roof rack DODGE TRUCK 1993 Service Repair Manual

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

11-14
EXHAUST
SYSTEM
AND
INTAKE
MANIFOLD

• The plenum pan rail must be clean and dry (free of
all foreign material).

INSPECTION
Inspect manifold for cracks.
Inspect mating surfaces of manifold for flatness
with a straightedge.

INSTALLATION
(1) Install the plenum pan, if removed, as follows: (a) Turn the intake manifold upside down. Sup­
port the manifold.
(b) Place a new plenum pan gasket onto the seal
rail of the intake manifold. Position the pan over
the gasket. Align all the gasket and pan holes with
the intake manifold. (c) Hand start all bolts.
(d) Tighten the bolts, in sequence (Fig. 10), as
follows:

V-6
V-8

Fig.
10
Plenum
Pan
Bolt
Tightening
Sequence

• Step
1-Tighten
bolts to 2.7 N*m (24 in. lbs.)
torque.
• Step 2-Tighten bolts to 5.4 N«m (48 in. lbs.)
torque.
• Step 3-Tighten bolts to 9.5 Nnn (84 in. lbs.)
torque.
• Step 4—Check that all bolts are tighten to 9.5 N®m (84 in. lbs.) torque.
(2) Using a new gasket, install the throttle body
onto the intake manifold. Tighten the bolts to 23
Nun (200 in. lbs.) torque. (3) Place the 4 plastic locator dowels into the holes
in the block Fig. 11).
(4) Apply MOPAR Silicone Rubber Adhesive Seal­
ant, or equivalent, to the four corner joints. An ex­ cessive amount of sealant is not required to ensure a
leak proof seal. However, an excessive amount of
sealant may reduce the effectiveness of the flange
gasket. The sealant should be slightly higher than
the cross-over gaskets, approx. 5 mm (0.2 in).
(5) Install the front and rear cross-over gaskets
onto the dowels (Fig. 11).

FRONT
CROSS-OVER
GASKET



REAR
CROSS-OVER
GASKET
J9209-99

Fig
11
Cross-Over
Gaskets
and Locator
Dowels

(6) Install the flange gaskets. Ensure that the ver­
tical port alignment tab is resting on the deck face of
the block. Also the horizontal alignment tabs must
be in position with the mating cylinder head gasket
tabs (Fig. 12). The words MANIFOLD SIDE should
be visible on the center of each flange gasket.
(7) Carefully lower intake manifold into position
on the cylinder block and cylinder heads. Use the alignment dowels in the cross-over gaskets to posi­
tion the intake manifold. After intake manifold is in
place, inspect to make sure seals are in place.
(8) Install the intake manifold bolts and tighten as
follows:
V-6 ENGINE—(Fig. 13)
• Step
1-Tighten
bolts 1 and 2 to 8 Nun (72 in. lbs.)
torque. Tighten in alternating steps 1.4 Nun (12 in. lbs.) torque at a time.
• Step 2—Tighten bolts 3 through 12, in sequence,
to 8 Nun (72 in. lbs.) torque.
• Step 3—Check that all bolts are tighten to 8 Nun (72 in. lbs.) torque.
• Step 4—Tighten all bolts, in sequence, to 16 Nun (12 ft. lbs.) torque.
• Step 5—Check that all bolts are tighten to 16 Nun (12 ft. lbs.) torque.

•

BODY
COMPONENTS
23 - 1
CONTENTS

page
page

CAB/BODY
INTERIOR COMPONENTS
35
FIXED
GLASS
. 29
DOORS
21
PAINT
CODE
CHART
54

EXTERIOR
COMPONENTS
1
REFINISHING
PROCEDURES
54
EXTERIOR COMPONENTS
INDEX

page

Battery
Tray
7

Blower Motor Housing
Insulation
Panel—Diesel
Engine
Only
7

Body
Mouldings, Nameplates
and
Decals .......
9

Cab
. 14

Cab/Body
and
Cargo
Box
Stripes
11

Cargo
Box
19
Cowl
Grille
7
Front
Fenders
8
Fuel
Filler
Door
and
Nozzle/Tubes
12

Grille
and
Grille
Extension Panel
1

Grille
Extension Panel Support Bracket
(With
Diesel Engine Only)
3
page

Grille
Opening Panel (GOP)
and
Radiator Support Panel
3

Hatchgate
and
Components
16

Hood
5

Hood
Inside Release Cable
5

Hood
Latch
4

Labels/Decals/Plates
1

Outside Mirrors
13
Roof
Vent—Ramcharger
. 20

Splash
Shields—Front Fender
9

Sport
Bar
18

Tailgate
14

LABELS/DECALS/PLATES
GENERAL
INFORMATION The labels, decals
and
plates that
are
attached
to

Ram Van
and
Wagon vehicles contain safety
or
oth­ erwise essential information (Figs.
1, 2, 3 and 4).

