window DODGE TRUCK 1993 Service Repair Manual

10 INTRODUCTION
•
INTERNATIONAL CONTROL AND DISPLAY SYMBOLS

ID

HIGH
BEAM P
FOG UGHTS -&
HEADLIGHTS,
PARKING UGHTS, PANEL UGHTS TURN SIGNAL A
HAZARD WARNING WINDSHIELD
WASHER
WINDSHIELD WIPER WINDSHIELD WIPER
AND WASHER WINDSCREEN DEMISTING
AND DEFROSTING *

VENTILATING
FAN 8
M f

REAR
WINDOW DEFOGGER
sp

REARWINLX)W WIPER
CD
l
m

REAR
WINDOW WASHER FUEL ENGINE COOLANT
TEMPERATURE BATTERY CHARGING
CONDITION ENGINE OIL

SEAT
BELT

(©) (®) ky

11 J

LIGHTER

BRAKE
FAILURE
PARKING
BRAKE
FRONT HOOD
REAR
HOOD

(TRUNK)
HORN
11 J

LIGHTER
93IN-9

INTERNATIONAL VEHICLE CONTROL AND DISPLAY

SYMBOLS
The graphic symbols illustrated in the chart below
are used to identify various instrument controls. The
symbols correspond to the controls and displays that are located on the instrument panel.

•

LUBRICATION
AND
MAINTENANCE
0 - 33 BODY LUBRICANT SPECIFICATIONS

COMPONENT
SERVICE
INTERVAL
LUBRICANT

Door
Hinges
As
Required
Engine
Oil

Door
Latches
As
Required Multi-Purpose Grease
NLGI
GC-LB

(Water
Resistant)
(1)

Hood
Latch Release Mechanism
&
Safety Latch
As
Required
(When Performing Other Underhood Services) Multi-Purpose Grease
NLGI
GC-LB
2
EP
(2)

Hood
Hinges
As
Required
Engine
Oil

Seat Regulator
&
Track Release Mechanism
As
Required Multi-Purpose Grease
NLGI
GC-LB
2
EP
(2)

Tailgate Hinge
As
Required Multi-Purpose Grease
NLGI
GC-LB
2
EP
(2)

Tailgate Support Arms
As
Required

Engine
Oil

Tailgate Latches
As
Required
White
Spray Lubricant
(3)

Tailgate Release Handle (Pivot & Slide Contact Surfaces)
As
Required Multi-Purpose Grease
NLGI
GC-LB
2
EP
(2)

Window System Components (Regulators, Tracks,
Rods

&
Channel Areas — Except
Glass
Run Weatherstrips
and
Felt
Lubricator,
if
Equipped)
As
Required

White
Spray Lubricant
(3)

Lock
Cylinders Twice/Year
Lock
Cylinder Lubricant
(4)

Parking Brake Mechanism
As
Required Multi-Purpose Grease
NLGI
GC-LB
(1)

1.
Mopar
Wheel
Bearing Grease (High
Temperature)

2. Mopar Multi-Mileage Lubricant 3. Mopar Spray
White
Lube
4. Mopar Lock Cylinder Lubricant

J9200-58

SPEEDOMETER
CABLE

SERVICE INFORMATION Speedometer cable lubrication is not necessary. For
service information involving noisy or erratic cables,
refer to Group 8E—Instrument Panel and Gauges.

•

ELECTRICAL
ELECTRICAL
8A - 1

Group

AUDIO
SYSTEMS
8F
BATTERY/STARTER/GENERATOR
SERVICE
.. 8B
BATTERY/STARTING/CHARGING
SYSTEMS

DIAGNOSTICS
8A

HORNS
8G

IGNITION
SYSTEMS
8D
INSTRUMENT PANEL AND
GAUGES
8E

LAMPS
8L

POWER
LOCKS
8P
INDEX

Group

POWER
MIRRORS
8T

POWER
WINDOWS 8S

REAR
WINDOW DEFOGGER 8N
TURN
SIGNALS
AND HAZARD WARNING
FLASHERS
8J
VEHICLE
SPEED
CONTROL SYSTEM 8H WARNING BUZZER SYSTEM 8U
WINDSHIELD WIPERS AND
WASHERS
8K
WIRING DIAGRAMS 8W

BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS
CONTENTS
page
page
BATTERY TEST
PROCEDURES
2 GENERATOR TEST
PROCEDURES
ON VEHICLE . 13

ENGINE
STARTER MOTOR TEST
PROCEDURES
..9 SPECIFICATIONS 18

GENERAL
INFORMATION 1

GENERAL INFORMATION

The Battery, Starting, and Charging Systems oper­
ate with one another, and therefore, must be thor­
oughly tested as a complete system. In order for the
vehicle to start and charge properly, it must have a
battery that will perform to specifications. The starter
motor, generator, wiring, and electronics also must
perform within specifications. Group 8A covers Start­ ing (Fig. 1) and Charging (Fig. 2) System diagnostic
procedures. These procedures include the most basic
conventional methods to On-Board Diagnostics (OBD)
built into the Powertrain Control Module (PCM).
Use of an ammeter, volt/ohmmeter, battery
charger, carbon pile rheostat (load tester), and 12
volt test light will be required.
All OBD sensing systems are monitored by the
PCM. The PCM will store in memory any detectable
failure in the monitored circuits. Refer to Using On-
Board Diagnostic System in this group for more in­ formation.
NEGATIVE

BATTERY
CABLE

A
7

POSITIVE

BATTERY
CABLE
BATTERY

J918A-11

Fig.
1 Starting
System
Components—Typical

•

AUDIO
SYSTEMS
8F - 7
SERVICE
PROCEDURES

RADIO
REPLACEMENT

REMOVAL
(1) Disconnect negative cable from battery.

CAUTION:
Map
lamp
must
be
removed
to
prevent

damage
to instrument panel.
(2) Remove 2 screws and the map lamp (if
equipped) (Fig. 9). (3) Remove 6 screws attaching I/P bezel to the in­
strument panel. Be sure the screw below the Heat-
er/C control is removed.

CLUSTER
BEZEL
J938E-51
Fig.
9 Instrument
Cluster
Bezel

(4) Remove 2 mounting screws from front of radio
(Fig. 10).
(5) Pull radio out of instrument panel and discon­
nect wiring and antenna.

(6)
Remove screw from ground strap.
RF431

Fig.
10 Radio to Instrument
Panel
Mounting
INSTALLATION

(1) Install ground strap.
(2) Install wiring and antenna. (3) Insert radio into panel and install mounting
screws.
(4) Install instrument cluster bezel.
(5)
Install map lamp, if equipped.
(6) Connect negative cable to battery.

DOOR
MOUNTED
SPEAKER

REMOVAL
(1) Remove remote control handle.
(2) Remove window regulator handle, if equipped.
(3) Remove pull strap if equipped.
(4) Remove screw at top of armrest.

(5)
Using a trim stick or other suitable flat tool,
gently pry trim panel away from door.
(6) Remove screws holding speaker (Fig. 11).
(7) Disconnect speaker leads.
(8) Remove speaker.
Fig.
11
Door
Mounted
Speaker

INSTALLATION

(1) Connect leads to speaker.
(2) Position speaker into place, install mounting
screws and tighten securely.
(3) Install door trim panel.

REAR
SPEAKER
-
STANDARD
CAB PICKUP

REMOVAL
(1) Remove grille and speaker assembly to pillar
mounting screws (Fig. 12). (2) Pull speaker and grille away from pillar and
disconnect wiring.
(3) Remove speaker to grille retaining nuts (2).

INSTALLATION
(1) Position speaker onto studs of speaker grille
and install nuts.
(2) Install wiring harness connector on speaker.
(3) Position speaker and grille on pillar and install
mounting screws.

