DODGE TRUCK 1993 Service Repair Manual

-
CHIME/BUZZER WARNING SYSTEMS
8U - 1

CHIME/BUZZER
WARNING SYSTEMS

CONTENTS
page

DIAGNOSIS

GENERAL
INFORMATION
page

1
KEY-IN SWITCH REPLACEMENT
3

1
OPERATION
1

GENERAL
INFORMATION
The buzzer module is located to the right of the
steering column (Fig. 1). The buzzer sounds an audi­
ble warning tone in any of the following conditions: • Vehicle lights are ON when the driver's door is
opened.
• The key is in the ignition and the driver's door is
open. • The ignition is switched ON and the driver's seat
belt is not buckled. Buzzer will quit after 4 to 8 sec­
onds.
In addition to the buzzer, a seat belt light in­
dicator turns on as a reminder to fasten seat belt.

BUZZER

MODULE

INTERMITTENT

WIPE MODULE

Fig, 1 Buzzer Module Location

OPERATION
Battery voltage for module operation is supplied to
two pins. Battery voltage is present at pin 7 at all
times (Figs. 2 and 3). Pin 1 receives voltage when
the ignition switch is turned ON.
SEA T BELT WARNING To sound the seat belt warning, the module needs:
• battery voltage at the ignition switch input (Pin 1)
• a ground at the seat belt switch.
• a ground at Pin 3 to activate the timer. This occurs when the seat belt switch is closed be­
cause the driver's seat belt is not buckled. The "fas­
ten belt" light will also turn on along with the
warning sound. KEY IN IGNITION
To sound the "key in ignition" alarm, the module

needs:

• the ignition key warning switch must be closed
• the driver's door jamb switch must be closed. These conditions ground pin 6 of the module. These
switches are closed when the driver's door is open
and the key is in the ignition.
LIGHTS ON To sound the "lights on" warning, the module

needs:

• the headlamp switch must be closed
*> the driver's door jamb switch must be closed. These conditions ground pin 6 of the module. These
switches are closed when the driver's door is open
and the headlamp switch is on.

DIAGNOSIS
If the buzzer unit does not operate as described,
check the two fuses for pins 1 and 7 (Figs. 2, 3 and 4) and replace as required. If the fuses are not defec­

tive,
perform the following tests to determine if the
problem is in the module or in the wiring. Using a flat blade screwdriver, release the locking plastic clip
while carefully pulling out the module. Plug in a known good module and check its operation. If the
problem is not corrected by replacing the module, re­ move the module and continue as follows:
VOLTAGE TESTS Ignition in run, measure between the following
pins and vehicle ground.
• Measure voltage at buzzer module connector pin 1.
Meter should read battery voltage. If not, repair open
to ignition switch.
Turn ignition off and remove key from igni­

tion.

• Measure voltage at buzzer module connector pin 7.
Meter should read battery voltage. If not, repair open
to fuse. Battery voltage is present at Pin 7 at all
times regardless of key position.

8U
- 2
CHIME/BUZZER
WARNING SYSTEMS
•
TERMINAL
7

TO
B
+
TERMINAL
6

TO DOOR SWITCH
KEY
IN
SWITCH
AND
HEADLAMP
ON
SWITCH
!cO=f
Mi c£K
*£h

• CZ3
EZZ3
EZI 1

TERMINAL
4

TO SEAT BELT
BUCKLE SWITCH TERMINAL
1

TO
IGNITION
SWITCH
TERMINAL
3

TO GROUND TERMINAL
2

TO SEAT BELT
WARNING
LIGHT
J928U-12

Fig.
2
Buzzer
Module
Connector
Terminal

Identification—Front
View

LIGHTS-ON/KEY-IN-IGNITION
WARNING
BATTERY
(+)
IS SI S K|
IGNITION
SEAT BELT
WARNING
LIGHT
GROUND SEAT BELT
SWITCH
J928U-9

Fig.
3
Buzzer
Module
Terminal
Identification—Front

View RESISTANCE TESTS

CAUTION:
Before making resistance measurements,

turn
ignition switch
OFF and
disconnect negative cable from
battery
to
avoid damaging ohmmeter.