INSTALLATION
Follow the instructions included with each replace­
ment label, decal
or
plate
to
affix
it to a
panel
or
component.

GRILLE
AND GRILLE EXTENSION PANEL
GRILLE
REMOVAL (1) Remove screws that attach the headlamp bezels
(Fig.
5) to the
grille.

(2)
Separate
the
bezels from
the
headlamps
(Fig.

5).
(3) Raise
and
support
the
hood.
(4) Remove the grille screws from the radiator sup­
port panel
and the
extension panel (Fig.
6).
(5) Remove
the
grille from the front
of
the vehicle.
EMISSION
CONTROL
DRIVE
BELT

INFORMATION
AND
VACUUM
ROUTING
LABEL
HOSE
ROUTING
LABEL
(DIESEL

Fig.
1 Underhood Labels, Decals & Plates
BODY
COMPONENTS

•

BODY
COMPONENTS 23 - 45

LOWER
SIDE TRIM PANEL
QUARTER
WINDOW
TRIM

PANEL
ROOF
INNER PANEL
\C SCREW
QUARTER PANEL SCREW
QUARTER WINDOW QUARTER WINDOW TRIM
PANEL
TRIM
PANEL
LOWER SECTION UPPER SECTION
SCREW
ASH
RECEIVER BEZEL
ASH RECEIVER LOWER SIDE TRIM PANEL CLIP
RETAINER LOWER
SIDE TRIM PANEL ROOF
INNER PANEL
RETAINER RAIL LOWER SIDE
TRIM PANEL
AT FLOOR PANEL SCREW REAR
HEADER TRIM
PANEL
ABOVE HATCHGATE
J9123-392 Fig.
31
Quarter
Panel & Hatchgate Header
Trim

Panels—Removal/Installation

QUARTER PANEL LOWER TRIM PANELS

REMOVAL
(1)
For
convenience, fold forward
the
rear passen­
ger seat.
(2) Remove
the
spare tire. (3) Remove
the
rear pillar panel screws from
the

hatchgate pillar inner panel
(Fig. 30).

(4)
Pry the
trim panel end retainers from
the
quar­
ter inner panel slots.
(5) Disengage
the
lower trim panel clip retainers
from
the
wheelhouse. (6) Remove
the
lower trim panel from
the
vehicle.

INSTALLATION
(1) Position
the
lower trim panel
in the
vehicle
at

the quarter.
(2) Engage
the
trim panel clip retainers with
the

wheelhouse rail retainers.
(3) Engage
the
trim panel
end
retainers with
the

quarter inner panel slots.
(4) Position
the
rear pillar panel
at the
hatchgate
pillar panel. Install
the
screws
and
tighten
to 1 N»m
(12
in. lbs.)
torque.
(5) Install
the
spare tire.

SPARE
TIRE
CARRIER

RETAINER
ROD AND
STAND-OFF
(2)
Remove
the
quarter window trim panel
and the

quarter panel lower trim panels.
If
necessary, refer
to
the
removal procedures. (3) Remove
the
rod retainer from
the
quarter panel
support bracket. (4) Remove
the
tire stand-off
cap, nut,
bolt
and

spacer from
the
quarter window lower panel.

INSTALLATION
(1) Install
the
tire stand-off bolt, spacer,
nut and

cap.
Tighten
the nut to 41 N»m (30 ft. lbs.)
torque.
(2) Install
the rod
retainer
in the
quarter panel
support bracket hole.
(3) Install
the
quarter window trim panel
and the

quarter panel lower trim panels.
If
necessary, refer
to
the
installation procedures.

(4)
Install
the
spare tire. QUARTER
WINDOW
TRIM PANEL
SPACER
BOLT SIDE
INNER
' PANEL SIDE
INNER
PANEL STAND-OFF
CAP
TIRE STAND-OFF
NUT
AND
INSERT J9123-409
Fig.
32 Spare Tire/Wheel
SHOULDER BELTS/LAP BELT/BUCKLES
WARNING:
WHEN
INSTALLING
SHOULDER BELT,
LAP
BELT
AND
BUCKLE ANCHOR BOLTS, VERIFY

THAT
THEY
ARE
TIGHTENED
TO 40 N-M (350 IN.
LBS.) TORQUE.
INSPECTION Inspect
the
condition
of all the
belts
and
buckles

(Figs.
33, 34 and
35). Replace
any
belt
or
buckle that
is damaged
in any way.
Also, replace
the
shoulder
belt
if
the retractor
is
inoperative.
FRONT SHOULDER BELTS/LAP

BELT/BUCKLES

REMOVAL
(1)
If
necessary, move
the
front seat(s)
all the way

forward
for
access. (2) Disconnect
the
shoulder belt warning wire har­
ness connectors.
REMOVAL

(1) Remove
the
spare tire
(Fig. 32).

