Power Distribution: Removal & Installation Dodge Pickup R2500

REMOVAL

1. Disconnect the positive and negative battery cables from the battery.
2. Partially remove the integrated power module from the engine compartment (Refer to «REMOVAL»(ref-211866-S16085637312005122000000) ).
3. Remove the front control module retaining screws.
4. Using both hands, pull the front control module straight from the integrated power module assembly to disconnect the 49-way electrical connector and remove the front control module from the vehicle.

INSTALLATION

1. Install the front control module on the integrated power module assembly by pushing the 49-way electrical connector straight in.
2. Install the front control module retaining screws. Torque the screws to 7 in. lbs.
3. Install the integrated power module (Refer to «INSTALLATION»(ref-211866-S31067628462005122000000) ).
4. Connect the positive and negative battery cables.

Scheme 358

All vehicles are equipped with an Ignition-Off Draw (IOD) fuse that is disconnected within the Integrated Power Module when the vehicle is shipped from the factory. Dealer personnel are to reconnect the IOD fuse in the Integrated Power Module as part of the preparation procedures performed just prior to new vehicle delivery.

A laser printed fuse layout map is integral to the Integrated Power Module cover to ensure proper fuse identification. The IOD fuse is a 20 ampere mini blade-type fuse, located in fuse cavity # 51 (Scheme 358) The fuse is secured within a black molded plastic fuse holder and puller unit that serves both as a tool for disconnecting and reconnecting the fuse in its Integrated Power Module cavity, and as a fuse holder that conveniently stores the fuse in the same Integrated Power Module cavity after it has been disconnected.

The Ignition-Off Draw (IOD) fuse is disconnected from Integrated Power Module fuse cavity # 51 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 Integrated Power Module cover.
3. Grasp the outer tabs of the IOD fuse holder unit in fuse cavity #51 between the thumb and forefinger and pull the unit firmly upward.
4. Install the Integrated Power Module cover.

1. Turn the ignition switch to the Off position.
2. Remove the Integrated Power Module cover.
3. To install the IOD fuse, use a thumb to press the IOD fuse holder unit in fuse cavity #51 firmly into the Integrated Power Module.
4. Install the Integrated Power Module cover.

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 protective cap from the power outlet receptacle base.
3. Look inside the cigar lighter or power outlet receptacle base and note the position of the rectangular retaining bosses of the mount that secures the receptacle base to the panel (Scheme 359)
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, using a gentle rocking motion, pull the pliers and the receptacle base out of the mount.
6. Pull the receptacle base away from the instrument 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.

Scheme 359

1. Reconnect the instrument panel wire harness connector to the cigar lighter or power outlet receptacle base connector receptacle.
2. Install the cigar lighter or power outlet mount into the instrument panel.
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 outlet receptacle base until the retaining bosses of the mount are fully engaged in their receptacles.
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.

1. Disconnect and isolate the negative battery cable.
2. Remove the relay by grasping it firmly and pulling it straight out from its receptacle. A slight back and fourth rocking motion may help the removal process.

1. Position the relay to the proper receptacle.
2. Align the relay terminals with the terminal cavities in the receptacle.
3. Push firmly and evenly on the top of the relay until the terminals are fully seated in the terminal cavities in the receptacle.
4. Connect the negative battery cable.

Scheme 360

A micro-relay is a conventional International Standards Organization (ISO) micro relay (Scheme 360) Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs by five integral male spade-type terminals that extend from the bottom of the relay base.

Relays cannot be adjusted or repaired and, if faulty or damaged, the unit must be replaced.

1. Disconnect and isolate the negative battery cable.
2. Remove the relay by grasping it firmly and pulling it straight out from its receptacle. A slight back and fourth rocking motion may help the removal process.

1. Align the micro-relay terminals with the terminal cavities in the receptacle.
2. Push firmly and evenly on the top of the relay until the terminals are fully seated in the terminal cavities in the receptacle.
3. Connect the battery negative cable.