1993 DODGE TRUCK fuel pump wiring

8D
- 18
IGNITION
SYSTEMS

•
COMPONENT REMGWAL/INSTALLATION

INDEX

page

Automatic
Shut Down (ASD) Relay
18
Camshaft
Position
Sensor
, 18

Crankshaft Position
Sensor
18
Distributor
Service
20
Engine
Coolant Temperature
Sensor
20

General
Information
18
Ignition
Coil
21
page

Intake
Manifold Charge
Air
Temperature
Sensor
. 22

Manifold Absolute Pressure (MAP)
Sensor
..... 22

Oxygen
(02)
Sensor
22
Powertrain
Control
Module (PCM)
22

Spark
Plug Secondary Cables
24

Spark
Plugs
23

Throttle
Position
Sensor
(TPS)
24

GENERAL
INFORMATION
This section
of the
group, Component Removal/In­
stallation, will discuss
the
removal
and
installation
of ignition system components. For basic ignition system diagnostics
and
service
adjustments, refer
to the
Diagnostics/Service Proce­
dures section
of
this group. For system operation
and
component identification,
refer
to the
Component Identification/System Opera­
tion section
of
this group.

AUTOMATIC
SHUT DOWN
(ASb)
RELAY
The automatic shut down
(ASD)
relay
is
located
in

the engine compartment
(Fig. 1).
TORQUE CONVERTER
CLUTCH RELAY
A/C
CLUTCH RELAY STARTER RELAY

AUTO
SHUTDOWN RELAY FUEL PUMP RELAY DATA UNK
CONNECTOR POWERTRAIN
CONTROL
MODULE
J9314-164

Fig.
1
Auto
Shut Down
Relay
REMOVAL

(1) Disconnect negative battery cable
at
battery.

(2)
Remove
the
relay
by
pulling from connector.

INSTALLATION
(1) Check
the
terminals
in the
relay connector
for

corrosion
or
damage before installation.

(2)
Push
the
relay into
the
connector.

CAMSHAFT POSITION SENSOR
The camshaft position sensor
is
located
in the
dis­
tributor
(Fig. 2).
REMOVAL

Distributor removal
is not
necessary
to
remove
camshaft position sensor.

CAMSHAFT POSITION
SENSOR
SYNC

SIGNAL

GENERATOR
DISTRIBUTOR
ASSEMBLY
J9314-82

Fig.
2
Camshaft Position Sensor—Typical
(1) Disconnect negative battery cable
at
battery.

(2)
Remove distributor
cap
from distributor
(two

screws).
(3) Disconnect camshaft position sensor wiring
harness from main engine wiring harness.
(4) Remove distributor rotor from distributor shaft.

(5)
Lift
the
camshaft position sensor assembly from
the distributor housing
(Fig. 2).

INSTALLATION
(1) Install camshaft position sensor
to
distributor.
Align sensor into notch
on
distributor housing.
(2)
Connect wiring harness.
(3) Install rotor.
(4) Install distributor
cap.
Tighten mounting
screws.

CRANKSHAFT
POSITION SENSOR
REMOVAL The sensor
is
bolted
to the top of the
cylinder block
near
the
rear
of
right cylinder head
(Fig. 3).

•

INSTRUMENT PANEL
AND
GAUGES
8E - 5
CLUSTER
AND
GAUGE TEST
PROCEDURES

INDEX
page
Fuel Gauge
Circuit
Test
9

Fuel Tank Sending
Unit
Test
5

Oil Pressure Gauge
Circuit
Test
..............
9
Sending
Unit
(Sensor) Test
5
page
Speedometer
10

Temperature
Gauge
Circuit
Test
8
Voltage Gauge
Circuit
Test
10

Warning Lamp System Tests
6

CAUTION:
Disconnect
battery
negative cable,
in
en­

gine compartment, before servicing instrument panel. When power
is
required
for
test purposes,
connect
battery
cable
(for
test only).

Disconnect battery negative cable after test
and before continuing service procedures.

SENDING
UNIT
(SENSOR) TEST
When
a
problem occurs with
a
cluster gauge,
be­

fore disassembling
the
cluster
to
check
the
gauge, check
for a
defective sending unit (sensor)
or
wiring.
(1) Sending units
and
wiring
can be
checked
by

grounding
the
connector leads,
at the
sending unit,
in
the
vehicle.

CAUTION:
When connecting
an
input
terminal
to

ground,
Do Not
leave
the
connection grounded
for
more than
a
few
seconds.

