1993 DODGE TRUCK fuel pump

•
WIRING DIAGRAMS 8W - 57 A21 HOB
A14 16RD-
TO

SPLICE

(SEE
SH 68)
A21 MOB 1 -\ ENG f-
- A142
160G/0R

•A142
16DG/0R-

A142 16DG/0R TL
TO HEATED
OXYGEN
SENSORS
(SEE
SH 17) A14 A14
16RD 16RD K51
A142
200B
16DG YL
_ OR
AUTOMATIC
SHUT DOWN RELAY

(LEFT
SIDE SHIELD)
-K51
20D8/YL"—

K51
20DB/YL
K51
20DB YL
FUEL PUMP RELAY

(LEFT
SIDE SHIELD)
FTO FUEL PUMP
^ (SEE SH 78)
TO CHARGING
SYSTEM

(SEE
SH 4) AH 16RD- —[ENGT—
—«— A21
14DB
A21 HOB A21 HOB AH
16RD K51
20DB
YL € TO
DATA
LINK
S CONNECTOR
(SEE
SH 17)
TO
TRANSMISSION OVERDRIVE SOLENOID

(SEE
SH 12)
A21
HDB K52
20PK BK EVAP
PURGE SOLENOID K35

(LEFT
REAR 20GY
OF ENGINE) YL
EGR
SOLENOID

(RIGHT
REAR OF ENGINE)
3 51 9 52
35
BATTERY ASD
IGNITION
EVAP

EGR

RELAY
FEED
PURGE
SOLENOID
SOLENOID SOLENOID
POWERTRAIN CONTROL MODULE II (PCM II) CONNECTOR (SEE SH 84)
J938H-11
(LEFT
FENDER SIDE SIELD)

IGNITION
SYSTEM

GAS
MFI ENGINES AD 16

•

WIRING DIAGRAMS
8W - 65

A21
14DB
A21
HOB
TO

TRANSMISSION

4
OVERDRIVE
>
SOLENOID
(SEE
SH 14)
TO TRANSFER

CASE
SWITCH
(SEE
SH 13)
Z12
18BK/TN
—' T41
18BR/YL—i

TO ENGINE
STARTER RELAY

(MANUAL
TRANS ONLY)
A2i

(SEE
SH 7) HOB
FUEL
HEATER
(ON
TOP OF

FUEL WATER SEPARATOR) •BLACK

I
1
THERMO
SWITCH A21
14DB
FUEL
SOLENOID

(LEFT
FRONT OF ENGINE) A21
18BL

EIZZll

COLD START ADVANCE
(K.S.B MOTOR) (ON PUMP)
(FRONT
OF
ENGINE)
J938W-11

DIESEL
CONTROL SYSTEM AD
24

WIRING
DIAGRAMS SW - 119
TO IGNITION SWITCH

(SEE
SH 10)
t 1—A21 HOB TO

1| SPLICE

(SEE
SH 68)
r
A21
HOB
47 F32 18PK/DB—,
F32 18PK/DB G26
20LB

lc£L
iCZD
• • • G10 20 LG/RD-
G10 20 LG/RD- Zl 20BK- ~1
G5
20DB/WT

G13 20DB/RD TO

FUSE
#5
[20 AMP)
SPLICE

(SEE
SH 47)
HEADLAMP KEY-IN
SEAT
BELT

COMBINED
BUZZER \ F32
\ 18PK
RIGHT OF STEERING COLUMN \ DB TO RIGHT
PRINTED CIRCUIT

BOARD
CONNECTOR
(SEE
SH 60)

(SEE
SH 58)

BLACK

G5
20DB/WT
G5
20DB/WT-

G10

20LG
Zl
20BK F32
18PK
DB

G26

20LB
TO STOP
-\ LAMP SWITCH
(SEE
SH
32,35)

< TO HEADLAMP
S SWITCH
(SEE
SH 47)