Measure between the following pins and vehi­
cle ground.
• Buzzer module connector pin 2. Meter should read almost zero ohms (bulb filament). If not, replace seat
belt indicator bulb.
• Buzzer module connector pin 3. Meter should read
zero ohms. If not, repair open to ground. • Buzzer module connector pin 4. Drivers seat belt
not buckled. Meter should read zero ohms. If not, re­
pair open to ground (or buckle switch may be defec­
tive).
Meter should read open circuit if drivers seat
belt is buckled. If not, repair short to ground (or buckle switch may be defective).
• Buzzer module connector pin 6. Open driver's door,
key in ignition, (in OFF position). Meter should read
zero ohms. If not, repair open to ground.
• Buzzer/chime module connector pin 6. Open driv­
er's door, headlamp switch on, meter should read
zero ohms. If not, repair open to ground.
r—i
DOORSW

±
7
(SHOWN
DOOR
CLOSED)

rFY<;w M
UGHTS
SW

(SHOWN
KEW/
f(SHOWN^JGHTS
OFF)

#5 -^•^Y
BELT(I)

SW
LAMP
JL
SEAT
BELT
SW

/.
(SHOWN
-
BUCKLED)
IGN
SW

(SHOWN
IGN OFF)

PIN
VIEW
(SAME
AS
REAR
SIDE
[WIRE
SIDE]
CONNECTOR
VIEW)
X
=
Do Not Care

FUNCTION
DESCRIPTION

IGN.
SEAT

BELT
DRIVER'S

DOOR
KEY

HEAD

LAMPS

Seat
Belt
Reminder
4
to
8
Second

Tone and

Lamp
Output
^On

OP
Not
Bckld
X
X
X

Seat

Belt
Reminder
4
to
8
Second

Lamp
Output
Only
^On

OfP
Bckld

X X
X

Key
and
Head Lamp Reminder*
Continuous,

Steady
Tone
X
X
Open
In

X

Key
and
Head Lamp Reminder*
Continuous,

Steady
Tone
X
X
Open

X
On

*On
some
vehicles,
the key
switch
opens
when the ignition is switched on.
J928U-8

Fig.
4
Buzzer
Module
Schematic

o
o o o
4 3 2 1

WIRE
CAVITY APPLICATION
CONTINUITY

BETWEEN
1

2
Hdo
lamp

Halo
lamp
1
& 2
Almost
zero
ohms

(bulb
filament)

3
4
Key-in
warning switch

Key-in
warning switch
3
& 4
with
key in ignition
J918M-3

Fig.
5 Halo
Lamp
And
Key-In
Warning
Switch
Continuity Chart

•

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

8U
- 4
CHIME/BUZZER WARNING
SYSTEMS

•
(e) Remove key cylinder (Fig, 10).

Fig.
10 Key Cylinder
Removal
INSTALLATION

(1) Install 2 wiring connectors to the switch. Make
sure that switch locking tabs are fully seated in the
wiring connectors.
(2) Mount ignition switch to column with 3 screws.
When equipped with column shift:
• the shifter must be in Park position
• the park lock dowel pin on the ignition switch as­
sembly must engage with column park lock slider
linkage (Figs. 11 and 12). Verify ignition switch is in lock position (flag is
parallel with ignition switch terminals). Apply a daub of grease to flag and pin. Position park lock link and slider to mid-travel. Position ignition switch
against lock housing face, making sure pin is in­
serted into park lock link contour slot. Torque retain­
ing screws to 2 N*m (17 in. lbs.).
(3) Assemble cover to the column with 3 screws.
Torque screws to 2 N*m (17 in. lbs.).
(4) Tilt column only—install tilt lever (clockwise). (5) Install negative cable to battery.
(6) Install key cylinder as follows: 908D-18
Fig.
11 Ignition Switch—View From
Column

Fig.
12 Ignition
Switch
Mounting
Pad
(a) With key cylinder and ignition in the Lock
position, gently insert key cylinder into the igni­
tion switch assembly until it bottoms.
(b) Insert key, while gently pushing on key cyl­
inder inward toward the ignition switch, rotate key clockwise to the Run position. (7) Check for proper operation of push-to-lock, halo
lighting, Accessory, Lock, Off, Run, Start, Column
Lock and Shift Lock (if applicable).

