Dodge Ram Truck 1500-2500-3500. Manual — part 603

4. After cleaning and inspecting the wiper components and the glass, if the wiper blade still fails to clear the glass

without smearing, streaking, chattering, hazing, or beading, replace the wiper blade.

WASHER SYSTEM

The washer system components should be inspected periodically, not just when washer performance problems are
experienced. This inspection should include the following points:

1. Check for ice or other foreign material in the washer reservoir. If contaminated, clean and flush the washer sys-

tem. (Refer to 8 - ELECTRICAL/WIPERS/WASHERS - CLEANING).

2. Inspect the washer plumbing for pinched, leaking, deteriorated, or incorrectly routed hoses and damaged or dis-

connected hose fittings. Replace damaged or deteriorated hoses and hose fittings. Leaking washer hoses can
sometimes be repaired by cutting the hose at the leak and splicing it back together using an in-line connector
fitting. Similarly, sections of deteriorated hose can be cut out and replaced by splicing in new sections of hose
using in-line connector fittings. Whenever routing a washer hose or a wire harness containing a washer hose, it
must be routed away from hot, sharp, or moving parts. Also, sharp bends that might pinch the washer hose must
be avoided.

CHECK VALVE

DESCRIPTION

A single washer system check valve is standard
equipment on this model, and is installed in the
washer system plumbing. The check valve is integral
to the washer nozzle plumbing wye fitting (2) located
in the cowl plenum area beneath the cowl plenum
cover/grille panel near the base of the windshield. The
check valve consists of a molded plastic body with a
raised arrowhead (4) molded into its center section
that indicates the direction of the flow through the
valve, and three barbed hose nipples (1 and 3) formed
in a wye configuration on the outside circumference of
the center section of the valve body. The check valve
cannot be adjusted or repaired and, if faulty or dam-
aged, it must be replaced.

OPERATION

The check valve provides more than one function in
this application. It serves as a wye connector fitting
between the engine compartment and washer nozzle
sections of the washer supply hose. It prevents
washer fluid from draining out of the washer supply
hoses back to the washer reservoir. This drain-back
would result in a lengthy delay from when the washer
switch is actuated until washer fluid was dispensed
through the washer nozzles, because the washer
pump would have to refill the washer plumbing from
the reservoir to the nozzles. Such a drain-back condi-
tion could also result in water, dirt, or other outside
contaminants being siphoned into the washer system
through the washer nozzle orifice. This water could
subsequently freeze and plug the nozzle, while other
contaminants could interfere with proper nozzle oper-
ation and cause improper nozzle spray patterns. In

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addition, the check valve prevents washer fluid from siphoning through the washer nozzles after the washer system
is turned Off.

When the washer pump pressurizes and pumps washer fluid from the reservoir through the washer plumbing, the
fluid pressure (5) unseats a diaphragm (3) from over a sump well within the valve by overriding the pressure applied
to a piston (2) by a spring (1). With the diaphragm unseated, washer fluid is allowed to flow toward the two washer
nozzles (4). When the washer pump stops operating, the spring pressure on the piston seats the diaphragm over
the sump well in the valve and fluid flow in either direction within the washer plumbing is prevented. The check
valve cannot be adjusted or repaired and, if faulty or damaged, it must be replaced.

REMOVAL

1. Remove both wiper arms from the wiper pivots.

(Refer to 8 - ELECTRICAL/WIPERS/WASHERS/
WIPER ARM - REMOVAL).

2. Unlatch and open the hood.

3. Remove the cowl plenum cover/grille panel from

over the cowl plenum. (Refer to 23 - BODY/EXTE-
RIOR/COWL GRILLE - REMOVAL).

4. From the underside of the cowl plenum cover/grille

panel (5), disconnect the cowl plenum (4) and
washer nozzle (1 and 6) hoses from the three
barbed nipples of the check valve (2).

5. Remove the check valve from the underside of the

cowl plenum cover/grille panel.

INSTALLATION

1. Position the check valve (2) to the underside of the

cowl plenum cover/grille panel (5). Be certain that
the flow direction arrow molded into the check
valve body is oriented towards the washer nozzles.

2. From the underside of the cowl plenum cover/grille

panel, reconnect the cowl plenum (4) and washer
nozzle (1 and 6) hoses to the three barbed nipples
of the check valve.

3. Reinstall the cowl plenum cover/grille panel over

the cowl plenum. (Refer to 23 - BODY/EXTERIOR/
COWL GRILLE - INSTALLATION).