GRAY

TO LEFT
PRINTED CIRCUIT
BOARD

CONNECTOR

(SEE
SH 60)
•G13 20DB/RD
, TO FUEL PUMP
Hi41 16DG/BK-A MOTOR FEED
(SEE
SH 16) G10
Zl
(LEFT
BASE
OF
18BK STEERING COLUMN) ^ I , 18BK Zl
8BK (AT SEAT ^ 18LG

BELT>
18BK

^BLUE

r
(LEFT
SIDE UNDER INSTR/PANEL)
G4 18DB/YL- TO
3
GROUND

SPLICE

[SEE
SH 48)
Zl 16BK XL Zl
16GY
BK

TO 7|GROUND
SPLICE

(SEE
SH 79) \ z^20
5~Zl 16BK -HT A61
16DG
BK
4o
o o d
) c
F. it
JJ Zl
18BK Z1>11
SEAT
BELT
SWITCH
(IN SEAT
BELT BUCKLE) 71 1ftR. f TO CARGO LAMP
-Zl 18BK—^ (SEE SH 50) -5 TO
SPLICE

(SEE
SH 48)
FUEL TANK MODULE

J938W-11
ELECTRONIC
FUEL INJECTION TANK GAUGE

AND
SEAT BELT WARNING
SYSTEM
AD
78

8W - 126
WIRING
DIAGRAMS
SMALL
INDEX
50 49 48
47
46 45
44 43 42 41
40 39
38 37
36 35
34 33 32
© 31
30 29
28 27
26
© 25
24 23
22 21
20 ©
19 18
17
16 15 14 13 12 11 10 9 8 7
6 5 4
3 2
1
LARGE

INDEX TERMINAL END
OF DISCONNECT
ENGINE COMPARTMENT CAVITY

1

10
11
12
13
14 15
16
17
18 19
20
21
22
23
24
25
26
27
28
29
30 31
32 33
34
35
36
37
38
39 40
41
42
43
44
45
46
47
48
50 ENGINE COMPARTMENT CIRCUITS
A3 12RD/WT C7 12BK/TN
A141 16DG/BK
L4
16VT/WT

L3 14RD/0R
V30 20DB/RD
V31 20BR/RD V33
20WT/LG

V32 20YL/RD

E5
20DG/WT

G34 16RD/GY
L20
14LG/WT

G21 20GY/LB G20
20VT/YL

G6 20GY
G60 20GY/YL
G85 20TN/OR
L61 18LG L60 18TN
A15 16PK
T61 20BK/0R
LI 18VT/BK
L7 18BK/YL
F20 18WT
V10 20BR
A41 16YL
X2 18DG/RD
Ml 18BK/TN
Gil
20WT/BK

V5 18DG/YL
V6 18DB
C21 18DB/0R
G3 20BK/PK
X4 20LG/BR V40 18WT/PK
G24 20GY/PK
G7 2GWT/0R T6
200R/WT

V3 18BR/WT
V4 18RD/YL
A21 14DB
A4 12BK/RD Al 12RD
A2 12PK/BK HEADLAMP SWITCH

A/C
AND HEATER BLOWER MOTOR
FUEL PUMP FEED (GAS ONLY)
HEADLAMP LOW BEAM (2 WIRES)
HEADLAMP HIGH BEAM (2 WIRES)
VEHICLE
SPEED
CONTROL
VEHICLE
SPEED
CONTROL VEHICLE
SPEED
CONTROL
VEHICLE
SPEED
CONTROL

WAIT
TO START LAMP (DIESEL
QNLYr

HIGH BEAM INDICATOR LAMP
HIGH BEAM FEED
TACHOMETER SIGNAL (DIESEL)
ENGINE COOLANT TEMPERATURE SENDING
UNIT

ENGINE OIL
PRESSURE
SWITCH
ENGINE OIL
PRESSURE
SENDING
UNIT

WATER-IN FUEL LAMP (DIESEL)
LEFT TURN SIGNAL LAMP RIGHT TURN SIGNAL LAMP
BATTERY-HAZARD FLASHER
TRANSMISSION
OVERDRIVE INDICATOR LAMP
BACK-UP LAMPS
PARKING LAMPS (2 WIRES)
BACK-UP LAMP SWITCH
WINDSHIELD WASHER MOTOR
ENGINE STARTER RELAY
-1GNITI
ON HORN
UNDERHOOD LAMP