(2) With
the
ignition
in the ON
position;
a

grounded input will cause
the oil,
fuel
or
tempera­
ture gauge
to
read
at or
above maximum.
FUEL TANK SENDING
UNIT
TEST

(1) Disconnect wire from terminal
on
fuel tank
sending unit (Fig.
1).

FUEL PUMP SUPPLY
INPUT
TO
GAUGE
SENDING
UNIT
GROUND
FUEL PUMP GROUND
J928E-49

Fig.
1
Fuel
Tank
Sending
Connector
Terminals
(2) Connect wire
to a
known good sending unit.
(3) Connect
a
jumper wire between sending unit
fuel pick
up
tube
and a
good ground.
(4) Check fuel gauge
as
described
in
following

steps.
Allow
at
least three minutes
at
each test point
for gauge
to
settle. Lightly tapping instrument clus­
ter
may
help position pointer.

FUEL GAUGE SYSTEM DIAGNOSIS
FUEL GAUGE SYSTEM DIAGNOSIS FUEL GAUGE

DOES
NOT

READ
FULL FAULTY PRINTED
CIRCUIT BOARD FUEL GAUGE
INOPERATIVE OR ERRATIC FUEL GAUGE
INACCURATE

E

1

I

CHECK
FAULTY WIRING
OR
TANK DEFORMED
TANK
NOT
FULL COMPONENTS
CHECK
CHECK
ALL WIRING INCLUDING GROUND
i

FAULTY FUEL GAUGE SENDING
UNIT
i 1
FUEL
C
1
DOES
1
READ
1
pAUGE
I

>N0?
1

EMPTY
1

r

TANK
NOT
EMPTY
CHECK
PROPER
ALIGNMENT
OF PICKUP AND

SENDER
ASSEMBLY.

REFER
TO
GROUP
14
FAULTY FUEL
GAUGE

J908E-74

WINDSHIELD
WIPER MOTOR
TO RIGHT
HEADLAMP
PARK/TURN
SIGNAL LAMP TO FUSIBLE LINK
CIRCUITS
TO VEHICLE SPEED
CONTROL SEE VIEW
Z

EEMC

RELAY
LEFT
HEADLAMP
GROUND
ENGINE
STARTER
A/C RELAY

COMPRESSOR

CLUTCH RELAY AUTOMATIC SHUT
DOWN RELAY
FUEL PUMP RELAY
BULKHEAD
DISCONNECT
A/C

LOW
PRESSURE
SWITCH

SIDE
MARKER LAMP
TO UNDERHOOD LAMP WIRING
VEHICLE

SPEED
CONTROL
SERVO
POWERTRAIN
CONTROL MODULE
A/C

CYCLING SWITCH TO BLOWER
MTR &

WINDSHIELD
WASHER
MTR

VIEW
IN
DIRECTION OF ARROW
Z
VIEW
IN
DIRECTION
OF ARROW
W a
o
>
o 30
>
2
m
J938W-99
Fig.
17
Engine
Compartment Wiring 3.9L, 5.2L, and 5.9L Gas
Engines

