DODGE TRUCK 1993 Service Repair Manual

8K
- 10
WINDSHIELD WIPER
AND
WASHER SYSTEMS

• (2) Mount multifunction switch
to
column
and (4)
Install tilt lever (tilt column only),
torque retaining screws
to 2 N»m (17 in.
lbs.).
(5)
Install battery cable. (3) Install steering column covers. Torque retain-
(6)
Check
all
functions
of
switch
for
proper opera-
ing screws
to 2 N»m (17 in.
lbs.). tion.

WINDSHIELD
WASHERS

GENERAL INFORMATION
All models
are
equipped with electric operated
windshield washer pumps. The electric pump assembly
is
mounted directly
to

the reservoir.
A
permanently lubricated sealed motor is coupled
to a
rotor type pump. Fluid, gravity
fed

from
the
reservoir,
is
forced
by the
pump through rubber hoses
to the
nozzles which direct
the
streams
to
the
windshield. These vehicles
are
equipped with special plastic
washer nozzles
(Fig. 1).
Because they
are
inserted
di­
rectly into
the
cowl panel, there
is no
adjustment
re­

quired.
Fig.
1
Windshield
Washer
System
WINDSHIELD WASHER PUMP REPLACEMENT
(Fig.

2)

REMOVAL (1) Remove liquid from reservoir.
(2) Remove reservoir mounting screws
and
remove
reservoir
and
pump assembly. (3) Disconnect electrical lead
and
rubber hose from
bottom
of
pump. (4) Using
an
extension
and
deep well socket, reach
through reservoir filler neck,
and
remove pump
mounting
nut and
plastic washer.

(5)
Remove pump from bottom reservoir.
(6) Remove rubber grommet from reservoir
and

throw away.

Fig.
2
Washer
Pump

INSTALLATION (1) Install
new
rubber grommet into place
in
bot­
tom
of
reservoir. (2) Position pump into place
in
reservoir. Install
plastic washer then mounting
nut, and
tighten
to 3
N»m
(25 in. lbs.)
torque.
Do not
overtighten.
(3) Connect electrical leads
and
hose
to
pump.
(4) Position reservoir into place, install mounting
screws
and
tighten securely. (5) Fill reservoir with water and/or washer fluid,
inspect
for
leaks
and
test system.

•

WINDSHIELD WIPER
AND
WASHER SYSTEMS
8K - 11 WINDSHIELD WASHER DIAGNOSIS

WASHER DOES NOT
OPERATE PROPERLY

T

PUMP MOTOR

DOES
NOT RUN

LOOSE WIRING,
TERMINALS, CORRODED TERMINALS

X

BROKEN WIRES
POOR GROUND

FAULTY
SWITCH

FAULTY
MOTOR PUMP MOTOR
RUNS

T •

PUMP RUNS-
PUMP
NOT

PUMPING
FLUID

NO
FLUID
IN
RESERVOIR
NOZZLE
JET
UNDER COWL PANEL
NOZZLE JETS PLUGGED
BROKEN
OR

LOOSE HOSE

FAULTY
PUMP MOTOR RUNS
PUMP PUMPING
FLUID

SYSTEM OPERATES
INTERMITTENTLY

LOOSE WIRING
CONNECTIONS
X

FAULTY
SWITCH

t

FAULTY
MOTOR SYSTEM OPERATES

WITHOUT

INTERRUPTION IATES
I
T I

ION
j
SYSTEM
OUTPUT

LOW
NOZZLES
AIMED
LOW

PINCHED
OR

LEAKY HOSES

X

LEAKY
OR
RESTRICTED PLASTIC HOSE CONNECTOR

X

POOR ELECTRICAL CONNECTIONS
DEFECTIVE MOTOR
J908K-27

•

LAMPS
LAMPS
8L - 1

CONTENTS

page page

BULB
APPLICATION 11 EXTERIOR
LAMPS
SERVICE
PROCEDURES
... 3
EXTERIOR
LAMPS
1 INTERIOR
LAMPS
10

EXTERIOR LAMPS

GENERAL
INFORMATION Each vehicle is equipped with various lamp assem­

blies.
A good ground is necessary for proper lighting operation. When changing lamp bulbs check the socket for
corrosion. Clean corrosion with a wire brush. Coat
the inside of the socket lightly with Mopar® Multi- Purpose Grease or equivalent.