•
BODY COMPONENTS 23 • 47

SPACER
SHOULDER
BELT COVER

TRIM

"PANEL

INNER
PANEL

SPACER

PILLER
SHOULDER BELT ANCHOR

BOLT

SHOULDER BELT
RETRACTOR
ANCHOR
BOLT

SHOULDER BELT
RETRACTOR
COVER
ANCHOR
BOLT

ANTI-

RATTLE

WASHER
SCREW

ANCHOR]
BOLT
RAMCHARGER
ANTI-

RATTLE

WASHER

MODELS
30 & 60

J9123-329

Fig.
35
Shoulder
Belt,
Anchor
Bolts
& Retractor (9) Remove the belt retractor support bracket an­
chor bolts from the quarter panels.
(10) Remove the shoulder belts and the retractors
from the vehicle.

INSTALLATION
(1) Position the shoulder belt retractor support
brackets at the quarters above the wheelhouse. In­ stall the support bracket anchor bolts in the quarter
panels. Tighten the anchor bolts to 40 Nnn (350 in. lbs.) torque.
(2) Position the other end of the shoulder belt at
the
floor
panel. Install the lower anchor bolt in the
floor panel. Tighten the anchor bolts to 40 Nnn (350
in.
lbs.) torque.
(3) Position the shoulder belt upper anchor plate at
the roof inner liner. Install the upper anchor bolts in
the roof inner liner. Tighten the anchor bolts to 40 Nnn (350 in. lbs.) torque.
(4) Position the covers over the upper anchor bolts.
(5) Install the quarter panel lower trim panel. If
necessary, refer to the installation procedure. (6) Install the shoulder belt cover on the trim
panel. Tighten the screws to 1 Nnn (12 in. lbs.)
torque.
(7) Position the buckles and the lap belt on the
folding seat frame.
(8) Install the anchor bolts in the seat frame.
Tighten the bolts to 40 N-m (350 in. lbs.) torque.
(9) If applicable, adjust the front seat position.
REAR

FOLDING
SEAT

FLOOR
PANEL
ANCHOR
BOLT

SEAT

RELEASE
J9123-610

Fig.
36 Rear
Folding
Seat
Shoulder
Belt
Buckle
&
Lap
Belt/Buckle
Anchors

ANCHOR
BOLT
SHOULDER BELT ROOF
OUTER

LINER
COVER
•
SCREW"