FUEL
INJECTOR
#6
FUEL
INJECTOR
#4
FUEL
INJECTOR
#2
BEYOND
THIS
POINT

SEE
VIEW
Z

EGR
SOLENOID/
TRANSDUCER
ASSEMBLY
A/C
COMPRESSOR

CLUTCH

GENERATOR
GROUND
POWER
STEERING
PUMP

AAAP

SENSOR
THROTTLE
EVAP/

POSITION
PURGE
(SENSOR)
SOLENOID IDLE
AIR

CONTROL MOTOR
TO
A/C

COMPRESSOR
CLUTCH
DISTRIBUTOR

IGNITION
COIL
ENGINE

COOLANT

TEMPERATURE

ENGINE
COOLANT
SENSOR
(PCM)
TEMPERATURE

SENSOR
(GAUGE)
ENGINE
OIL

PRESSURE

SENDING
UNIT/
SWITCH
DISTRIBUTOR

CONNER ,NJECTOR#1
INJECTOR
#3
VIEW
IN
DIRECTION OF ARROW
1
FUEL
INJECTOR
#5
TO

'TRANSMISSION
WIRING

J938W-85 INS
m
a

o

>

o

>
2

m Fig. 23 Engine
Wiring
3.9L MPI Engine

FUEL
INJECTOR
#8
FUEL
INJECTOR #4 FUEL
INJECTOR
#2

EGR

SOLENOID/

TRANSDUCER

DISTRIBUTOR
IGNITION
COIL
THROTTLE

BODY

CHARGE
AIR

TEMPERATURE
SENSOR

BEYOND
THIS
POINT
SEE
VIEW,
Z

TO
A/C

COMPRESSOR
CLUTCH ^DISTRIBUTOR

GENERATOR
GROUND

POWER

STEERING
PUMP ENGINE
OIL

PRESSURE
SENDING
UNIT/SWITCH

VIEW
IN
DIRECTION OF ARROW
Y

TO TRANSMISSION WIRING

THROTTLE
POSITION
(SENSOR)
IDLE AIR
CONTROL MOTOR

GENERATOR
ENGINE COOLANT

TEMPERATURE
SENSOR
(PCM)
ENGINE
COOLANT

TEMPERATURE

SENSOR
(GAUGE)
MAP

SENSOR

FUEL
INJECTOR
#3

EVAP/PURGE

SOLENOID

FUEL
INJECTOR #7
FUEL
INJECTOR.
#5

FUEL
INJECTOR
#1

A/C
CLUTCH VIEW
IN
DIRECTION
OF ARROW
Z

J938W-86
Fig.
24 Engine Wiring 5.2L and 5.9L MPI Engine o
>
30

>

2
w

oo !\3

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 - 39

Wiring
Diagram
Name
Sheet
Number

Service Reminder Lamp .58
Side
Marker Lamp
Left
Front
43,45

Side
Marker Lamp Right
Front
. .44,46
Stop
Lamp-Left
Rear 79,81 Stop Lamp-Right Rear 80,81

Tachometer
.48
Tail
Lamp-Left
Rear .79,81

Tail
Lamp-Right Rear 80,81
Turn
Signal
Indicator
Lamps .79,80,81

Turn
Signal
Lamp-Left
Front
43,45

Turn
Signal Lamp-Right
Front
44,46
Turn
Signal
Lamp-Left
Rear .79,81

Turn
Signal Lamp-Right Rear 80,81
Underhood Lamp 29

Left
Printed
Circuit
Board .59

Left
Printed
Circuit
Board Connector 60
Liftgate
Ajar
Switch
51

Map
Lamp and Cargo Lamps .49

Message
Center
(Diesel Engine) 57
Message
Center
(Gas Engine) .58
Modules
Daytime
Running Lamp . .46
Intermittent
Wiper
.54

Key
-In
77,78

Seat
Belt
Warning 77,78
Motors Blower-A/C
with
Diesel Engine .69
Blower-A/C
with
Gas Engine 67
Blower-Heater
.66
Engine
Starter
with
Diesel Engine . .7 Engine
Starter
with
Gas Engine 9
Heater
Blower
66,67
Idle
Air
Control
............... ........
.19
Intermittent
Windshield
Wiper
54
Power Door
Lock-Left
.73
Power Door Lock-Right 74
Power
Mirror
Left
75
Power
Mirror
Right .76 Power
Window-Left
71
Power Window-Right .72
Windshield Washer Pump 53

Neutral/Park
Position
Switch
with
Diesel Engine 7

Neutral/Park
Position
Switch
with
Gas Engine 9
Oil Pressure Sending
Unit
with
Diesel Engine 27
Oil Pressure Sending
Unit
with
Gas Engine 28 Oil Pressure
Switch
with
Diesel Engine 27
Oil Pressure &
Temperature
System (Diesel) 27 Oil Pressure &
Temperature
System (Gas) . 28
Oil Pressure Warning Lamp • -59 Parking Brake
Switch
.31,33 Power Door Lock System . . 73,74
Left
Door Motor . .73

Left
Door
Switch
. 73
Right Door Motor . -74 Right Door
Switch
74
Power
Mirrors
75,76

Fuse
75
Left
Motor 75
Wiring
Diagram
Name
Sheet
Number

Right Motor 76

Switch
76

Powertrain
Control
Module
........
.11,12,14,15,16,17,18,
19,20,21,22,23,24,35,37

Powertrain
Control
Module Connector .83,84
Power Window System 71,72
Circuit
Breaker 71
Left
Door
Switch
71
Left
Motor 71 Right Door
Switch
72
Right Motor 72

Printed
Circuit
Board Connectors 60
Radio-4 Speakers 61,62,63,64
Radio-2 Speakers 65
Rear
Lighting
System 79,80

Rear
Wheel
Anti-Lock
Brake System (Diesel) 33,34 Brake Warning Lamp
Switch
.34 Data
Link
Connector 33
Dual Solenoid
Hydraulic
Valve 34
Electronic
Vacuum
Sensor
34

