1993 DODGE TRUCK clock

IGNITION
SYSTEMS
80 - 25

IGNITION
SWITCH

INDEX

General
Information
page
. . 25

GENERAL
INFORMATION
The ignition switch is located in the steering col­
umn. The Key-In-Switch and Halo Light are integral
with the ignition switch. Refer to Group 8M for Key- In-Switch and Halo Light diagnosis.

IGNITION
SWITCH
AND
KEY
CYLINDER
SERVICE

REMOVAL
(1) Disconnect negative battery cable.
(2) Tilt column: Remove tilt lever (counterclock­

wise).

(3) Remove upper and lower shrouds (Fig. 1).
STEERING
WHEEL
NUT
TILT
UPPER
LEVER SHROUD PANEL

BRACKET

SPACER

CLOCK SPRING LOWER
SHROUD NUT
J928J-2

Fig.
1
Shroud
Removal/Installation—Typical (4) Remove ignition switch mounting screws
(Snap-on torx bit tool TTXR20B0 or equivalent re­
quired—Fig. 2).
(5) Gently pull switch away from the column. Re­
lease two connector locks on the 7-terminal wiring
connector. Remove the connector from the ignition switch (Fig. 3).
(6) Release connector lock on the Key-In-Switch
and Halo Light 4-terminal connector (Fig. 3).
(7) Remove the key cylinder from the ignition
switch as follows:
Ignition
Switch
and Key
Cylinder
Service

page

. . 25
STEERING
COLUMN
IGNITION

SWITCH
908D-14

Fig.
2 Ignition
Switch
Screw
Removal
KEY-IN SWITCH &
HALO
LIGHT
MULTIFUNCTION

SWITCH
IGNITION

SWITCH
TURN
SIGNAL
SWITCH & LEVER

SPEED

CONTROL
J918J-2

Fig.
3 Key in
Switch
and Halo
Lamp
Connector

(a) With the key inserted and the ignition switch
in the lock position, proceed as follows: Use a small screwdriver to depress the key cylinder retaining
pin flush with the key cylinder surface (Fig. 4).
(b) Rotate the key clockwise to the OFF position.
The key cylinder should now be unseated from the ignition switch assembly (Fig. 5).

CAUTION:
Do not
remove
key
cylinder
at
this
time.
(c) With key cylinder in unseated position (key
cylinder bezel about 1/8 inch above ignition switch

8D
- 28
IGNITION
SYSTEMS

SMALL
SCREWDRIVER
KEY
CYLINDER
RETAINING
PIN

KEY
CYLINDER
RETAINING
PIN

IGNITION SWITCH
908D-15

Fig.
4 Key Cylinder Retaining Pin

KEY
CYLINDER

BEZEL

j
HALO
LIGHT

^
RING
908D-16

Fig.
5 Unseated Key Cylinder
halo light ring), proceed as follows: Rotate the key
counterclockwise to the Lock position and remove
the key. (d) Remove key cylinder (Fig. 6).

INSTALLATION
(1) Install electrical connectors to switch. Make
sure that the switch locking tabs are fully seated in
the wiring connectors. (2) Mount ignition switch to the column (Fig. 7).
i-i-ii
\IGNITION
SWITCH HALO
LIGHT

RING

908D-17

Fig.
6 Key Cylinder
Removal
Park-lock dowel pin on ignition switch assembly
must engage with column park-lock slider linkage (Fig. 8). Verify ignition switch is in lock position
(flag is parallel with the ignition switch terminals)
(Fig. 6). Apply a dab of grease to flag and pin. Posi­
tion park-lock link and slider to mid-travel. Position ignition switch against lock housing face. Be sure pin
is inserted into park-lock link contour slot. Tighten
retaining screws to 2 N#m (17 in. lbs.) torque.

FASTENER
LOCATIONS LOCATING
PIN

PARK
LOCK
'DOWEL
PIN

IGNITION SWITCH

ELECTRICAL

CONNECTION COLUMN

LOCK

FLAG 908D-18
Fig.
7 Ignition
Switch
View From
Column

(3) Assemble cover to the column (3 screws).
Tighten retaining screws to 2 N»m (17 in. lbs.)
torque.
(4) Tilt column: Install tilt lever (clockwise).
(5) Install negative battery cable.
(6) Install key cylinder. (a) With key cylinder and ignition in lock posi­
tion, gently insert key cylinder into ignition switch assembly until it bottoms.
(b) Insert key. While gently pushing on the key
cylinder (inward) toward the ignition switch, rotate key clockwise to end of travel.

