roof DODGE TRUCK 1993 Service Repair Manual

INTRODUCTION

PRIMARY SECONDARY
PAINT PAINT VINYL ROOF

CODE VEHICLE
ORDER-
NUMBER
PAINT- PI
PROCEDURE
(2)

(1)
XXX
)
XXXXX)
X
XXX xxxxxx
X)0C xxxx xxxx xxxx xxx XXX x xxxxxxxxxxxxxxxxx

TRANSMISSION
I
VEHICLE IDENTIFICATION CODE
J
NUMBER
MARKET
U-C-B-M
CODE 90IN-3

Fig. 2 Vehicle Code Plate
VEHICLE CODE DECODING
VEHICLE
MODEL
•NUMBER
ENGINE
-CODE
-INTERIOR TRIM CODE

Line #1 Digit
1-3 Transmission Sales Code
Digit 4 Open Space
Digit
5
Market Code - U-C-B-M
Digit 6 Open Space
Digit 7-23 Vehicle Identification No.
Line #2 Digit
1-3 Paint Procedure
Digit 4 Open Space
Digit 5-8 Primary Paint
Digit 9 Open Space
Digit 10-13 Secondary Paint
Digit 14 Open Space
Digit 15-18 Trim Code
Digit 19 Open Space
Digit
20-22
Engine Sales Code
Digit 23 Open Space
Line #3 Digit 1-12 Vehicle Order Number
Digit 13 Open Space
Digit 14-16 Vinyl Roof Code (Door Combo
Digit
Code - Pillette)
Digit 17 Open Space
Digit 18-23 Model

J901N-20 MAJOR COMPONENT IDENTIFICATION

Refer to the applicable group for identification
data.
EQUIPMENT IDENTIFICATION PLATE

The Equipment Identification Plate is located at
the right, front corner of the inner hood panel. The
plate lists information concerning the vehicle as fol­
lows:
The model
The wheelbase
The VIN (Vehicle Identification Number)
The
T.O.N,
(order number)
The optional and special equipment installed on
the vehicle
Refer to the information listed on the plate when
ordering replacement parts.

r§Wll
EQUIPMENT
IDENTIFICATION
mmm

MODELS
V.I.N. T.O.N.

CODE
NO.
DESCRIPTION
CODE
NO.
DESCRIPTION

. ^

Fig.
3 Equipment
Identification
Plate

•

TURN
SIGNALS
AND
HAZARD WARNING FLASHER
8J - 3 (4) Using an ohmmeter, test for continuity (no re­
sistance) between the terminals of the switdh as shown in the following continuity chart (Pig. 4).
VIEW
FROM TERMINAL CASE
SWITCH POSITIONS

TURN
SIGNAL HAZARD WARNING
CONTINUITY
BETWEEN

NEUTRAL
OFF 12
AND 14 AND 15

LEFT
LEFT
LEFT
OFF
OFF
OFF 15
AND 16 AND 17

12
AND 14

22
AND 23 WITH OPTIONAL CORNER LAMPS

RIGHT
RIGHT
RIGHT
OFF
OFF
OFF 11
AND 12 AND 17

14
AND 15

23
AND 24 WITH OPTIONAL CORNER LAMPS

NEUTRAL
ON 11
AND 12 AND 13 AND 15 AND 16

908J-4
Fig.
4 Turn
Signal
and Hazard Switch Continuity Chart

MULTIFUNCTION SWITCH SERVICE PROCEDURES
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove tilt lever (Tilt column only).
(3) Remove both upper and lower steering column
covers. (4) Remove multifunction switch tamper proof
mounting screws (tamper proof torx bit Snap On
TTXR20B2 or equivalent required). (5) Gently pull switch away from column. Loosen
connector screw. The screw will remain in the con­
nector. (6) Remove wiring connector from multifunction
switch (Fig. 5).

INSTALLATION
(1) Install wiring connector to switch and tighten
connector retaining screw to 17 in. lbs. (2) Mount multifunction switch to column and
torque retaining screws to 17 in. lbs. (3) Install steering column covers. Torque retain­
ing screws to 17 in. lbs. (4) Install tilt lever (tilt column only).
(5) Install negative cable to battery.
(6) Check all functions of switch for proper opera­
tion.
HAZARD
WARNING

908J-9

Fig.
5 Muitifunction Switch

WINDSHIELD
WIPER
AND
WASHER
SYSTEMS
8K - S

BLADE
PIVOT
ASSEMBLY

WIPER MOTOR
RK755

Fig.
6 Wiper
Linkage
RIGHT PIVOT ASSEMBLY
REMOVAL
(1) Remove wiper arms.
(2) Remove screws attaching louvered cowl cover
to dash panel. (3) Remove cowl cover by pulling forward with a
slight upward movement.