•

WIRING DIAGRAMS
8W
- 1
CONTENTS

page page
COMPONENT IDENTIFICATION
.............
9
SPLICE LOCATIONS
29

GENERAL
INFORMATION
1
WIRING DIAGRAMS AD-BODY
37

GENERAL
INFORMATION
INDEX
page

Circuit
Identification
2

Component
Identification
3

Connectors
3
Fusible Links
3

Harness
Repair
3

Locating
A
System
or
Component
2
page
Secondary
Ignition
Wiring
1

Splice Locations
3
Symbols
and
Fuses
5

Troubleshooting
Wiring
Problems
3

Wire Code
Identification
2

Wiring
Diagram Sheets
and
Indexes
1

The wiring diagrams contain
the
latest information
available
at
time
of
publication. Throughout
out
this
group references
may
be
made
to a
particular vehicle
by letter
or
number designation.
A
chart showing
the
breakdown
of
these designations
is
included
in the
Introduction Section
of
this service manual.

SECONDARY
IGNITION WIRING
Secondary ignition wiring
is
shown
in
Figures
1

and 2.
For
information
on
ignition systems
or
distrib­
utor operation refer
to
Group
8D
Ignition Systems.
SPARK
PLUGS

RIGHT
BANK

3.9L
SIX-CYLINDER
ENGINE

DISTRIBUTOR—CLOCKWISE
ROTATION
FIRING
ORDER
1-6-5-4-3-2
RN755
Fig.
1
Secondary
Ignition Wiring 3.9L
Engine

WIRING DIAGRAM SHEETS AND INDEXES
The wiring diagram sheets
are
organized
so
that
systems relating
to the
basic vehicle
and all of
its op­

tions
are
shown. Add-on
or
non-factory options
are
SPARK
PLUGS

LEFT
BANK

EIGHT
CYLINDER
DISTRIBUTOR-CLOCKWISE
ROTATION
FOR
318
AND
360
CUBIC
INCH
ENGINES

FIRING
ORDER-1-8^-3-63-7-2 RP899 Fig.
2
Secondary
Ignition Wiring 5.2L and 5.9L

Engine
not covered.
The
diagram pages
are
identified
by a

sheet number which
is
located
at the
lower right
or

left hand corner
of
each sheet. Page numbers
at the

top
of
each page
do not
apply
to
diagram sheets.
Diagram sheets show
all
information relating
to

the system. This includes feeds, grounds, switch
in­
ternal circuity, connectors, splices,
and
pin
identifica­
tion
for
controllers
and
modules.
In certain instances
a
wire
may be
referenced
to

another sheet. When this happens,
the
wire will
be

identified
as to
where
it is
going.
The index used
for the
diagrams
is
located
at the

beginning
of the
diagrams.
It
covers
all
systems shown
in the
diagrams
and is in
alphabetical order.

WIRING
DIAGRAMS

8W
- 2
WIRING
DIAGRAMS

•
WIRE CODE
IDENTIFICATION

Each wire shown in the diagrams contains a code
(Fig. 3) which identifies the main circuit, part of the
main circuit, gauge of wire, and color. The color is shown as a two letter code which can be identified by
referring to the Wire Color Code Chart (Fig. 4). If
the wire has a tracer and it is a standard color an asterisk will follow the main wire color. If the tracer
is non-standard the main wire color will have a slash (/) after it followed by the tracer color. 18
LB/YL*
COLOR
OF
WIRE

(Light
Blue
with
Yellow
Tracer)
.
GAUGE
OF
WIRE
(18
Gauge)

PART
OF
AAAIN CIRCUIT

(Varies
Depending
on
Equipment)

AAAIN CIRCUIT
IDENTIFICATION
918W-16

Fig.
3
Wire
Color
Code
Identification

CIRCUIT IDENTIFICATION
All circuits in the diagrams use an alpha/numeric
code to identify the, wire and its function. To identify
which circuit code applies to a system, refer to the
Circuit Identification Code Chart. This chart shows
the main circuits only and does not show the second­ ary codes that may apply to some models.
COLOR