ELECTRIC
VACUUM
SENSOR
(DIESEL) (2 WIRES)
WINDSHIELD WIPER MOTOR
WINDSHIELD WIPER MOTOR
AIR CONDITIONING DAMPED
PRESSURE
SWITCH
MALFUNCTION INDICATOR LAMP
4 WHEEL DRIVE SWITCH

BRAKE
SENSOR
SRI
LAMP (GAS ENGINE ONLY)
VEHICLE
SPEED SENSOR

TRANSMISSION
OVERDRIVE
WINDSHIELD WIPER MOTOR
WINDSHIELD WIPER MOTOR
SPLICE-IGNITION RUN CIRCUIT
IGNITION
OFF DRAW

IGNITION
SWITCH
IGNITION
SWITCH
AD 85 50-WAY BULKHEAD DISCONNECT
J938W-11

•

WIRING
DIAGRAMS
8W - 127
CAVITY
INSTRUMENT PANEL CIRCUITS

1

10
11
12

13
14

15

16
17
18
19
20
21
22

23

24
25

26
27
28 29
30 31
31
32

33

34

35

36
37
38
39
40
41
42

43

44

45
46
47
48
49
50
A3
12RD/WT

C7 12BK/TN
A61 16DG/BK
L4
16VT/WT

L3
16RD/0R

V30 20DB/RD
V31 20BR/RD
V33
20WT/LG

V32 20YL/RD
V32 20YL/RD G86
20DG/WT

G34 16RD/GY
L20
20LG/WT

G21 20GY/LB
G20
18VT/YL

G6
20GY

G60 20GY/YL G85
20TN/0R

L61
18LG

L61
18LG

L60
18TN

L60
18TN
A15
16PK

T61 20BK/OR
LI
18VT/BK

L7 18BK/YL
F20
18WT

V10 20BR
A41
14YL

S21 14YL/BK
X2
18DG/R0

Ml
18PK

Gil
20WT/BK
V5
18DG

V6
18DB
C2 18DB/YL
G3 20BK/PK
Gl 20DG/GY
V40
18WT/PK
G24 22GY/PK
G7
20WT/0R
T6
200R/WT

V3 18BR/WT
V4 18RD/YL
A21
14DB

A21
14DB

A4 12BK/RD
Al
12RD

A2 12PK/BK BATTERY FEED

A/C
AND
HEATER BLOWER MOTOR
FUEL PUMP FEED
(GAS
ONLY)
HEADLAMP-LOW BEAM
HEADLAMP-HIGH BEAM VEHICLE
SPEED
CONTROL
VEHICLE
SPEED
CONTROL VEHICLE
SPEED
CONTROL
VEHICLE
SPEED
CONTROL

WAIT
TO
START LAMP (DIESEL ONLY)
HIGH BEAM INDICATOR LAMP
HIGH BEAM FEED (D.R.L. MODULE)
TACHOMETER (DIESEL)
ECT SEND/UNIT
OR
SWITCH
ENGINE
OIL
PRESSURE
LAMP
ENGINE
OIL
PRESSURE
GAUGE-SEND
UNIT

WATER
IN
FUEL LAMP (DIESEL)
LEFT FRONT TURN SIGNAL LAMP
RIGHT FRONT TURN SIGNAL LAMP
HAZARD FLASHER
TRANSMISSION
OVERDRIVE INDICATOR LAMP

BACK-UP
LAMPS

PARKING
LAMPS

BACK-UP
LAMP FEED
WINDSHIELD WASHER MOTOR
IGNITION START
IGNITION START (DIESEL)