DIAGNOSTIC
PROCEDURES
Always begin any diagnosis by testing all of the
fuses and circuit breakers in the system. Refer to Group 8W, Wiring Diagrams. Conventional and halogen headlamps are inter­
changeable. It is recommended that they not be in­
termixed on a given vehicle.

MULTI-FUNCTION
SWITCH TESTING
PROCEDURES
The multi-function switch contains electrical cir­
cuitry for:
• Headlamp Dimmer Switch
• Passing Lights
• Turn Signals
• Hazard Warning • Windshield Wiper
• Pulse Wiper
• Windshield Washer

HEADLAMPS
HIM
ENGINE
IDLING

OR
IGNITION
OFF

TEST CHARGING
SYSTEM
HEADLAMP
DIAGNOSIS

SEALED
BEAM

OR
BULB
BURNS

OUT
FREQUENTLY
][

TEST CHARGING SYSTEM
HEADLAMPS
DIM

ENGINE
RUNNING
ABOVE
IDLE

][

TEST CHARGING SYSTEM
HEADLAMPS

RANDOM
FLASH

[
HEADLAMPS

WILL
NOT
LIGHT

POORLY GROUNDED HEADLAMP CIRCUIT
LOOSE
CONNECTION
IN HEADLAMP CIRCUIT
HIGH RESISTANCE IN HEADLAMP CIRCUIT
LOOSE
CONNECTION
IN HEADLAMP CIRCUIT HIGH RESISTANCE
IN HEADLAMP CIRCUIT
LOOSE
CONNECTION
IN HEADLAMP CIRCUIT OPEN OR CORRODED
CONTACT
IN

HEADLAMP SWITCH

CRACKED
LENS ON HALOGEN SEALED BEAM ONLY
FAULTY
SEALED

BEAMS
OR BULBS OPEN OR CORRODED
CONTACT IN DIMMER SWITCH

FAULTY
SEALED

BEAMS
OR BULBS
FAULTY
SEALED

BEAMS
OR BULBS

RR8LD21

8L
- 2
LAMPS

• This switch is mounted to the left hand side of the
steering column. Should any function of the switch

fail,
the entire switch must be replaced.

SWITCH
TEST
(1) Disconnect battery negative cable.
(2) Remove tilt lever.
(3) Remove upper and lower column covers to gain
access to the switch connector (Fig. 1).
(4) Remove lower fixed column cover.
(5) Loosen steering column upper bracket nuts. Do
not remove nuts.
(6) Move upper fixed column cover to gain access
to rear of multi-function switch.
(7) Remove switch connector (Figs. 2 and 3). (8) Use an ohmmeter to test for continuity. Check
between the terminals of the switch as shown in the continuity chart (Fig. 4).
(9) Refer to Service Procedures for assembly.
UPPER SHROUD GROUND
CLIP UPPER
FIXED SHROUD
SUPPORT BRACKET
LOWER
SHROUD LOWER
FIXED
SHROUD
J9119-22

Fig.
1 Steering
Column
Covers
STEERING

COLUMN
ASSY.

J918J-1
TURN
SIGNAL

MULT
I
SWITCH
AND
*® FUNCTION
LEVER
SWITCH

CONNECTOR

Fig.
2 Multi-function
Switch
Connector

KEY-IN
SWITCH
&
HALO
LIGHT
MULTIFUNCTION

SWITCH

IGNITION
SWITCH
TURN
SIGNAL

SWITCH
&
LEVER

SPEED

CONTROL
J918J-2

Fig.
3 Steering
Column
Connectors

24 23 22 21 20 19 18

EZJ
C=3 C=3 E=3
CZZJ
E=3 E=3
17 16 15 14 13 12 11 10
a a a 8=3 ( ( ) ) 1=3 1=3 1=3 9 8 7 6 \5_y4 3 2 1
VIEW
FROM
TERMINAL
SIDE

SWITCH POSITION CONTINUITY BETWEEN

LOW
BEAM

HIGH
BEAM

OPTICAL
HORN
18 AND 19
19 AND 20
20
AND
21

908J-5
Fig.
4
Beam
Select
Switch
Continuity Chart

•

LAMPS
8L - 3
EXTERIOR
LAMPS
SERWICE PROCEDURES

INDEX

page

Cargo
Lamp
7

Clearance Lamps
for
Dual Wheel Model
........
5
Daytime Running
Light
Module (Canada Only)
... 8