•

REAR
WINDOW DEFOGGER
8N - 1
REAR
WINDOW
DEFOGGER

CONTENTS
page

REPAIR
PROCEDURES (GRID LINES,
TERMINALS,
AND
PIGTAILS)
3

GENERAL
INFORMATION
The electrically heated rear window defogger
is

available
on
Ramcharger with sunscreen glass only. The system consists
of a
rear window with
two
ver­
tical
bus
bars
and a
series
of
electrically connected
grid lines baked
on the
inside surface. Circuit protection
for the
heated grid circuit
is
pro­
vided
by a 18
gauge fusible link wire located
in the

engine compartment.
The
relay circuit
is
protected
by
a 20 amp
fuse, located
in the
fuse block. When
the
rear window defogger switch
is
placed
in

the
ON
position, current
is
directed
to
rear window
grid lines.
The
heated grid lines
in
turn heat
the

rear window
to
clear
the
surface
of fog or
snow.

CAUTION;
Grid lines
can be
damaged
or
scraped
off
with
sharp instruments. Care should
be
taken
in
page

SERVICE
PROCEDURES
4

TEST
PROCEDURES
1

cleaning
the
glass
or
removing foreign materials,

decals
or
stickers. Normal
glass
cleaning solvents
or
hot
water
used
with
rags
or
toweling
is
recom­ mended.

SYSTEM
DESCRIPTION CONTROL
SWITCH/TIMER
RELAY MODULE
The control switch
and
timer relay
are
integrated
into
a
single panel mounted assembly. Actuating
the
switch energizes
the
electronic timing circuit. This
allows current
to
flow through
the
grid system
for

approximately
10
minutes,
or
until either
the
control
switch
or
ignition
is
turned
off. An
indicating lamp
illuminates
a
lens inlaid
in the
control switch.

TEST PROCEDURES

SYSTEM
TEST
Electrically heated rear window defogger operation
can
be
checked in-vehicle
in the
following manner: (1) Turn
the
ignition
ON.

(2) Turn rear window defogger control switch
ON.

(3) Monitor vehicle voltmeter. With
the
control
switch
ON, a
distinct needle deflection should
be

noted. (4)
The
rear window defogger operation
can be

checked
by
feeling
the
glass.
A
distinct difference
in

temperature between
the
grid lines
and
adjacent clear glass
can be
detected
in 3 to 4
minutes
of
oper­ation. (5) Contact negative lead
of a DC
voltmeter
(Fig.

1),
to
terminal
"B"
(passenger side). Contact positive
lead
to
terminal
"A"
(driver side).
The
voltmeter
should read
10-14
volts. Only steps
(3) and (4) or (5)
above will confirm sys­
tem operation. Indicator light illumination means
that there
is
power available
at the
output
of the re­
lay only,
and
does
not
verify system operation.
If rear window defogger does
not
operate,
the
prob­
lem should
be
isolated
in the
following manner:
(1) Confirm that ignition switch
is ON.
VOLTMETER

Fig.
1
Grid
Line
Test (2) Ensure that heated rear window feed wire
is

connected
to
terminal
or
pigtail
and
that ground wire
is
in
fact grounded.
(3) Ensure that fuse
is
operational
and all
electri­
cal connections
are
secure.
When above steps have been completed
and the

system
is
still inoperative,
one or
more
of the
follow­
ing
is
defective:
(a) Control switch/timer relay module.

8N
- 2
REAR WINDOW DEFOGGER

• (b) Rear window grid lines (all grid lines would
have to be broken) or one of the feed wires are not
connected for the system to be inoperative.
The following paragraphs outline component check­
out procedures.
If turning the switch ON produces severe voltmeter
deflection, the circuit should be closely checked for a shorting condition. If system operation has been verified but indicator
bulb does not light, check and replace bulb.
For detailed wiring information, refer to Group 8W
- Wiring Diagrams.