8D
- 28
IGNITION
SYSTEMS

•
GENERAL
INFORMATION

The following specifications
are
published from
the

latest information available
at the
time
of
publica­

tion.
If
anything differs between
the
specifica­
tions found
on the
Vehicle Emission Control Information (VECI) label
and the
following spec­
ifications,
use
specifications
on
VECI label.
The
SPECIFICATIONS

VECI label
is
located
in the
engine compartment.
IGNITION
TIMING

Ignition timing
is not
adjustable
on any
engine.
Refer
to
Ignition Timing
in the
Diagnostics/Service
Procedures section
of
this group
for
more informa­
tion.
IGNITION
COIL

COii
TOYODSNSO

Primary Resistance .95-
1.20
Ohms .96-
1.18
Ohms

Secondary
Resistance
at
70°
-
80
°F
11,300-
13,300
Ohms
11,300
-
15,300
Ohms

SPARK PLUGS J918D-25

Engine
Spark
Plug
Application
Gap
Tightening
Torque Size

Engine

Original
Equipment Replacement Application

Gap
Tightening
Torque Size
3.9L/5.2L/5.9L
RC12YC RC12YC
All
.035°

(0.9mm)
41
Nm

(30
ft.
lbs.)
14mm
%"
Reach
J928D-23
SPARK PLUG CABLE RESISTANCE
ENGINE FIRING ORDER-3.9L
V-6
ENGINE
MINIMUM

MAXIMUM

250 Ohms
Per
Inch 1000 Ohms
Per
Inch

3000
Ohms
Per
Foot
12,000
Ohms
Per
Foot
J908D-43
a

FRONT
OF
ENGINE CLOCKWISE
ROTATION

1
-6-5-4-3-2
,
©

V©
^ ©y
©

J9314-80

IGNITION
SYSTEMS
8D - 29
ENGINE FIRING ORDER—5.2L/5.9L V-8 EN­
GINES TORQUE

FRONT
OF

ENGINE
CLOCKWISE
ROTATION

1-8-4-3-6-5-7-2
Description
Torque
Crankshaft
Position
Sensor..

Distributor Hold Down Bolt..
Powertrain
Control Module
Mounting
Screws............

Powertrain
Control Module

(PCM)
Elect. Connector...

Spark
Plugs

All Engines
8
N*m (70
in.
lbs.)

23
N«m(17ft.ibs.)

1
N«m (9 in. lbs.)
4 N*m (35
in.
lbs.)

41
N<>m
(30
ft.
lbs.)
J9314-166

J9314-79

1

• • ^ ^ ^ INSTRUMENT PANEL AND GAUGES 8E - 1
CONTENTS

page
CLUSTER AND GAUGE SERVICE PROCEDURES . 12
CLUSTER AND GAUGE TEST PROCEDURES .. i
GENERAL INFORMATION . 1
page

MESSAGE CENTER-DIESEL ENGINE ........ 4
MESSAGE CENTER-GAS ENGINE .......... 3

SWITCH
AND PANEL COMPONENT SERVICE . 16
GENERAL
INFORMATION
INDEX

page

Generator
Indicating
System
2
Distance
Sensor
2

Electronic
Digital
Clock
3

Fuel
Level
Indicating
System
1
page

Malfunction
Indicator
(Check
Engine)
3

Oil
Pressure
Warning
Lamp
................. 2
Speedometer/Odometer
System
2

Temperature
and Oil
Indicating
System
......... 2
D-body trucks have an instrument cluster which
includes gauges for fuel level, coolant temperature,
oil pressure, and charging system voltage (Fig. 1).
When the ignition switch is in the OFF position all
the gauges will show a reading except the voltage gauge. However, the readings are only accurate
when the ignition switch is in the ON position.
The cluster also includes warning lamps for:
• seat belt warning
• low oil pressure
• high beam
• left and right turn signals
• check engine. J908E-66