CODE COLOR
STANDARD
TRACER

COLOR COLOR

CODE
COLOR
STANDARD

TRACER
CODE
BL BLUE WT
OR ORANGE

BK
BK
BLACK
WT PK
PINK
BK
OR WT

BR
BROWN
WT RD
RED WT
DB DARK
BLUE WT
TN
TAN WT
DG DARK
GREEN WT
VT

VIOLET
WT
GY GRAY
BK

WT

WHITE
BK

LB
LIGHT

BLUE
BK

YL YELLOW

BK

LG
LIGHT

GREEN
BK

*

WITH
TRACER

918W-136
Fig.
4
Wire
Color
Code
Chart

LOCATING
A
SYSTEM
OR
COMPONENT
To locate a system or component in the diagrams,
refer to the alphabetical index at the front of the di­ agrams. Determine the diagram sheet number. Sheet
numbers are located at the lower right or left hand
corner of each sheet. Page numbers at the top of
the page do not apply to diagram sheets. The diagram index identifies the main system and
all components that relate to that system. There are
also sections of the index that identify specific com­
ponents only (for example modules, lamps, etc.). Re-

MAIN
CIRCUIT IDENTIFICATION

CIRCUIT
DESCRIPTION
CIRCUIT
DESCRIPTION

A
Battery
Feed: Fused and Unfused
P
Power
Assist
System:
Locks,
Mirrors

B
ABS
System Q Power
Assist
System: Windows

C
Air Conditioning System

R
Airbag System

D
CCD
(+),
CCD
(-)
S
Air Suspension, Automatic Load Leveling

E
Interior
Lamp
Illumination
T Electronic Automatic Transaxle
F
Battery
Feed: Fused and Unfused
V
Windshield Wipers and Washers,

G
Sensors,
Sending Units, Switches Vehicle Speed Control System

K
Powertrain
Central
Module W Power
Assist
System: Windows

L
Exterior
Lighting, Stop Lamp Switch
X
Horn, Radio, Radio Speakers, Power Locks
M
Interior
Lamps
Z
Ground Circuits: Includes power and signal

Interior
Lamps

grounds
for PCM

938W-17

•

WIRING
DIAGRAMS
8W - 3 fer to a components name in the index if you are
unclear as to what a system may be called.
Diagram pages are arranged starting with the bat­
tery and fuses. Then working into charging, starting, and ignition systems. After this they start at the
front of the vehicle and work to rear of the vehicle.
The diagrams end with connector identification

pages.

COMPONENT
IDENTIFICATION
To find a components actual location on the vehicle
refer to the wiring and components section index. This section shows the wire harness routing and the compo­
nents location in the vehicle. When using this section
refer to the wiring diagrams for the general location of
the component. Then use the component identification index to locate the proper figure number.

SPLICE
LOCATIONS
Splices are indicated in the wiring diagrams by a
diamond with splice circuit code within it (Fig. 5 ex­ ample 1). If there is more than one splice per circuit
splice code a small box will be connected to the dia­
mond with the splice number in it (Fig. 5 example 2). To locate a splice in the wire harness determine
the splice number from the wiring diagrams, then re­
fer to the splice location index. This section shows
the general location of the splice in the harness.

EXAMPLE
1
EXAMPLE
2 918W-18

Fig.
5 Wiring
Splice
Examples

CONNECTORS
The connectors shown in the diagram are viewed from
the terminal end unless otherwise specified. For view­ ing bulkhead and engine controller connectors refer to
the back of the wiring diagrams. This area shows major connectors for pin and cavity identification.

TROUBLESHOOTING
WIRING
PROBLEMS
When troubleshooting wiring problems there are
six steps which can aid in the procedure. The steps
are listed and explained below. (1) Verify the problem.
(2) Verify any related symptoms. Perform opera­
tional checks on components in the same circuit as the problem area. Refer to the wiring diagram fuse
application chart for circuit information. (3) Analyze the symptoms. Use the wiring dia­
grams to determine what the circuit is doing, where
the problem most likely is occurring and where the diagnosis will continue. (4) Isolate the problem area. (5) Repair the problem.
(6) Verify proper operation. For this step check for
proper operation of all items on the circuit repaired. Refer to the wiring diagram fuse application chart.