REAR
WINDOW GRID LINES TEST
Horizontal grid lines and vertical bus bar lines
printed and baked on inside surface of rear window glass (Fig. 1) comprise an electrical parallel circuit.
The electrically conductive lines are made of a silver- ceramic material. When baked onto glass they be­
come bonded to the glass and are highly resistant to abrasion. It is possible, however, that a break may
exist or occur in an individual grid line resulting in
no current flow through the line. To detect breaks in
grid lines, the following procedure is required: (1) Turn ignition on and push control switch to
ON. Indicator light should come on. (2) Contact negative lead of a DC voltmeter, to
vertical bus bar connecting grid lines on passenger side of vehicle (point A of Fig. 1). Contact positive
lead of voltmeter, to vertical bus bar on driver side of
vehicle (point B of Fig. 1). Voltmeter should read 10-14 volts. (3) With negative lead of voltmeter, contact a good
body ground point. Voltage reading should not change. A different reading indicates a poor ground connection. (4) Connect negative lead of voltmeter to Point A
on passenger side bus bar and touch each grid line at
Mid-Point with positive lead. A reading of approxi­ mately 6 volts indicates a line is good. A reading of 0
volts indicates a break in line between Mid-Point C and Point B. A reading of 10-14 volts indicates a
break between Mid-Point C and ground Point A. Move toward break and voltage will change as soon as break is crossed.

CONTROL SWITCH/TIMER MODULE TEST
Control switch/timer relay module may be tested
in-vehicle or bench tested. In vehicle testing is ac­
complished in the following manner: (1) Remove switch from instrument panel (refer to
Control Switch Replacement) and leave switch con­
nector plugged in. (2) Turn ignition ON.
(3) Using a DC voltmeter, check voltage at termi­ nals B, I and L (Figs. 2 and 3). Terminals B and I
should confirm a voltage of 10 to 14 volts to ground.
Terminal L should confirm 0 volts to ground. When terminals B and I show no voltage, trace circuit up­
stream of switch/relay module for cause:
• wiring cut
• fusible link faulty
• circuit breaker inoperative
• bulkhead connection bad, etc. If terminal L indicates voltage, place switch in
OFF position. If voltage at L is still indicated or in­
dicator lamp remains on, switch/relay module should
be replaced.
"XI
FUSE
#14
rr~
P 3
AAAP
P
FUSE
#3
20
AAAP
BATTERY

HEATED
REAR

WINDOW
DEFOGGER
SWITCH

(INSTRUMENT
PANEL)

ON/OFF
ILLUMINATION
LAMP

fez TIMER
L.E.I
INDICATOR
LIGHT
-©-
18
GAUGE

FUSIBLE
LINK

IGNITION POWER
MIDPOINT
"C"

CONNECTOR (TYPICAL)
POINT
"A"
POINT
"B"
GROUND
CONNECTOR

REAR
WINDOW
GRID
LINE
STRUCTURE
Fig.
2
Systems
Electrical Circuit
J928N-5

(4) If the relay checks out to this point, momen­
tarily operate switch to ON position. The indicator lamp should come on and remain on for approxi­
mately 10 minutes. Terminal L should confirm volt­
age.
If the indicator lamp fails to light or voltage at
terminal L is not confirmed the switch/relay module should be replaced.
Bench checking of the relay may be accomplished
in the following manner. By following the in-vehicle
procedure except Step 2: With a DC power supply, apply 12 volts to terminal B and I and ground termi­
nal G.

e
,
REAR
WINDOW
DEFOGGER
8N
- 3

L
-
TO
BACK GLASS

B
-
HIGH
AMP
SUPPLY

I
-
IGNITION

G
-
GROUND
S
-
ILLUMINATION
LIGHT

RELAY-TIMER

SWITCH
ASSEMBLY
J908N-8
Fig.
3
Rear Window Defogger
Switch,
Timer,
Relay
Connector
REPAIR
PROCEDURES
(GRID LINES, TERMINALS* AND PIGTAILS)

The
repair
of
grid lines
or the
terminal
is
possible
using
the
MOPAR Repair
Kit
No. 4267922
or
equiv­ alent.