Fig.
11nstrument
Cluster
FUEL LEVEL INDICATING SYSTEM (FIG. 2)
A hinged float arm in the fuel tank raises or lowers
depending on the fuel level. The float arm contacts a
variable resistor in the gauge sending unit. This pro­
vides a change of resistance in the fuel gauge circuit
with any up or down movement of the float. This sender
resistance is shown as fuel level on the gauge. Resistance is greatest when the fuel level in the
tank is low and the float arm drops. With high resis­
tance current flow is low and consequently positions
the instrument panel gauge pointer to low.
Resistance in the circuit is at a minimum when the
tank is full and the float arm is raised. With resis­
tance at a minimum, current flow is high registering
full on the instrument panel gauge.
12
VOLTS
TO

GAUGE
IP

FUEL
TANK

SENDING
UNIT

FLOAT

SENDING
UNIT
1:
1
j
^
fCONNECTOR

!g|yj-»—
FUEL

GAUGE

FUEL

TANK

J098E-47

Fig.
2
Fuel
Level
Indicating
System

INSTRUMENT PANEL AND GAUGES

•

INSTRUMENT PANEL
AND
GAUGES
8E - 3
MALFUNCTION INDICATOR (CHECK ENGINE)

Fig.
5
Distance Sensor
If
the
input from
one of the
following sensors fails
an internal Powertrain Control Module
(PCM)
self
check,
the PCM
turns
on the
Check Engine Lamp. The
PCM
then substitutes
a
modified signal
in
place
of
the one
that failed until
a
repair
is
made:
• Manifold Absolute Pressure (MAP) Sensor
• Throttle Position Sensor
• Coolant Temperature Sensor
• Battery Voltage Sense
• Battery Voltage
Too
High
Refer
to the
appropriate Powertrain Diagnostic
Test Procedures manual
for
further information.

ELECTRONIC DIGITAL CLOCK
The electronic digital clock
is in the
radio.
The

clock
and
radio each
use the
display panel built into
the radio.
A
digital readout indicates
the
time
in

hours
and
minutes whenever
the
ignition switch
is in

the
ON or ACC
position. When
the
ignition switch
is in the OFF
position
or

when
the
radio frequency
is
being displayed, time keeping
is
accurately maintained. The procedure
for
setting
the
clock varies slightly
with each radio.
The
correct procedure
is
described under
the
individual radio operating instructions
re­

ferred
to in the
Owner Manual supplied with
the ve­

hicle.

MESSAGE CENTER—GAS ENGINE

The message center
(Fig. 6),
located above
the

Heater-A/C controls, includes warning lamps
for the:

• brake systems (parking
and
service)
•
ABS
brakes • liftgate open (Ramcharger only)
• maintenance required.

O/D
BRAKE
(P)(7

GATE OPEN

MAINT
REQD.

J938E-54
Fig.
6
Message Center—Gas Engine

EMISSIONS
MAINTENANCE REMINDER
This system
is
designed
to act as a
reminder that
scheduled vehicle emissions maintenance should
be

performed.
It is not
intended
to
indicate
a
warn­
ing
or
that
a
state
of
emergency exists which must
be
corrected
to
insure safe vehicle opera­
tion.
The
components covered
by the
system include
the
EGR
system,
PCV
valve,
and
oxygen sensor. Refer
to
Group
25 -
Emissions,
for
further informa­
tion.

ABS
WARNING
LIGHT
This light monitors
the ABS
Brake System. This
light will come
on
when
the
ignition
key is
turned
to

the
ON
position
and may
stay
on for as
long
as

thirty seconds.
If the ABS
light remains
on or
comes on during driving,
it
indicates that
the ABS
portion
of
the
brake system
is not
functioning. Refer
to
Group
5 -
Brakes
for
further information.

BRAKE
SYSTEM WARNING
LIGHT
The dual brake system provides
a
reserve braking
capability
in the
event
of a
failure
to a
portion
of the

hydraulic system. Failure
of
either
of the
dual sys­
tem
is
indicated
by the
brake warning light which
will glow when
the
service brake pedal
is
depressed.
The light will remain
on
until
the
cause
is
corrected. The light will also come
on
when
the
parking
brake
is
applied with
the
ignition
in the ON
position.
Refer
to
Group
5 -
Brakes
for
further information.

8E
- 20
INSTRUMENT PANEL
AND
GAUGES

•
INSTALLATION

(1) Position indicator to bezel and attach with two
screws. (2) Install cluster bezel.
(3) Install map lamp.

CIGAR LIGHTER
(Fig. 8) REMOVAL (1) Open ash receiver.
(2) Remove lighter element from shell.
(3) Disconnect wiring.
(4) