turn signal bulb DODGE TRUCK 1993 Service Repair Manual

•

INSTRUMENT PANEL
AND
GAUGES
8E - 15
PRND21 INDICATOR

REMOVAL
(1) Remove bezel. Refer to Cluster Bezel Removal.

(2)
Remove cluster mask and lens. Refer to Cluster
Mask and Lens Removal. (3) Remove cluster assembly. Refer to Instrument
Cluster Removal. (4) Remove screws attaching PRND21 mechanism
to cluster housing.
(5)
Remove PRND21 mechanism.
INSTALLATION (1) Position PRND21 mechanism to cluster hous­
ing. (2) Install mounting screws.

(3)
Install cluster assembly. (4) Install mask-lens.

(5)
Install bezel.

LAMP BULBS
CLUSTER ILLUMINATION LAMPS TURN SIGNAL INDICATOR LAMPS
LOW OIL PRESSURE INDICATOR LAMP
HIGH BEAM INDICATOR LAMP CHECK ENGINE LAMP
SEAT BELT WARNING LAMP
REMOVAL (1) Disconnect negative cable from battery.
(2) Remove instrument cluster. See cluster re­
moval.
(3)
Twist lamp socket assembly and remove from
printed circuit board. (4) Remove bulb from socket.
INSTALLATION (1) Install bulb into socket.
(2) Install socket assembly into printed circuit
board.
(3)
Position cluster into place in panel. See cluster
installation. (4) Connect battery negative cable.

LAMP BULB REPLACEMENT—MESSAGE CENTER

REMOVAL (1) Disconnect battery negative cable.
(2) Remove instrument cluster bezel assembly. Re­
fer to Instrument Cluster removal.
(3)
Twist lamp socket assembly and remove from
printed circuit board. (4) Remove bulb from socket.
INSTALLATION (1) Install bulb into socket assembly. (2) Install lamp socket assembly into printed cir­
cuit board.

(3)
Install Instrument Cluster bezel assembly to
instrument panel. Refer to Instrument Cluster instal­
lation.
(4) Connect negative cable from battery.
FOUR WHEEL DRIVE INDICATOR LAMP (1) Pull bulb and socket assembly from rear of
housing. (2) Remove bulb from socket.

(3)
Reverse removal procedures to install.

SPECIFICATIONS
Fuel
Gauge Calibration
Mntar Position Resistance
Empty Graduation 90
ohms
± 3
ohms
Empty Stop
Greater
than
96.5 ohms

Full
Graduation 12 ohm
± 3
ohms

Full
Stop
Less
than
8
ohms

1/2
45.3 ohms
± 3
ohms

Temperature
Gauge
Calibration

Pointer
Position Resistance
Cold Graduation 655 ohms
Hot Graduation 64 ohms
Oil Pressure Gauge Calibration

Pointer
Position Resistance
Low Graduation 100 ohms
High Graduation 12 ohms

J908E-58

•
TURN SIGNALS
AND
HAZARD WARNING FLASHER
8J - 1

CONTENTS

page page

GENERAL
INFORMATION
1
MULTIFUNCTION SWITCH TESTING MULTIFUNCTION SWITCH SERVICE PROCEDURES
2
PROCEDURES
3

GENERAL
INFORMATION

TURN SIGNALS

DESCRIPTION With
the
ignition
key ON and the
multi-function
lever
in its UP or
DOWN position, current flows
through
the:
• turn signal flasher canister • Turn/Hazard switch
• turn indicator lamp
• front
and
rear bulbs. The selected turn signal indicator with front
and

rear turn signal bulbs will flash.
DIAGNOSIS High generator output voltage
can
burn
out

lamps rapidly. (1) Remove
and
inspect fuse
in
cavity
#9 of
fuse
block. Replace
if
necessary.
The
fuse block
is
behind
the lower instrument panel cover under steering wheel. (2) Turn
key to
ACCY. There should
be
battery
voltage
at the
fuse side
of the
turn signal flasher (bottom terminal).
If
not,
repair open circuit
in
wir­
ing between fuse
and
flasher.
(3) Replace Turn Flasher with
2
lamp
12
volt rated
flasher that
is
know
to be
good.
The
lamps should
flash. If
not,
replace with original flasher
and
go to

next step.
(4) Measure voltage
at the
Turn/Hazard switch
connector cavity
#17.
Meter should read battery volt­

age.
If
OK,
replace Turn/Hazard switch assembly.
If

not, repair open circuit
in
wiring between flasher
and Turn/Hazard switch connector.
HAZARD WARNING SYSTEM

DESCRIPTION
With
the
hazard switch
OUT,
current flows
through
the

• hazard flasher canister
• hazard switch
•
two
front turn signal bulbs
•
two
rear turn signal bulbs
• both indicator bulbs.
All
of the
turn lamps
and
both indicators will
flash.
DIAGNOSIS Hazard switch
in
ON.
The
park
and
stop lamps
should light.
If
not
replace
the 20
amp
fuse
in
fuse
block cavity
#13.