WARNING: REPAIR
KIT
MAY
CAUSE SKIN
OR
EYE
IRRITATION.
CONTAINS EPOXY RESIN
AND
AMINE TYPE

HARDENER,
HARMFUL
IF
SWALLOWED. AVOID
CONTACT
WITH
SKIN
AND
EYES.
FOR
SKIN,
WASH
AFFECTED AREAS
WITH
SOAP
AND
WATER.
DO
NOT TAKE INTERNALLY.
IF
TAKEN INTERNALLY,
INDUCE VOMITING; CALL
A
PHYSICIAN IMMEDI­
ATELY.
IF IN
CONTACT
WITH
EYES,
FLUSH
WITH
PLENTY
OF
WATER.
USE WITH
ADEQUATE VENTI­
LATION.
DO
NOT USE
NEAR FIRE
OR
FLAME.
CONTENTS CONTAIN
3%
FLAMMABLE SOLVENTS.
KEEP
OUT
OF
REACH
OF
CHILDREN.

(1) Mask repair area
so
conductive epoxy
can be

extended onto
the
line
or the bus bar
(Fig.
4).
(2) Follow instructions
in
repair
kit for
preparing
damaged area.
(3) Remove package separator clamp
and mix
plas­
tic conductive epoxy thoroughly. Fold
in
half and
cut
center corner
to
dispense epoxy.
(4)
For
grid line, mark
off
area
to be
repaired with
masking tape
or a
template (Fig.
4).
(5) Apply epoxy through slit
in
masking tape.
Overlap both ends
of the
break
by at
least
19mm

(0.75
in).

(6)
For a
terminal
or
pigtail replacement, mask
ad­

jacent areas
so
epoxy
can be
extended onto line
as
BREAK
GRID
LINE

MASKING TAPE PR1509A

Fig.
4
Grid
Line
Repair
(Typical)
well
as bus bar.
Apply
a
thin layer
of
epoxy
to
area
where terminal
was
fastened
and to
adjacent line.
(7) Apply
a
thin layer
of
conductive epoxy
on
ter­
minal
and
place terminal
on
desired location.
To
pre­
vent terminal from moving while
the
epoxy
is
curing, it must
be
wedged
or
clamped.
(8) Carefully remove masking tape from grid line.

CAUTION:
Do not
allow
the
glass
surface
to
exceed

400°F,
glass
may
fracture.

(9) Allow epoxy
to
cure
24
hours
at
room tempera­
ture
or use
heat
gun
with
a
260°-371°C (500°-700°F) range
for 15
minutes. Hold
gun
approximately 254mm
(10
inches) from repaired area.
(10) After conductive epoxy
is
properly cured
re­

move wedge from terminal
and
check
out
operation
of rear window defogger.
Do not
attach connectors
until curing
is
complete.

81 - 4
REAR
WINDOW
DEFOGGER

•
SERVICE
PROCEDURES

HEATED
REAR
WINDOW
CONTROL
SWITCH
REPLACEMENT

REMOVAL (1) Locate chime module. Grasp chime module and
twist it to remove it from the bracket. (2) Squeeze rear window defogger switch retaining
tangs and pull switch from rear of bezel. (3) Remove connector from switch.
INSTALLATION (1) Connect electrical connector to switch.
(2) Insert switch into bezel making sure retaining
tangs lock into position.
(3) Install chime module on to bracket.