4. Close and latch the hood.

5. Reinstall both wiper arms onto the wiper pivots.

(Refer to 8 - ELECTRICAL/WIPERS/WASHERS/
WIPER ARM - INSTALLATION).

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SENSOR-WASHER FLUID LEVEL

DESCRIPTION

The washer fluid level switch is a single pole, single
throw reed-type switch mounted on the side of the
washer reservoir (4) in the engine compartment. Only
the molded plastic switch mounting flange (1) and the
integral connector receptacle (8) are visible when the
switch is installed in the reservoir. A short nipple for-
mation (2) extends from the inner surface of the
switch mounting flange, and a barb on the nipple is
pressed through a rubber grommet seal (5) installed in
the mounting hole of the reservoir.

A small, molded plastic float (3) has two pivot pins (6)
near its center that are snapped into two receptacles
near the ends of two stanchions that extend toward
the float from the nipple formation. A small magnet (7)
is secured within the end of the float nearest the nip-
ple, and a reed switch is concealed within the nipple.
A diagnostic resistor is connected between the two
switch terminals within the switch mounting flange.
The washer fluid level switch cannot be adjusted or
repaired. If faulty or damaged, the switch must be
replaced.

OPERATION

The washer fluid level switch uses a pivoting, oblong float to monitor the level of the washer fluid in the washer
reservoir. The float contains a small magnet. When the float pivots, the proximity of this magnet to a stationary reed
switch within the nipple formation of the switch changes. When the fluid level in the washer reservoir is at or above
the float level, the float moves to a vertical position, the influence of the float magnetic field is removed from the
reed switch, and the normally open reed switch contacts open. When the fluid level in the washer reservoir falls
below the level of the pivoting float, the float moves to a horizontal position, the influence of the float magnetic field
is applied to the reed switch, and the contacts of the normally open reed switch close.

The washer fluid level switch is connected to the vehicle electrical system through a dedicated take out and con-
nector of the right (except SRT-10 and diesel engines) or left (SRT-10 and diesel engines only) headlamp and dash
wire harness. The switch is connected in series between a clean ground output of the Front Control Module (FCM)
on a sensor return circuit and the washer fluid switch sense input to the FCM. When the switch closes, the FCM
senses the ground on the washer fluid switch sense circuit. The FCM is programmed to respond to this input by
sending an electronic washer fluid indicator lamp-on message to the instrument cluster over the Programmable
Communications Interface (PCI) data bus. The instrument cluster responds to this message by illuminating the
washer fluid indicator and by sounding an audible chime tone warning.

The washer fluid level switch may be diagnosed and tested using conventional diagnostic tools and procedures.
However, conventional diagnostic methods may not prove conclusive in the diagnosis of the instrument cluster, the
FCM, or the electronic message inputs to or outputs from the instrument cluster and the FCM that control the oper-
ation of the washer fluid visual and/or audible indicators. The most reliable, efficient, and accurate means to diag-
nose the washer fluid level indicator, the instrument cluster, the FCM, or the electronic message inputs and outputs
related to the washer fluid indicator requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic
information.

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REMOVAL

EXCEPT SRT-10 OR DIESEL ENGINE

NOTE: The washer fluid level switch can be removed from the washer reservoir without removing the res-
ervoir from the vehicle.

1. Unlatch and open the hood.

2. Disconnect and isolate the battery negative cable.

3. Disconnect the washer hose (1) from the barbed

outlet nipple of the washer pump/motor unit (5) and
allow the washer fluid to drain into a clean con-
tainer for reuse.

4. Disconnect the right headlamp and dash wire har-

ness (4) connector for the washer fluid level switch
(3) from the switch connector receptacle.

NOTE: The pivoting float of the washer fluid level
switch must be in a horizontal position within the
reservoir in order to be removed. With the reser-
voir empty and in an upright position, the pivoting
float will orient itself to the horizontal position
when the switch connector receptacle is pointed
straight upwards.

5. Using a trim stick or another suitable wide flat-bladed tool, gently pry the barbed nipple of the washer fluid level

switch out of the rubber grommet seal in the washer reservoir sump (2). Care must be taken not to damage the
reservoir.

6. Remove the washer fluid level switch from the washer reservoir.

7. Remove the rubber grommet seal from the washer fluid level switch mounting hole in the washer reservoir and

discard.

SRT-10 OR DIESEL ENGINE ONLY

NOTE: The washer fluid level switch can be removed from the washer reservoir without removing the res-
ervoir from the vehicle.

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