the mirror glass of each of the outside rear view mir-
rors. When energized, each of the outside mirror
heating grids produces enough heat to warm the
glass of the outside rear view mirrors.
DIAGNOSIS AND TESTING - HEATED MIRROR
SYSTEM
If only one of the outside mirror heating grids is
inoperative, perform continuity checks on the circuits
and heater grid for that mirror only. If both outside
mirror heating grids are inoperative, proceed with
the heated mirror system diagnosis as follows. (Refer
to Appropriate Wiring Information).
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.The operation of the heated mirror system can be
confirmed in one of the following manners:
1. Turn the ignition switch to the On position.
While monitoring the instrument panel voltmeter,
momentarily depress and release the heated mirror
switch. When the heated mirror system is turned On,
a distinct voltmeter needle deflection should be
noted.
2. Turn the ignition switch to the On position.
Momentarily depress and release the heated mirror
switch to turn the heated mirror system On. The
heated mirror operation can be checked by feeling
the outside rear view mirror glass. A distinct differ-
ence in temperature between the unheated and
heated mirror glass can be detected within three to
four minutes of system operation.
The above checks will confirm system operation.
Illumination of the heated mirror system indicator
lamp means that there is electrical current available
at the heated mirror relay, but does not confirm that
the electrical current is reaching the outside mirror
heating grids.
If the heated mirror system does not operate, the
problem should be isolated in the following manner:
(1) Confirm that the ignition switch is in the On
position.
(2) Check the fuses in the Power Distribution Cen-
ter (PDC) and in the Junction Block (JB). The fuses
must be tight in their receptacles and all electrical
connections must be secure.
When the above steps have been completed and
both outside mirror heating grids are still inopera-
tive, one or more of the following is faulty:
²Heated mirror switch, electronic control logic
and timer circuitry, and heated mirror relay.
²Heated mirror wire harness circuits or connec-
tors.
²Outside mirror heating grid (both mirror grids
would have to be faulty).
If turning On the heated mirror system produces a
severe voltmeter deflection or fuse failures, check for
a shorted circuit between the output of the heated
mirror relay and the outside mirror heating grids.
8G - 2 HEATED MIRRORSDR
HEATED MIRRORS (Continued)

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DODGE RAM 2003 Service Repair Manual HEATED SEAT SYSTEM
TABLE OF CONTENTS
page page
HEATED SEAT SYSTEM
DESCRIPTION..........................3
OPERATION............................4
DIAGNOSIS AND TESTING - HEATED SEAT
SYSTEM..............

HEATED SEAT SYSTEM
TABLE OF CONTENTS
page page
HEATED SEAT SYSTEM
DESCRIPTION..........................3
OPERATION............................4
DIAGNOSIS AND TESTING - HEATED SEAT
SYSTEM.............................4
HEATED SEAT ELEMENT
DESCRIPTION..........................5
OPERATION............................6
DIAGNOSIS AND TESTING - HEATED SEAT
ELEMENT............................6
REMOVAL.............................6
INSTALLATION..........................6
HEATED SEAT SENSOR
DESCRIPTION..........................7OPERATION............................7
DIAGNOSIS AND TESTING - HEATED SEAT
SENSOR.............................7
REMOVAL.............................7
HEATED SEAT SWITCH
DESCRIPTION..........................7
OPERATION............................8
DIAGNOSIS AND TESTING - HEATED SEAT
SWITCH.............................8
REMOVAL.............................9
INSTALLATION..........................9
HEATED SEAT SYSTEM
DESCRIPTION
Individually controlled, electrically heated front
seats are available as a factory-installed option on
some DR models. Vehicles with this option can be
visually identified by the leather trim seats and two
separate heated seat switches mounted in the lower
center of the instrument panel. The heated seat sys-
tem allows the front seat driver and passenger to
select from two different levels of electrical seat heat-
ing, or no seat heating to suit their individual com-
fort requirements. The heated seat system for this
vehicle includes the following major components,
which are described in further detail later in this sec-
tion:
²Heated Seat Switches- Two heated seat
switches are used per vehicle. One switch is used for
each front seat. The switches are mounted in the
instrument panel, below the radio (Fig. 1). Each
switch also includes two Light-Emitting Diode (LED)
indicator lamps and an incandescent back lighting
bulb.
²Heated Seat Module- also referred to as the
Seat Heat Interface Module (SHIM), this module con-
tains the solid state electronic control and diagnostic
logic circuitry for the heated seat system. One heated
seat module is used per vehicle and is mounted
under the drivers front seat cushion (Fig. 1). Refer to
the Electronic Control Modules section of the service
manual for additional heated seat module informa-
tion.²Heated Seat Elements- Four heated seat ele-
ments are used per vehicle. One element is used for
each front seat back and one element and sensor
assembly is used for each front seat cushion (Fig. 1).
The heating elements are integral to the individual
front seat and seat back cushions and cannot be
removed once installed at the factory. Replacement
seat heating elements are available, without having
to replace the entire seat cushion or trim cover. Refer
to the detailed procedure later in this section.
²Heated Seat Sensors- Two heated seat sen-
sors are used per vehicle. One heated seat tempera-
ture sensor is used for each front seat cushion. The
sensors are integral to the individual front seat cush-
ion heating elements (Fig. 1) and cannot be removed
once installed at the factory. Replacement seat heat-
ing elements with the sensors are available, without
having to replace the entire seat cushion or trim
cover. Refer to the detailed procedure later in this
section.
Following are general descriptions and operations
of the major components in the heated seat system.
See the owner's manual in the vehicle glove box for
more information on the features, use and operation
of the heated seat system. Refer toWiringfor the
location of complete heated seat system wiring dia-
grams.
DRHEATED SEAT SYSTEM 8G - 3

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