(4)
Reach through access hole and remove drive
link from right pivot by prying retainer bushing
from pivot pin with a suitable size screwdriver.
(5) Remove right pivot mounting screws.
(6) Remove pivot through access hole.
INSTALLATION (1) Position pivot into place, install mounting
screws, and tighten to 11 N*m (95 in. lbs.) torque. (2) Install right pivot pin in drive link retainer
bushing by snapping together with channel lock pli­
ers.

(3) Position cowl cover into place, install mounting
screws and tighten securely.

(4)
Install wiper arms.

WIPER SWITCH REPLACEMENT
(1) Disconnect negative cable from battery.
(2) Remove tilt lever (Tilt column only).
(3) Remove both upper and lower steering column
covers.
(4)
Remove multifunction switch tamper proof
mounting screws.
(5) Gently pull switch away from column. Loosen
connector screw. The screw will remain in the con­
nector.
(6) Remove wiring connector from multifunction
switch (Fig. 7).
HAZARD WARNING
BUTTON
WINDSHIELD WASHER BUTTON
WINDSHIELD WIPER CONTROL MULTI-FUNCTION
SWITCH

908J-9

Fig.
7 Multifunction
Switch

INSTALLATION
(1) Install wiring connector to switch and tighten
connector retaining screw to 2 Nnn (17 in. lbs.).

8L
- 10
LAMPS

•
INTERIOR

DOME LAMP

STANDARD
CAB (1) Remove two screws and lens.
(2) Twist bulb to remove.
LENS
SCREW
J908L-65

Fig.
1
Dome
Lamp
(Standard Cab)

EXTENDED
CAB (1) Squeeze the front and rear of the lens together
and pull down to remove (Fig. 2).
(2) Pull bulb down to remove from socket.

SPORT
UTILITY (1) Squeeze the front and rear of the lens together
and pull down to remove (Fig. 3). (2) Pull bulb down to remove from socket.

READING LAMP (SPORT
UTILITY)
(1) Squeeze the front and rear of the lens together
and pull down to remove (Fig. 4).
J908L-66
Fig.
2
Dome
Lamp
(Extended Cab)
LAMPS

LENS
J918L-30

Fig.
3
Dome
Lamp
(Sport
Utility)
(2) Remove 2 screws holding the dome and reading
lamp assembly to the mounting bracket.
(3) Lower the assembly.
(4) Remove the bulb.
ROOF

MOUNTING
SCREW
J918L-31

Fig.
4
Reading
Lamp

•

CHIME/BUZZER
WARNING
SYSTEMS
8U - 3
KEY-IN
SWITCH REPLACEMENT
REMOVAL
(1) Disconnect negative cable from battery.
(2) Tilt column only—remove tilt lever (counter­
clockwise).
(3) Carefully remove both upper and lower steer­
ing column covers. Requires removal of 3 screws (torx T-20). (4) Remove 3 ignition switch mounting screws
(tamper proof torx bit Snap On TTXR15A2 or equiv­
alent required) (Fig. 6).

STEERING
COLUMN IGNITION
SWITCH
908D-14

Fig.
6 Ignition
Switch
Screw
Removal

(5) Gently pull switch away from column. Release
2 connector locks on 7 terminal wiring connector,
then remove connector from ignition switch.
(6) Release connector lock on 4 terminal Key In
and Halo light connector then remove connector from
ignition switch (Fig. 7).

KEY-IN SWITCH
&
HALO
LIGHT
MULTIFUNCTION
SWITCH
IGNITION SWITCH TURN SIGNAL
SWITCH
&
LEVER
SPEED

CONTROL
J918J-2

Fig.
7 Key In
Switch
And Halo
Lamp
Connector

(7) Remove key cylinder from ignition switch as
follows:
(a) Insert key in ignition switch and move switch
to Lock position. (b) Use a small screw driver to depress key cyl­
inder retaining pin flush with key cylinder surface (Fig. 8).