Front
Park
and
Turn Signal Lamp Bulb
4

Headlamp
Adjustment
Using
Alignment
Screen
... 3

Headlamp
Alignment
3

Headlamp
Alignment
Preparation
3
page

Headlamp Switch
4

License
Lamp
............................
7

Sealed
Beam Replacement
4

Side
Marker Lamp
and
Bulb
. 5

Tail,
Stop, Turn Signal, Rear Side Marker
and

Back-Up
Lamps
5

Underhood Lamp
8

HEADLAMP
ALIGNMENT
Headlamps
can be
aligned using
the
screen method
provided
in
this section. Alignment Tool C4466-A
or

equivalent
can
also
be
used. Refer
to
instructions
provided with
the
tool
for
proper procedures.
The
preferred headlamp alignment setting
is 0 for

the left/right adjustment
and
1" down
for the up/
down adjustment.

HEADLAMP
ALIGNMENT PREPARATION
(1) Verify headlamp dimmer switch
and
high beam
indicator operation. (2) Correct defective components that could hinder
proper headlamp alignment. (3) Verify proper tire inflation. (4) Clean headlamp lenses.
(5) Verify that luggage area
is not
heavily loaded.
(6) Fuel tank should
be
FULL.
Add 2.94 kg (6.5

lbs.)
of
weight over
the
fuel tank
for
each estimated
gallon
of
missing fuel.

HEADLAMP
ADJUSTMENT USING ALIGNMENT

SCREEN

ALIGNMENT SCREEN PREPARATION (1) Position vehicle
on a
level surface perpendicu­
lar
to a
flat wall
7.62
meters
(25 ft)
away from front
of headlamp lens.
(2)
If
necessary, tape
a
line
on the
floor
7.62

meters
(25 ft)
away from
and
parallel
to the
wall.

CENTER
OF

VEHICLE
TO
CENTER
OF

HEADLAMP
LENS

VEHICLE
CENTERLINE" LOW BEAM
HOT

SPOT AREA FLOOR
TO

CENTER
OF

HEADLAMP
LENS

PREFERRED
HOT SPOT
LOCATION

7.62
METERS
(25
FEET)

FRONT
OF

HEADLAMP
938L-25X

Fig.
1 Headlamp
Alignment
Screen
—Typical

8L
- 4
LAMPS

• (3) Up 1.27 meters (5 feet) from the floor, tape a
line on the wall at the centerline of the vehicle.
Sight along the centerline of the vehicle (from rear of
vehicle forward) to verify accuracy of the line place­
ment.
(4) Rock vehicle side-to-side three times to allow
suspension to stabilize. (5) Jounce front suspension three times by pushing
downward on front bumper and releasing. (6) Measure the distance from the center of head­
lamp lens to the floor. Transfer measurement to the alignment screen (with tape). Use this line for up/
down adjustment reference.
(7) Measure distance from the centerline of the ve­
hicle to the center of each headlamp being aligned. Transfer measurements to screen (with tape) to each side of vehicle centerline. Use these lines for left/
right adjustment reference.

HEADLAMP
ADJUSTMENT
A properly aimed low beam headlamp will project
top edge of high intensity pattern on screen from 50 mm (2 in.) above to 50 mm (2 in.) below headlamp
centerline. The side-to-side outboard edge of high in­
tensity pattern should be from 50 mm (2 in.) left to 50 mm (2 in.) right of headlamp centerline (Fig. 1).
The preferred headlamp alignment is 0 for the
up/down adjustment and 1" down for the left/
right adjustment. The high beam pattern should be correct when the iow beams are aligned properly (Fig. 2).
To adjust headlamp aim, rotate alignment screws
to achieve the specified high intensity pattern.

1.
HORIZONTAL
ADJ. SCREW
- RH
2.
VERTICAL
ADJ. SCREW
3.
HORIZONTAL
ADJ. SCREW
- LH
J908L-24

Fig.
2
Sealed
Beam
Headlamp
Alignment

SEALED
BEAM REPLACEMENT
(1) Remove the headlamp bezel (Fig. 3).
(2) Remove four screws from retaining ring (Fig.