(1) Measure voltage
at
the
fuse side
of
the
flasher
(side terminal). Meter should read battery voltage.
If

not, repair open circuit
in
wiring
to
fuse. (2) Replace Hazard flasher with known good
flasher. Lamps should flash.
If
not, replace with orig­
inal flasher
and go
to
next step.
(3) Measure voltage
at the
Turn/Hazard switch
connector cavity #13. Meter should read battery volt­

age.
If
not,
repair open circuit
in
wiring
to
hazard
flasher.

TURN
SIGNAL AND HAZARD
WARNING
FLASHER
LOCATION

The turn signal
and
hazard warning flasher
are

both located
on the
fuse block (Fig.
1). The
fuse block is
on the
lower instrument panel cover under
the
steering column.
TURN SIGNALS AND HAZARD WARNING
FLASHER

•

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

•

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

8L
- 8
LAMPS

CONNECTOR

CUP
FRONT

LAMP
ASSEMBLY
LICENSE
PLATE

SCREW
LAMP
ASSEMBLY

LICENSE
PLATE

RR8LD24

Fig.
15
License
Plate
Lamps
-
Step
Bumper
TO
TAIL,
STOP,

TURN
SIG. AND
BACK
UP
LAMPS

LICENSE
PLATE
LICENSE
PLATE
LAMP
AND

LAMP
CONNECTOR
BRACKET
ASSEMBLY
J908L-74

Fig.
16
License
Plate
Lamp
Without Rear
Bumper

UNDERHOOD
LAMP
When equipped, the underhood lamp is installed on
the hood left, rear inner panel (Fig, 17). The lamp is
illuminated when the hood is opened (Fig. 18). UNDERHOOD LAMP BULB REPLACEMENT

REMOVAL
(1) Disconnect the wire connector from the under­
hood lamp (Fig. 17).
(2) Rotate the bulb counter-clockwise. Remove it
from the lamp base socket (Fig. 18).

INSTALLATION
(1) Insert the replacement bulb in the lamp base
socket. Rotate it clockwise.
(2) Connect the wire connector to the lamp (Fig.

17).

UNDERHOOD LAMP REPLACEMENT

REMOVAL
(1) Disconnect the wire connector from the lamp
(Fig. 17). (2) Rotate the bulb counter-clockwise. Remove it
from the lamp base socket (Fig. 18). (3) Remove the screw that attaches the lamp re­
flector and support bracket to the hood inner panel (Fig. 17).
(4) Remove the lamp from the hood inner panel.
INSTALLATION (1) Position the underhood lamp on the hood inner
panel. (2) Install the screw through the lamp and into the
hood panel (Fig. 17). Tighten the screw securely. (3) Insert a replacement bulb in the lamp base
socket (Fig. 18). Rotate it clockwise. (4) Connect the wire connector to the lamp (Fig.

17).
HOOD

J9223-446

Fig.
17
Underhood
Lamp
DAYTIME
RUNNING
LIGHT
MODULE
(CANADA

ONLY)
The headlamps on vehicles sold in Canada will il­
luminate when the ignition is ON. The module also
receives a signal from the distance sensor. This pro-
SUPPORT

BRACKET RETAINER
LIQUID

TAB SWITCH
ENCLOSURE

WIRE
HARNESS
CONNECTOR

\
1

d1^—1—l
L/

CMD>

LAMP

REFLECTOR
BULB
(105)
BASE
J9281"1
Fig.
18
Underhood
Lamp
Components

•

LAMPS
8L - 11
BULB
APPLICATION

GENERAL
INFORMATION
The following Bulb Application Table lists
the

lamp title
on the
left side
of the
column
and
part
number
on the
right.

CAUTION:
Do not use
bulbs
that
have
a
higher
can­

dle power than
the
bulb
listed
in the
Bulb
Applica­

tion Table.
Damage
to
lamp
can
result.