Fuse
.33 Module 33 Park Brake
Switch
33
Rolls Test Connector .33 Resistor .34

Sensor
. .34 Stop Lamp
Switch
. .34

Rear
Wheel
Anti-Lock
Brake System (Gas) . .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

Relays
Air
Heater
(Diesel Engine) .21
Automatic
Shut Down
with
Diesel Engine 22

Automatic
Shut Down
with
Gas Engine 16

EMCC
Relay 11 Engine
Starter
Relay .7,9
Fuel Pump 16
Horn 30
Ignition
Lamp
Time
Delay 49
Wide Open
Throttle
Cut-Out Diesel Engine 70
Wide Open
Throttle
Cut-Out Gas Engine 68
Resistor 24,32,34,36,38
Right
Printed
Circuit
Board 59 Right
Printed
Circuit
Board Connector 60 Rolls Test Connector .31,33
Seat
Belt
Warning System 77,78
Sending
Units

Fuel Gauge-Diesel Engine 77 Fuel
Gauge-Gas
Engine 78
Oil-Diesel Engine 27

WIRING
DIAGRAMS
8W - 43

FUSIBLE
LINK
(18GY)

12BK/RD
FUSIBLE
LINK

(200R)

(LEFT
FRONT
WHEELHOUSE) HEATED

REAR
WINDOW
SH
39
FUSIBLE
LINK

(200R)

(LEFT
FRONT
WHEELHOUSE)
I—A22
12BK/0R

IT

1
30
AMPS
J CIRCUIT
,—h BREAKER —P CAVITY
#12
-A22
12BK/0R-

RUN ONLY
IGNITION

SWITCH
SH
10

A31

14BK/WT

RUN
AND ACC
F21
12TN

POWER WINDOW
SH
71
FUSE
#11
30 AMP

CI
12DG

A/C
AND
HEATER BLOWER MOTOR
SH
66.67.69

S
FUSE
#10

10*ZJ20
AMP
O

FUSE
#8
310 AMP
-A41
14YL-

ENGINE
STARTER
SYSTEM

SH
7.8.9

A21
14DB
FUSE
#1

3
2 AMP
RUN
AND
START

V34

20WT/RD
A2I
14DB
VEHICLE

SPEED
CONTROL (GAS)

SH
36

VEHICLE

SPEED
CONTROL (DIESEL)
SH
38
FUSE
#3
20 AMP

F20
18WT

BACK-UP
LAMP
SH
79.80

HEATER REAR WINDOW
SH
39
G5

20DB/WT

TO
4tART
D

FUSE
# 2

3
5 AMP

LAMP LOW

FUSE
#9
120 AMP

V6
18DB
WINDSHIELD WIPER

SYSTEM

SH
54.55
RADIO
AND
CLOCK

SH
61.63.65
L5
18RD

i

TURN SIGNAL FLASHER
SH
56

TACHOMETER

PROVISIONS

SH
48

REAR
WHEEL ANTI-LOCK
MODULE

SH
31.33
AUTOMATIC
SHUT DOWN
RELAY

SH
16.22

TRANSMISSION
OVERDRIVE

SOLENOIDS
SH
12.14

FUEL PUMP RELAY
SH
16

GENERATOR
SH
4

VACUUM SENSOR

SH
34

AIR SWITCHING
SOLENOIDS
SH
16

PMC

SH
16

AIR HEATER CONTROLLER

SH
21

WOT RELAY
SH
68.70
A/C

ELECTRONIC CYCLING SWITCH

SH
68.70

3.R.L.
MODULE
SH
46

EMCC
RELAY

SH
11

FUEL HEATER AND PUMP
SH
24
WAIT
TO
START

SH
57

FUEL LAMP
SH
57

GAUGES
SH
59

BRAKE
LAMP
SH
57.58

SEAT
BELT LAMP AND BUZZER
SH
77 78

WATER
IN
FUEL LAMP
SH
57

4
WHEEL DRIVE
INDICATOR LAMP
SH
13

LOW ENGINE
OIL
LAMP
SH
59

MALFUNCTION
INDICATOR LAMP

SH
59

ANTI-LOCK LAMP
SH
57 58

LIFTGATE OPEN LAMP
SH
58

TRANSMISSION

CONTROL MODULE
SH
12.14

SERVICE
REMINDER INDICATOR LAMP
SH
58

J938W-11
FUSE
APPLICATION
CHART

AD
2