IGNITION SWITCH MOUNTING
SCREWS
(3)

STEERING
COLUMN IGNITION
SWITCH
938 D-1

Fig.
8 Key Cylinder Pin
(c) Rotate key clockwise to Off position. The key
cylinder should now be unseated from ignition
switch assembly.

CAUTION:
Do not try to remove key cylinder at this
time.
(d) The key cylinder is unseated and the key cyl­
inder bezel should be about 1/8 inch above ignition
switch halo light ring (Fig. 9). Rotate key counter­
clockwise to Lock position and remove key.

KEY
CYLINDER
BEZEL

HALO
LIGHT
RING
908D-16

Fig.
9 Unseated Key Cylinder

COMPONENT
IDENTIFICATION

INDEX

Caption
Fig.

A/C-Heater
Wiring
15
Cab
Wiring (Extended
Cab)
8

Cab
Wiring (Standard Cab)
7

Door
Wiring (Body
Side)
10

Door
Wiring
9

Engine
Compartment Wiring
3.9L,
5.2L, and 5.9L
Gas

Engines
.17

Engine
Compartment Wiring
5.9L
Diesel
Engine
. 18
Engine
Wiring
3.9L
MPI
Engine
23

Engine
Wiring
5.2L
and 5.9L
MPI
Engine
24

Engine
Wiring
5.9L
Diesel
Engine
25

Four
Wheel Drive Wiring
.20

Frame
Wiring
2
Instrument Panel Wiring (Right
Side)
13
Caption
Fig^

Instrument Panel Wiring
12

Interior
Wiring (Sport
Utility)
6

Liftgate
Wiring (Sport
Utility)
......
4

Rear
Clearance Lamp Wiring
3

Roof
Wiring (Sport
Utility)
5

Starter Wiring
19
Steering
Column Wiring
. 11

Stop
Lamp Switch Wiring
. 14

Tail
Lamp Wiring
1

Transmission
Wiring (Diesel Engine)
. .22

Transmission
Wiring (Gas
Engines)
21
Underhood
Lamp Wiring
. .16

WIRING
DIAGfiAlS
8W - 13

TO FRONT
DOME LAMP

TO
VIEW REAR DOME

LAMP

TO
ROOF
WIRING
SPEAKER VIEWX J908W-85
Fig. 5 Roof Wiring (Sport Utility)

TO
LIFTGATE
GROUND TO DOME
LAMP TO BODY
WIRING
TO REAR
SPEAKER
TO SEAT
BELT
WIRING

J928W-170

Fig. 6 Interior Wiring (Sport Utility)

WIRING
DIAGRAMS
8W
- 37

WIRING DIAGRAMS AD-BODY

INDEX

Wiring Diagram Name Sheet Number

A/C
Heater System
with
Diesel Engine ............ .69,70 Blower Motor
. .69

Compressor
.70

Cycling Switch
.70
Diodes
70

Fuse
69
Low Pressure Switch
70

Resistor
. 69

Switch-Blower
. 69

Vacuum
Control
Switch
.69
Wide Open
Throttle
Cut-Out Relay
70

A/C
Heater System
with Gas
Engine .67,68 Blower Motor
.67

Compressor
.68

Cycling Switch
68
Low Pressure Switch
.68

Diodes
. .68
Fuse
. .67
Resistor
67

Switch-Blower
67

Vacuum
Control
Switch
.67
Wide Open
Throttle
Cutout Relay
68

Air Heater Relay Diesel Engine
.21
Air
Intake
Heater Diesel Engine
22

Anti-Lock Rear Brake System
with
Diesel Engine
.....
.33,34 Brake Warning Lamp Switch
34

Data Link Connector
33

Duel Solenoid Hydraulic Valve
34

Electronic Vacuum
Sensor
.34
Fuse
33

Module
.33
Park
Brake Switch
.33
Resistor
34

Rolls
Test Connector
33

Sensor
34

Stop
Lamp
34

Anti-Lock Rear Brake System
with Gas
Engine .31,32 Brake Warning Lamp Switch
.32

Data Link Connector
. .31

Dual Solenoid Hydraulic Valve
32

Fuse
31
Module
31
Park
Brake Switch
.31
Resistor
32

Rolls
Test Connector
31

Sensor
32

Stop
Lamp Switch
32

Back-Up
Lamp Switch
with
Diesel Engine
.7
Back-Up
Lamp Switch
with Gas
Engine
.9

Battery
.1,3,5
Brake Warning
Indicator
Lamp (Diesel Engine)
.57

Brake Warning
Indicator
Lamp
(Gas
Engine)
58

Brake Warning
Indicator
Lamp Switch (Diesel Engine)
. . . .34
Wiring Diagram Name Sheet Number
Brake Warning
Indicator
Lamp Switch
(Gas
Engine)
32
Bulkhead Disconnect 50-Way .85,86
Buzzer-Combined Headlamp,
Key In, and
Seat
Belt
. . .
.27,28