EXTERIOR LAMPS
Auxiliary Turn Signal (Snow Plow) 2057
Auxiliary Headlamps (Snow Plow) .6054
Back-up....................... .......1156 Cargo Lamp..
922

Clearance Lamps
194

Front Side Marker
168

Headlamp/Sealed Beam .6052
License Plate
168
Park/Turn Signal 2057
TaiyStop/Turn Signal ...2057

INTERIOR LAMPS

DIMMER CONTROLLED LAMPS Service procedures
for
most
of the
lamps
in the in­

strument panel
are
located
in
Group
8E,
Instrument
Panel
and
Gauges. Some components have lamps
that
can
only
be
serviced
by an
Authorized Service Center (ASC). These components must
be
removed
from
the
vehicle
for
service. Contact local dealer
for
location
of
nearest
ASC.
A/C Heater Control
158

Ash Receiver
..158

Gear Shift Selector...........................................PC194
Heater Control
158

Instrument Cluster.. PC 194
Radio
ASC
Snow Plow Control
.158

INDICATOR LAMPS Service procedures
for
most
of the
lamps
in the in­

strument panel,
and
switches
are
located
in
Group

8E,
Instrument Panel
and
Gauges. Anti-lock Brake PC194
Brake Warning PC194 Check Engine PC194
Engine
Oil
Pressure
158

Fasten Seat Belts.. PC 194 Four Wheel Drive ....158
Hazard Flasher
194

High Beam PC194
Low Fuel....... JPC194
Maintenance Required PC 194
Transmission Temperature ..PC 194 Turn Signal PC194
NON-DIMMING LAMPS Service procedures
for
most
of the
lamps
in the
fol­
lowing list
can be
found
in
Group
23,
Body.
Dome
1004

Engine Compartment ...105 Glove Compartment....
1891

Ignition Lock
ASC

Reading Lamp
912

•

FUEL SYSTEM
14 - 37 used only on vehicles equipped with the 5.9L heavy
duty cycle (HDC) engine. Refer to Group 25, Emis­
sion Control System for information.

EVAP CANISTER PURGE SOLENOID-PCM

OUTPUT
Refer to Group 25, Emission Control System. See
EVAP Canister Purge Solenoid.

FUEL INJECTORS-PCM
OUTPUT
The fuel injectors are attached to the fuel rail (Fig.

15).
3.9L engines use six injectors. 5.2L and 5.9L en­
gines use eight injectors. The nozzle ends of the injectors are positioned into
openings in the intake manifold just above the in­
take valve ports of the cylinder head. The engine
wiring harness connector for each fuel injector is equipped with an attached numerical tag (INJ 1, INJ 2 etc.). This is used to identify each fuel injector with
its respective cylinder number. The injectors are energized individually in a se­
quential order by the powertrain control module (PCM). The PCM will adjust injector pulse width by
switching the ground path to each individual injector
on and off. Injector pulse width is the period of time
that the injector is energized. The PCM will adjust injector pulse width based on various inputs it re­
ceives. During start up, battery voltage is supplied to the
injectors through the ASD relay. When the engine is
operating, voltage is supplied by the charging sys­
tem. The PCM determines injector pulse width based on various inputs.
FUEL

INJECTOR
J9214-30

Fig.
15
Fuel
injectors—Typical
MALFUNCTION INDICATOR LAMP-PCM OUTPUT

The malfunction indicator lamp (formerly referred
to as the check engine lamp) illuminates at the bot­
tom of the instrument panel each time the ignition key is turned on. It will stay on for three seconds as a bulb test. If the powertrain control module (PCM) receives an
incorrect signal, or no signal from certain sensors or
emission related systems, the lamp is turned on. This
is a warning that the PCM has recorded a system or
sensor malfunction. In some cases, when a problem is
declared, the PCM will go into a limp-in mode. This
is an attempt to keep the system operating. It signals an immediate need for service. The lamp can also be used to display a diagnostic
trouble code (DTC). Cycle the ignition switch
On-Off-
On-Off-On within three seconds and any codes stored
in the PCM memory will be displayed. This is done
in a series of flashes representing digits. Refer to On-
Board Diagnostics in the General Diagnosis section
of this group for more information.

IGNITION COIL-PCM OUTPUT
System voltage is supplied to the ignition coil pos­
itive terminal. The powertrain control module (PCM)
operates the ignition coil. Base (initial) ignition
timing is not adjustable. The PCM adjusts ignition
timing to meet changing engine operating conditions. The ignition coil is located near the front of the
right cylinder head (Fig. 16 or 17). Refer to Group 8D, Ignition System for additional
information.

Fig.
16 Ignition Coii-3.9U5.2U5.9L
LDC-Gas
Engine

SCI
TRANSMIT—PCM OUTPUT
SCI Transmit is the serial data communication
transmit circuit for the DRB II scan tool. The power- train control module (PCM) transmits data to the DRB II through the SCI Transmit circuit.