HORNS

UNDERHOOD LAMP
ELECTRIC VACUUM
SENSOR
(DIESEL) WINDSHIELD WIPER SWITCH
WINDSHIELD WIPER SWITCH
A/C
COMPRESSOR CLUTCH
MALFUNCTION INDICATOR
4 WHEEL DRIVE SWITCH

BRAKE
SENSOR

SRI
LAMP
(GAS
ENGINE ONLY)
VEHICLE
SPEED
SENSOR
(2
WIRES)
TRANSMISSION
OVERDRIVE SWITCH
WINDSHIELD WIPER
LOW
SPEED

WINDSHIELD WIPER HIGH
SPEED

IGNITION-RUN
I
START
BATTERY FEED IGNITION SWITCH
(Bl)

IGNITION SWITCH
(B3)
SHEET
NO

4,6.30,47
66,67,68 78
43,45,47
36,38
23

43,46
46,47
22
27,28
23

43.45,56
43,45.56

3,5,56
12,14 7.79
43,45,47
7.9
53.55 8,9
30
29
34
54,55 67,69 19,22

13

32,34,36,38
19

19,25
12,14
54.55
10,23.77,78
3.5.39

4,6.10
4.6.10
TERMINAL
END

OF DISCONNECT
ff
p
45 46
47
48 49
50
35 36 37
38 39
40 41
42
43 44
29 30 31
© 32
33 34
23 24
25
© 26
27 28
17 18
19 ©
20 21 22
7 8 9
10 11
12 13
14 15 16
1
^
1.
2
3
4 5 &

J *j

LARGE
INDEX
INSTRUMENT PANEL
J938W-11

50-WAY BULKHEAD
DISCONNECT
AD
86

8W - 130
WIRING
DIAGRAMS

•

1 2 3

A 4

5 6

7
8

/

9
10

11
/


12 13
14

15 16

/

17
18
19
20

21

u
22
23
24

25 26

u

27
28 29

30
31
u

32 33
34

u

35 36

37

38 39
u

40
41 42

u

VIEW FROM WIRE
END
HEADLAMP
I
DASH
WIRING
CAV
IGNITION
SYSTEM CIRCUITS
SHEET
NO

1 A21
14DB
IGNITION
FEED 16
2
Zl 14BK

GROUND
9.68

3

4
LI 18VT/BK BACK-UP LAMPS 9
5 K54 200R/BK
EMCC
SOLENOID
11
6 A141 16DG/BK
FUEL PUMP 16

7
C20
18BR
A/C
COMPRESSOR CLUTCH 18
8 G3 20BK/PK MALFUNCTION INDICATOR LAMP 19
9 A14
16RD
BATTERY FEED 16

10

11
Zll
16BK/WT

SIGNAL GROUND
17

12 V40 18WT/PK
BRAKE
SIGNAL 35
13 Z12 16BK/TN

POWER
GROUND
17
14
T41 18BR/YL ENGINE STARTER RELAY COIL 9
15 G60 20GY/YL ENGINE
OIL
PRESSURE
SEND/UNIT 28
16 G6 20GY
ENGINE
OIL
PRESSURE
SWITCH 28

17 T6
200R/WT
TRANSMISSION
OD
OVERRIDE 12
18 T61 20BK/0R

TRANSMISSION
OD
LAMP SIGNAL
12
19

20
F20
18WT

BACK-UP LAMP SWITCH 9
21
22 T22 14DB/WT
EMCC

11
23

24
G24 20GY/PK
SRI
LAMP
19
25 C13 20DB/0R
A/C
COMPRESSOR CLUTCH RELAY
18
26 G20
20VT/YL
ECT SEND/UNIT
28

27
V31 20BR/RD VEHICLE
SPEED
CONTROL-
SET
35
28 V32 20YL/RD VEHICLE
SPEED
CONTROL- OFF/ON
35
29 V33
20WT/LG
VEHICLE
SPEED
CONTROL- RESUME 35