Bypass
Jumper
(Clutch
Pedal Position)
8

Cargo
Lamp .49,50
Cargo
Lamp Switch
49

Charging System
with
Diesel Engine ..............
.5,6
Battery
5

Generator
. .6

Charging System
with
Gas Engine
.3,4
Battery
3

Generator
, . .4

Cigar
Lighter,
Ash &
Glove
Box
Lamps
52

Circuit
Breakers Power Windows
2,71

Clearance Lamps Duel Rear Wheels
.
.41,43 Clearance Lamps Roof Mounted
40

Clockspring 30,36,38
Clutch Pedal Position Switch
.8

Cold
Start
Advance Motor
24

Compressor,
A/C
68,70 Data Link Connector 17,23,31,33
Data Link Connectors
Rear
Wheel Anti-Lock Diesel Engine
.33

Rear
Wheel Anti-Lock Gas Engine
31

Daytime Running
Light
Module
46

Diesel
Control
System .21,22,23,24,25,26
Air Heater Relay
. .21

Air
Intake
Heater
21
Automatic
Shut Down Relay
22

Cold
Start
24

Crankshaft Position
Sensor
. .25
Data Link Connector
. .23

Engine
Coolant Temp Switch
.26

Fuel Heater
24

Fuel Solenoid
24
Intake
Air
Temp
Sensor
25

Powertrain
Control
Module 21,22,23,25,26

Resistor
.24

Thermo Switch
24

Throttle
Position (Sensor)
26

Transmission Thermo Switch
. . .26

Vehicle Speed
Sensor
25,26 Water
in
Fuel
Sensor
.25

Dimmer Switch-Headlamp
. .47

Diode 68,70
Diode
and
Mold Assembly
51

Dome
and
Cargo Lamp
50

Door
Jamb Switches
49
Left
Switch
.49
Right Switch
49

Dual Solenoid Hydraulic Valve
.32
EMCC
System (3-Speed)
. .11

8W
- 38
WIRING
DIAGRAMS

• Wiring Diagram Name Sheet Number

EMCC
Relay
11

EMCC
Solenoid
11

Ground
11

EMCC
Relay
with Gas
Engine
11,16

EMCC
Solenoid
with Gas
Engine
11,12

Engine
Oil
Pressure Sending
Unit
.27,28
Engine
Starter
Motor
7,9
Engine
Starter
Relay
.7,9

Engine
Starter
System 1,7,8,9 Back-Up Lamp
Switch
.7,9

Bypass
Jumper
(Clutch
Pedal
Position)
8

Clutch
Pedal
Position
Switch
8

Fuse
. 7,9

Motor
7,9
Park/Neutral
Position
Switch
. .7,9

Relay
7,9

Engine Temp Sending
Unit
.
.27,28
Flasher-Hazard Warning
.56
Flasher-Turn Signal
56

Four Wheel
Drive
Indicator
Lamp
13

Front
End
Lighting
. .
.43,44

Front
End
Lighting
(Canada) 45,46

Fuel
Gauge
81,82

Fuel
Tank Gauge
Level
Sending
Unit
Diesel Engine
77

Fuel
Tank Gauge
Level
Sending
Unit
with Gas
Engine
78
Fuel
Heater
Diesel Engine
24