8P
- 2 POWER DOOR LOCKS
• SERVICE PROCEDURES
DOOR LOCK MOTOR REPLACEMENT

REMOVAL
(1) Remove remote control handle (Fig. 2).
TRIM

PANEL
TRIM
PANEL

CLIPS
(6)

REMOTE

CONTROL
HANDLE

SCREW

TRIM
PANEL
CLIPS
J908P-12

Fig.
2
Door
Trim
Panel
(2) Remove power window/lock switch by inserting
a standard blade screwdriver into notch on forward
end of switch housing and push to depress locking

tab.
Pull out and forward to remove switch bezel
from door panel.
(3) Remove 2 screws at bottom front and rear of
trim panel.
(4) Remove screw behind remote handle.
(5) Using a device such as a trim stick, pry trim
panel away from door around perimeter.
(6) Roll door watershield away from lower rear cor­
ner of door to reveal inside panel access opening.
(7) Remove motor link at motor (Fig. 3).
(8) Disconnect motor lead wires.
(9) Remove 2 motor mounting bracket screws and
remove motor assembly from mounting.
DOOR
LOCK

MOTOR

J918P-9

Fig.
3
Door
Lock
Motor Replacement
INSTALLATION

(1) Attach motor mounting bracket to door inside
panel and install 2 screws. (2) Connect link to motor rod and connect wires.
(3) Reset watershield at lower rear corner of door.
(4) Install door trim panel. (5) Install door panel attaching screws.
(6) Install remote control handle.
(7) Install power window/lock switch.

•

POWER
WINDOWS
8S - 1
POWER WINDOWS
CONTENTS
page

SERVICE
PROCEDURES
3

GENERAL
INFORMATION
Power window motors are of the permanent mag­
net type. A positive and negative battery connection
to either of the two motor terminals will cause the motor to rotate in one direction. Reversing current
through these same two connections will cause the motor to rotate in the opposite direction. Both motors are grounded through the master
switch by a black wire attached to a ground stud.
The stud is located on the back of the instrument
panel, on the right side of the steering column. It is necessary that the window be free to slide up
page

TEST
PROCEDURES
....................... 1
and down in the glass channels or tubes and tracks.
If the window is not free to move up and down, the
window motor will not be able to move the glass.
To determine if the glass is free, disconnect the
electric window regulator lift arm sliders from the
glass lift channels. Slide the window up and down by
hand.
A less positive method is to shake the glass in the
door, (with glass positioned between the up and down
stop positions). If the glass will move slightly from
side to side, front to rear, and up and down, the win­
dow is probably not bound tight in the tracks.

TEST
PROCEDURES

SWITCH
VOLTAGE TEST
The following wiring test sequence determines
whether or not voltage is continuous through the
body harness to switch. (1) Remove power window/lock switch by inserting
a standard blade screwdriver into notch on forward
end of switch housing. Push screwdriver to depress
locking tab. Pull bezel out and forward to remove
from door panel. (2) Carefully separate multiple terminal block on
wiring harness from switch body. (3) Connect one lead of test light to black (BK)
wire terminal. Touch other test light lead to tan (TN)
wire terminal. If test light comes on, the wiring cir­ cuit between the battery and switch is functional. If
light does not come on, check 30 amp circuit breaker,
or for a broken wire or poor ground.

CIRCUIT
BREAKER
TEST
Locate the circuit breaker in fuse cavity number 12
on fuse block. Pull out slightly but be sure that cir­
cuit breaker terminals still contact terminals in fuse
block. Connect ground wire of voltmeter to a good ground. With probe of voltmeter positive wire, check both terminals of circuit breaker for battery voltage.
If only one terminal checks at battery voltage, circuit
breaker is defective and must be replaced. If neither
terminal shows battery voltage, check for open or shorted circuit to circuit breaker.

SWITCH TEST
For switch testing, remove the switch from its
mounting location. Using an ohmmeter, refer to Figs. 1 and 2 to determine if continuity is correct in the
UP and DOWN switch positions. If continuity is cor­
rect perform window lift motor test.

WINDOW
MOTOR TEST
(1) Connect positive lead (from a test battery) to
either of the two motor terminals. (2) Connect negative lead (from test battery) to re­
maining motor terminal. (3) The motor should now rotate in one direction to
either move window up or down. (a) If window happens to already be in full UP
position and motor is connected to rotate in UP di­ rection, no movement will be observed.