30
V35 20LG/RD VEHICLE
SPEED
CONTROL- VENT
35
31 V36 20TN/RD VEHICLE
SPEED
CONTROL- VACUUM
35
32
33 G7
20WT/0R
VEHICLE
SPEED
SENSOR 19

34
C3 14DB/BK
A/C
COMPRESSOR CLUTCH FEED 68
35
36

37

38
39

40

41
42
&

GjCUQjQ

UXJUXj
O

"IT
mJKXTV
ENGINE WIRING

- ENG

AD
89
GAS
ENGINE WIRING CONNECTOR
J938W-11

9
- 2
ENGINES

rial surrounds each mounting hole. Excess material
can easily be wiped off. Components should be
torqued in place within 15 minutes. The use of a lo­ cating dowel is recommended during assembly to pre­
vent smearing the material off location.

ENGINE PERFORMANCE
To provide best vehicle performance and lowest ve­
hicle emissions, it is most important that the tune-up
be done accurately. Use the specifications listed on
the Vehicle Emission Control Information label found on the engine compartment hood.
(1) Test cranking amperage draw (refer to Group

8B,
Battery/Starter/Generator Service for the proper
procedures).
(2) Tighten the intake manifold bolts (refer to
Group 11, Exhaust System and Intake Manifold for
the proper specifications). (3) Perform cylinder compression test:
(a) Check engine oil level and add oil, if neces­
sary.
(b) Drive the vehicle until engine reaches normal
operating temperature. (c) Select a route free from traffic and other
forms of congestion, observe all traffic laws and
briskly accelerate through the gears several times. The higher engine speed may help clean out valve seat deposits which can prevent accurate compres­
sion readings.

CAUTION:
DO NOT
overspeed
the
engine.
(d) Remove all spark plugs from engine. As
spark plugs are being removed, check electrodes for
abnormal firing indicators - fouled, hot, oily, etc.
Record cylinder number of spark plug for future
reference.
(e) Disconnect coil wire from distributor and se­
cure to good ground to prevent a spark from start­
ing a fire.
(f) Be sure throttle blades are fully open during
the compression check. (g) Insert compression gage adaptor into the
No.l spark plug hole. Crank engine until maxi­
mum pressure is reached on gauge. Record this
pressure as No.l cylinder pressure.
(h) Repeat Step 3g for all remaining cylinders.
(i) Compression should not be less than 689 kPa
(100 psi) and not vary more than 172 kPa (25 psi)
from cylinder to cylinder.
(j) If cylinder(s) have abnormally low compres­
sion pressures, repeat steps 3a through 3h. (k) If the same cylinder(s) repeat an abnormally
low reading, it could indicate the existence of a
problem in the cylinder.
The recommended compression pressures are
to be used only as a guide to diagnosing engine
problems. An engine should NOT be disassem­ bled to determine the cause of low compression
unless some malfunction is present. (4) Clean or replace spark plugs as necessary. Ad­
just gap (refer to Group 8D, Ignition System for gap adjustment and torque).
(5) Test resistance of spark plug cables (refer to
Group 8D, Ignition System.
(6) Inspect the primary wire. Test coil output volt­

age,
primary and secondary resistance. Replace parts as necessary (refer to Group 8D, Ignition System and
make necessary adjustment).
(7) Set ignition timing to specifications (refer to
Specification Label on engine compartment hood).
(8) Perform a combustion analysis.
(9) Test fuel pump for pressure and vacuum (refer
to Group 14, Fuel System for the proper specifica­

tions).

(10) Inspect air filter element (refer to Group 0,
Lubrication and Maintenance for the proper proce­
dure).

(11) Inspect crankcase ventilation system (refer to
Group 0, Lubrication and Maintenance for the proper
procedure).
(12) For emission controls refer to Group 25, Emis­
sion Controls System for service procedures.
(13) Inspect and adjust accessory belt drives (refer
to Group 7, Cooling System for the proper adjust­
ments).

(14) Road test vehicle as a final test.