Fuel
Solenoid Diesel Engine
.24

Fuse
Application
Chart
1,2

Fuse
Block Module
and
Relay Bank
82

Fuses
Fuse
1 2,36
Fuse
2
.........
2,10,12,13,14,58,77,78

Fuse
3
2,7,9,10,39
Fuse
4
1,30,47

Fuse
5
1,77,78
Fuse
6
......
.1,73

Fuse
7
1,10,52

Fuse
8
.2,10,61,63
Fuse
9
.2,10,31,33,56

Fuse
10
.2,10,54,55

Fuse
11
2,10,66,67,69

Fuse
12
2,10,71
Fuse
13 1,56
Fuse
14
1,47,52,61,63

Fuse
15
1,49,51,52,61,63,75
Fusible Links 1,2,3,4,5,6,21

Gas
Engine
Wiring
Connector
89

Gauge-Fuel .77,78

Generator
.4,6

Glove
Box
Lamp
Switch
52

Hazard Warning System
. .56
Headlamp Dimmer
Switch
47

Headlamp
Switch
1,47

Headlamp
Switch
Controlled
Interior
Lamps
Headlamps 43,44,

Heated
Rear Window
(Sport
Utility)
Heater
Motor
Resistor

Heater
System Wiring Diagram Name Sheet Number
Horn System
30
Identification
Lamps-Dual Rear Wheels
41,42

Identification
Lamps-Roof Mounted
. 40
Ignition
Coil
.16

Ignition
Switch
.2,10

Ignition
Switch
System
10

Ignition
System (Gas Engine)
.........
.15,16,17,18,19,20
Automatic
Shut Down Relay
.16
Camshaft
Position
Sensor
20

Crankshaft
Position
Sensor
.18

Data
Link
Connector
* . . .17
Engine Coolant Temp
Sensor
20

EVAP
Purge Solenoid
16
Exhaust Gas
Recirculation
Solenoid
16
Fuel
Pump Relay
.16

Heated
Oxygen
Sensor
. . . 17

Idle
Air
Control
Motor
.19

Ignition
Coil
.15
Injectors
.15

Intake
Air
Temp
Sensor
. .20

Map
Sensor
. .20
Powertrain
Control
Module .15,16,17,18,19,20

Throttle
Position
(Sensor)
.18

Vehicle
Speed
Sensor
.20

Ignition
Time
Delay Relay
49

Injectors
.15 Intermittent
Wiper
System .53,54
Control
Unit
.54 Intermittent
Windshield
Wiper
Motor
54

Windshield
Washer Pump
Motor
53

Wiper
Switch
53

Key-In
Switch
49

Key-In Warning Buzzer 77,78
Lamps
Air-Conditioning
and
Heater
Switch
Lamp
48

Ash
Receiver .48,52 Back-Up Lamps
......
79,80,81
Cargo Lamp
.
.49,50 Clearance Lamps-Dual Rear Wheels .41,42
Clearance Lamps Roof Mounted
.40

Cluster
Illumination
Lamps
.
.57,58,59
Dome Lamp
50,51

Four Wheel
Drive
Indicator
.13

Glove
Box
Lamp
52
Headlamp-Left
43,45 Headlamp-Right 44,46
Headlamp
Switch
Controlled
Interior
Lamps
. 48

Heater
Switch
Lamp
.48
High Beam
Indicator
Lamp
.59

Identification
Lamp
.
.40,41

Ignition
Switch
Lamp
.49
Instrument
Panel
Illumination
Lamps
.
.57,58,59
License Lamp
. . . 80
.
.48 Low
Engine
Oil
Pressure Lamp
59

45,46
Map
Lamp
49

.
.39
Parking
Lamp-Left
Front
43,45
66,67 Parking Lamp-Right
Front
44,46 .
.66
Rear
End
Lighting
System .79,80,81

•

WIRING DIAGRAMS
8W - 81
TO

HEADLAMP
SWITCH

(SEE
SH 47)
L7 18BK/YL
SPLICE

(SEE
SH 47)
L7 18BK/YL • L7 18BK/YL

BLACK
Onj )-L7 18BK/YL

(LEFT
SIDE
OF
INSTRUMENT PANEL)
BLACK

cur (AT LAMP)
L7 18BK

CLEARANCE

LAMP
L7
18BK YL
L7
18BK YL
L7
18BK YL
L7
18BK YL
BLACK
CDX
(AT LAMP)

-BLACK

an:
[AT LAMP)

-BLACK

an (AT LAMP)

-BLACK
an
(AT LAMP) L7 18BK-
L7 18BK-
IDENTIFICATION

LAMP

IDENTIFICATION
LAMP

L7 18BK- IDENTIFICATION

LAMP

L7 18BK-
CLEARANCE

LAMP

J938W-11
FRONT
CLEARANCE
AND
IDENTIFICATION

LAMPS
(ROOF)
AD 40