FUSIBLE
LINKS
Vehicle wiring harnesses are equipped with fusible

links.
For protection against harness damage in the
event of a short. Fusible links are color coded as to
wire gauge size. Refer to the fusible link chart for color and gauge identification (Fig. 6).
Wire and
Gauge
Color
Code
Color

12 Ga.
BK
Black

14 Ga.
RD
Red

16 Ga.
DB
Dark
Blue

18 Ga.
GY
Gray

20 Ga.
OR
Orange

22 Ga.
WT
White
918W-19

Fig.
6 Fusible
Link
Chart

HARNESS
REPAIR

FUSIBLE
LINK
REPLACEMENT

CAUTION:
Do not replace blown fusible
links
with
a

standard
wire.
Only
use fusible type
wire
with
hyp-

alon
insulation or
damage
to the electrical
system
could
occur.
Also
make
sure
correct
gauge
of
wir­
ing
is
used.
Refer to the wiring
diagrams
for proper

gauge
and
color.

When a fusible link blows it is important to find
out what the problem is. They are placed in the elec­
trical system for protection against shorts to ground
that can be caused by a component or various wiring
failures. Do not just replace the fusible link to correct the problem.
When diagnosing a faulty fusible link it is impor­
tant to check the wire carefully. In some instances
the link may be blown and it will not show through the insulation, the wire should be checked over its
entire length for internal breaks.
(1) Disconnect battery negative cable.
(2) Cut out the blown portion of the fusible link.
(3) Strip 1 inch of insulation from each end of the
existing fusible link.
(4) Place a piece of heat shrink tubing over one
side of the fusible link. Make sure the tubing will be
long enough to cover and seal the entire repair area.
(5) Cut a replacement piece of fusible link approx­
imately two inches longer than the piece removed. (6) Remove one inch of insulation from each end of
the replacement fusible link.

8W
- 4
WIRING
DIAGRAMS

(7) Spread
the
strands
of
wire apart
on
each
of the

exposed wires
(Fig. 7
example
1).
(8) Push
the two
ends
of the
wire together until
the strands
of
wire
are
close
to the
insulation
(Fig. 7

example
2).

(9) Twist
the
wires together
(Fig. 7
example
3).

(10) Solder
the
wires together using rosin core type
solder only.
Do not use
acid core type solder.
(11) Center
the
heat shrink tubing over
the
joint
and heat using
a
heat
gun.
Heat
the
joint until
the

tubing
is
tightly sealed
and
sealant comes
out of
both ends
of the
tubing. (12) Secure
the
fusible link
to the
existing ones
to

prevent chafing
or
damage
to the
insulation.
(13) Connect battery
and
test
all
affected systems.
Fig.
7
Wire Repair
918W-20

WIRING REPAIR When replacing
or
repairing
a
wire,
it is
important
that
the
correct gauge
be
used
as
shown
in the
wir­ ing diagrams.
The
wires must also
be
held securely
in place
to
prevent damage
to the
insulation.
(1) Disconnect battery negative cable.
(2) Remove
1
inch
of
insulation from each
end the

wire.

(3) Place
a
piece
of
heat shrink tubing over
one

side
of the
wire. Make sure
the
tubing will
be
long
enough
to
cover
and
seal
the
entire repair area.
(4) Spread
the
strands
of the
wire apart
on
each
part
of the
exposed wires
(Fig. 7
example
1).
(5)
Push
the two
ends
of
wire together until
the

strands
of
wire
are
close
to the
insulation
(Fig. 7 ex­

ample
2).

(6) Twist
the
wires together
(Fig. 7
example
3).

(7) Solder
the
connection together using rosin core
type solder only.
Do not use
acid core solder.
(8)
Center
the
heat shrink tubing over
the
joint and heat using
a
heat
gun.
Heat
the
joint until
the

tubing
is
tightly sealed
and
sealant comes
out of
both
ends
of the
tubing.
(9) Secure
the
wire
to the
existing ones
to
prevent
chafing
or
damage
to the
insulation.
(10) Connect battery
and
test
all
affected systems.
CONNECTOR REPLACEMENT (1) Disconnect battery.
(2) Disconnect
the
connector that
is to be
repaired
from
its
mating
half.
(3) Remove connector locking wedge
(Fig. 8).

CONNECTOR

CONNECTOR
LOCKING
WEDGE
TAB
928W-143

Fig.
8
Connector Locking Wedge
Tab

(4) Position
the
connector locking finger away from
the terminal. Pull
on the
wire
to
remove
the
termi­ nal from
the
connector
(Fig. 9).

(5) Reset
the
terminal locking tang,
if it has one.

(6) Insert
the
removed wire
in the
same cavity
on

the repair connector.
(7) Repeat steps four thru
six for
each wire
in the

connector. Check that
all
wires
are
inserted into
the

proper cavities.
For
connector
pin out
identification refer
to the
wiring diagrams.
(8) Insert
the
connector locking wedge into
the re­

paired connector.
(9) Connect connector
to its
mating
half.

(10) Connect battery
and
test
all
affected systems.

CONNECTOR
AND
TERMINAL ASSEMBLY
REPLACEMENT
(1) Disconnect Battery.
(2) Disconnect
the
connector being repaired form
its mating
half.
(3)
Cut off the
existing wire connector directly
be­

hind
the
insulator
and
remove
six
inches
of
tape
from
the
harness.
(4) Stagger
cut all
wires
on the
harness side about

1/2
inch apart
(Fig. 10).
(5) Remove
1
inch
of
insulation from each wire
on

the harness side.

WIRING DIAGRAMS
SW - 5

CONNECTOR
LOCKING WEDGE
CONNECTOR
LOCKING
FINGER

If
928W-144

Fig.
9
Connector
Locking
Finger
and
Locking
Wedge
(6) Stagger cut the matching wires on the repair
connector assembly in the opposite order as was done
on the harness side of the repair. Allow extra length
for soldered connections. Check that the overall length is the same as the original (Fig. 10).

REPAIR SIDE STAGER CUTS WIRES

HARNESS
WIRES
928W-145

Fig.
10
Stagger
Cutting Wires (7) Remove 1 inch of insulation from each wire.
(8) Place a piece of heat shrink tubing over one
side of the wire. Make sure the tubing will be long
enough to cover and seal the entire repair area.
(9) Spread the strands of the wire apart on each
part of the exposed wires (Fig. 7 example 1).
(10) Push the two ends of wire together until the
strands of wire are close to the insulation (Fig. 7 exam­
ple 2).
(11) Twist the wires together (Fig. 7 example 3).
(12) Solder the connection together using rosin
core type solder only. Do not use acid core solder.
(13) Center the heat shrink tubing over the joint
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both ends of the tubing. (14) Repeat steps 8 thru 13 for each wire.
(15) Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. (16) Reconnect the repaired connector.
(17) Connect battery and test all affected systems.

TERMINAL
REPLACEMENT
(1) Disconnect battery.
(2) Disconnect the connector being repaired form
its mating
half.
(3) Remove connector locking wedge (Fig. 8).
(4) Position the connector locking finger away from
the terminal. Pull on the wire to remove the termi­ nal from the connector (Fig. 9).
(5) Cut the wire 6 inches from the back of the con­
nector. (6) Remove 1 inch of insulation from the wire on
the harness side.
(7) Select a wire from the terminal repair assem­
bly that best matches the color wire being repaired. (8) Cut the repair wire to the proper length and re­
move 1 inch of insulation.
(9) Place a piece of heat shrink tubing over one of
side of the wire. Make sure the tubing will be long
enough to cover and seal the entire repair area.
(10) Spread the strands of the wire apart on each
part of the exposed wires (Fig. 7 example 1). (11) Push the two ends of wire together until the
strands of wire are close to the insulation (Fig. 7 ex­
ample 2).
(12) Twist the wires together (Fig. 7 example 3).
(13) Solder the connection together using rosin
core type solder only. Do not use acid core solder.
(14) Center the heat shrink tubing over the joint
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both ends of the tubing.
(15) Insert the repaired wire into the connector.
(16) Install the connector locking wedge and recon­
nect the connector to its mating
half.

(17) Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. (18) Connect battery and test all affected systems.

SYMBOLS
AND
FUSES
Various symbols are used throughout wiring dia­
grams. These symbols can be identified by referring
to symbol identification chart (Fig. 11). For fuse block and relay bank information refer to
(Fig. 12).

CAUTION:
When replacing
a
blown fuse,
it is
impor­

tant
to
replace
it
with
a
fuse having
the
correct
am­
perage rating.
The use of a
fuse
with
a
rating other
than indicated
may
result
in a
dangerous
electrical
overload.
If a
proper
rated
fuse continues
to
blow,
it
indicates
a
problem
that
should
be
corrected.