H0NIN6
CYLINDER
BORES
Before honing, stuff plenty of clean shop towels un­
der the bores and over the crankshaft to keep abra­ sive materials from entering the crankshaft area.
(1) Used carefully, the Cylinder Bore Sizing Hone
C-823 equipped with 220 grit stones, is the best tool
for this job. In addition to deglazing, it will reduce
taper and out-of-round as well as removing light scuffing, scoring or scratches. Usually a few strokes
will clean up a bore and maintain the required lim­
its.

CAUTION:
DO NOT use rigid type
hones
to remove

cylinder
wall
glaze.

(2) Deglazing of the cylinder walls may be done if
the cylinder bore is straight and round. Use a cylin­
der surfacing hone, Honing Tool C-3501, equipped
with 280 grit stones (C-3501-3810). 20-60 strokes, de­
pending on the bore condition, will be sufficient to
provide a satisfactory surface. Using honing oil C-3501-3880 or a light honing oil available from ma­
jor oil distributors.

CAUTION:
DO NOT use engine or
transmission
oil, mineral
spirits
or
kerosene.

•

ENGINES
9 - S
ENGINE
DIAGNOSIS
Engine diagnosis is helpful in determining the
causes of malfunctions not detected and remedied by
routine tune-ups. These malfunctions may be classified as either per­
formance (e.g., engine idles rough and stalls) or me­ chanical (e.g., a strange noise). Refer to the Service Diagnosis—Performance chart
and the Service Diagnosis—Mechanical chart for pos­
sible causes and corrections of malfunctions. Refer to
Group 14, Fuel System for the fuel system diagnosis.

SERWIGE DIAGNOSIS (GASOLINE ENGINES)
-
PERFORMANCE
CONDITION

POSSIBLE
CAUSES
CORRECTION

ENGINE
WILL
NOT
START
1.
Weak
battery.

2.
Corroded
or
loose
battery
connections.

3.
Faulty
starter.

4.
Moisture
on
ignition wires and distributor
cap.

5.
Faulty
ignition
cables.

6.
Faulty
coil
or
control
unit.

7.
Incorrect
spark
plug
gap.
8.
Incorrect
ignition timing.
9.
Dirt
or
water
in
fuel
system.

10.
Faulty
fuel
pump.
1.
Test
battery
specific
gravity.
Charge
or
replace
as
necessary.

2. Clean
and
tighten
battery
connections.
Apply
a
coat
of light
mineral
grease
to
the terminals.
3. Refer to
Group
8A, Battery/Starter/Charging
System
Diagnostics.

4. Wipe
wires
and
cap
clean
and
dry.
5.
Replace
any
cracked
or
shorted
cables.

6.
Test
and
replace,
if
necessary
(refer
to
Group
8D,
Ignition
System).

7.
Set
gap
(refer
to
Group
8D, Ignition
System).

8. Refer to
Group
8D, Ignition
System.

9. Clean
system
and
replace
fuel
filter.

10. Install new
fuel
pump
(refer
to
Group
14,
Fuel
System).

ENGINE
STALLS
OR

ROUGH
IDLE
1.
Idle
speed
set
too
low.
2.
Idle
mixture
too
lean
or
too
rich.
3. Leak in
intake
manifold.
4. Worn or burned distributor
rotor.

5.
Incorrect
ignition wiring.
6.
Faulty
coil.

7.
EGR
valve leaking.
1.
Refer to
Group
14,
Fuel
System.

2. Refer to
Group
14,
Fuel
System.

3.
Inspect
intake
manifold
gasket
and
vacuum
hoses.
Replace,
if
necessary
(refer
to
Group
11,
Exhaust
System
&
Intake

Manifold).

4.
Install new distributor
rotor.

5. Install
correct
wiring.
6.
Test
and
replace,
if
necessary
(refer
to
Group
8D,
Ignition
System).

7.
Test
and
replace,
if
necessary
(refer
to
Group
25,
Emissions
Control
System).

J9309-105