4).
(3) Separate sealed beam from seat and disconnect
from the socket. To install, reverse the removal procedures.
HEADLAMP
BEZEL

: ') J918L-29
Fig.
3 Headlamp
Bezel

RETAINING

RING

SCREWS
J918L-28

Fig.
4
Sealed
Beam
Replacement

HEADLAMP SWITCH
To remove or replace the headlamp switch see in­
structions in Group 8E - Instrument Panel and
Gauges.

FRONT
PARK AND
TURN
SIGNAL LAMP BULB
(1) Remove 2 screws securing the Park/Turn signal
lamp (Fig. 5) (2) Twist out lamp socket from back of lamp hous­
ing. (3) Replace bulb.
To install, reverse removal procedures.

•

LAMPS
8L - 5
J918L-27

Fig.
5
Park
and Turn
Signal
Lamp

SIDE MARKER LAMP AND BULB
(1) From inside engine compartment, twist out
socket from back of housing. (2) Remove nuts attaching lamp to fender. (3) Lift lamp away from outside of fender.
To install, reverse the removal procedures.
TAIL,
STOP, TURN
SIGNAL,
REAR SIDE MARKER
AND BACK-UP LAMPS

SWEPTLINE MODELS

REMOVAL
(1) Remove screws and remove lamp assembly.
(2) Twist out socket.
INSTALLATION (1) Twist in socket.
(2) Position the lamp and install screws.
CAB CHASSIS MODELS
REMOVAL (1) Remove 4 screws holding lens to lamp. (2) Twist out bulb.
INSTALLATION (1) Install bulb.
(2) Position lens and install screws.
SPORT UTILITY MODELS

REMOVAL
(1) Remove screws and remove lamp assembly.
(2) Twist out socket. (3) Replace bulb.
Fig.
6
Tail,
Stop,
Turn
Signal,
Rear
Side
Marker and

Back-Up
Lamp

LAMP
ASSEMBLY
PR1086

Fig.
7
Tail,
Stop,
Turn
Signal,
and
Back-Up
Lamp

INSTALLATION
(1) Twist in socket. (2) Position the lamp and install screws.
CLEARANCE LAMPS
FOR
DUAL WHEEL MODEL

WHEEL FLARE AND TAILGATE CLEARANCE

LAMPS
To change bulb, remove lamp as follows: (1) Pry out retaining clamps.
(2) Pull lens away from mounting plate.

8L
- 6

LAMPS

•

ASSEMBLY
* J908L-63

Fig.
8
Tail,
Stop,
Turn
Signal,
Rear
Side
Marker and
Back-Up
Lamp

(3)
Disconnect electrical connector from bulb and
lens assembly (Figs. 9 and 10).
(4) Connect electrical connector to new lamp and
snap into housing. J908L-73

Fig.
9
Wheel
Flare
Clearance
Lamp

CAB
CLEARANCE LAMPS
To change bulb, remove lamp as follows: (1) Remove mounting screws (Fig. 11).
(2) Slide lens down and out of housing. (3) Twist out socket and replace bulb.

Fig.
10 Rear Clearance
Lamps

•

LAMPS
8L - 7 (4) To install, reverse procedures. Make sure the
grounding eyelet is under a mounting screw.

Fig.
11 Cab Clearance
Lamps

CARGO
LAMP
STANDARD
CAB (1) Remove two mounting screws. (2) Pull assembly out and disconnect wiring con­
nector. (3) To install, reverse the procedures.

J908L-59.

Fig.
12
Cargo
Lamp—Standard Cab

CLUB
CAB (1) Remove two mounting screws.
(2) Pull assembly out and disconnect wiring con­
nectors.
(3) To install, reverse the procedures.

LICENSE
LAMP
STANDARD BUMPER
(1) Remove rear license plate.
(2) Remove 2 lamp mounting screws.
(3) Remove lamp assembly. (4) Remove 2 screws attaching lamp lens to hous­
ing.
Fig.
14
License
Plate
Lamp
- Standard Rear
Bumper

STEP BUMPER
(1) Remove 2 lamp assembly mounting screws
(Fig. 15)
(2) Remove lamp from bumper.
(3) Disconnect wire connector.
(4) Remove lens from lamp.
(5) Twist out bulb.
(6) To install, reverse the removal procedures.
WITHOUT REAR BUMPER (1) Remove screws holding lamp assembly to li­
cense bracket (Fig. 16).
(2) Disconnect electrical connector and remove
lamp assembly.
(3) Install new lamp assembly with screws and
connect electrical connector.