SHOULDER^ BELT
RETRACTOR
ANCHOR
BOLT
SIDE

INNER PANEL

J9123 -330

Fig.
37 Rear
Seat
Shoulder
Belt—Ramcharger

•
^ ^ —
BODY COMPONENTS
23 - 49

HEADLINER ROOF
INNER PANEL
ROOF
INNER PANEL

SCREW
ROOF
RAIL
HEADER

TRIM
PANEL HEADLINER

J9123-353

Fig.
40
Cloth-Covered
Molded
Cab Headliner

ROOF
INNER PANEL RETAINER RAIL
CENTERING HOLE

REAR

HEADLINER
RETAINER PERIMETER
RETAINER
INSTALLATION
TRIM

'MOULDING

J9123-358

Fig.
41
Ramcharger
Headliner
INNER
BACK

PANEL
ROOF
—

INNER
PANEL
REAR

WINDOW

UPPER
TRIM

SUNVISOR SUNVISOR
AND WINDSHIELD HEADER
TRIM
DOME LAMP LENSE
DOME AND
WINDOW
TRIM
LAMP

LENSE
J9l
23-352

Fig.
42 Ram
Truck/Chassis
Cab
Sunvisor
&
Dome
Lamp
ROOF
INNER
v
PANEL


SIDE

TRIM

MOULDING
HEADLINER

RETAINER
RAIL

FRONT

HEADLINER

SCREW

SIDE
OF VEHICLE ROOF INNER PANEL
WINDSHIELD
WEATHERSTRIP
SEAL
ROOF
INNER PANEL

REAR

HEADLINER

SCREW
RETAINER SNAP-ON

TRIM
MOULDING
ENDCAP CENTER OF VEHICLE

FRONT

HEADLINER
REAR

HEADLINER ROOF INNER
PANEL WINDSHIELD
HEADER
TRIM

MOULDING

FRONT
OF VEHICLE
SCREW

SCREW

SUN VISOR SCREW
REAR
TRIM

ARM
MOULDING
REAR
OF VEHICLE

J9123-359
Fig.
43
Ramcharger
Sunvisor
& Headliner
Trim

Moulding

ROOF
INNER PANEL
BRACKET

BULB

HOLDER DOME
LAMP
BRACKET

HEADLINER
LENSE
DOME LAMP

WITH
HEADLINER
SCREW

DOME LAMP CLUB CAB
BULB

HOLDER
J9123-401

Fig.
44 Ram
Truck/Chassis
Cab
Dome
Lamps

DOME/READING LAMP

REMOVAL
(1) Squeeze the dome lamp lense to remove it from
the bracket.
(2) If applicable, remove the lense bracket screws.
(3) Remove the lense bracket from the headliner
and roof inner panel. (4) Disconnect the bulb holder wire harness con­
nectors (Fig. 44). (5) Remove the lense, bulb holder and bracket
from the roof inner panel.

INSTALLATION
(1) Position the dome/reading lense, bulb holder
and lense bracket to the roof inner panel.

23
- 50 BODY COMPONENTS — < ^ ^ • •

DOME LAMP DOME/READING LAMP
J9123-400

Fig.
45
Ramcharger
Dome Lamp
&
Dome/Reading Lamp (2) Connect
the
bulb holder wire harness connec­

tors.
(3) Insert
the
lense bracket
in the
headliner hole.
Install
the
screws
in the
roof inner panel. Tighten
the screws
to 4 N#m (35 in. lbs.)
torque.
(4) Install
the
lamp lense
on the
bracket.

DOME LAMP-CLUB
CAB

REMOVAL
(1) Remove
the
screws
and the
dome lamp lense
from
the
lamp housing
(Fig. 44).

(2) Disconnect
the
bulb holder wire harness con­
nectors.
(3) Remove
the
screws
and the
bulb holder bracket
from
the
lamp housing. (4) Remove
the
bulb holder
and
bracket from
the

lamp housing.

INSTALLATION
(1) Position
the
bulb holder
and
bracket
at the

lamp housing.
(2) Install
the
bulb holder bracket screws
in the

lamp housing. Tighten
the
screws
to 4 N°m (35 in.

lbs.) torque.
(3) Connect
the
bulb holder wire harness connec­

tors.

(4) Position
the
lense
on the
lamp housing. Install
the screws. Tighten
the
screws
to 4 N#m (35 in. lbs.)

torque.

SUNVISORS

REMOVAL
(1) Remove
the
screws that attach
the
sunvisor
arm support bracket
to the
roof inner panel (Figs.
42

and
43).
(2) Detach
the
sunvisor from
the
clip.
(3) Remove
the
sunvisor from
the
roof inner panel. (4) Remove
the
screw
and the
clip from
the
roof
in­

ner panel.

INSTALLATION

(1) Install
the
sunvisor clip with
the
screw.
Tighten
the
screw
to 4 N*m (35 in. lbs.)
torque, (2) Position
the
sunvisor
in the
clip. Align
the arm

support bracket holes with
the
headliner holes.
(3) Install
the
screws that attach
the
sunvisor
arm

support bracket
to the
roof inner panel. Tighten
the

screws
to 4
N*m
(35 in. lbs.)
torque.

FLOOR
CONSOLE AND
REAR STORAGE TRAY
CONSOLE

REMOVAL
(1) Open
the
console
lid (Fig. 46).

(2) Remove
the
console front
and
rear screws from
the floor panel.
(3) Remove
the
console from
the
floor.

INSTALLATION
(1) Position
the
console
on the
floor. (2) Install
the
screws
in the
floor panel. Tighten
screws
to 4 N«m (35 in. lbs.)
torque. (3) Close
the
console
lid.

STORAGE
TRAY-STANDARD
CAB

REMOVAL
(1) Remove
the
contents from
the
storage tray.
(2) Remove
the
screws from
the
floor panel
and the

tray
(Fig. 47).
(3) Remove
the
storage tray from
the
floor panel.

INSTALLATION
(1) Position
the
storage tray
on the
floor panel. (2) Install
the
screws
in the
tray
and
floor panel.
Tighten
the
screws
to 4 N«m (35 in. lbs.)
torque.
Fig.
46
Floor
Console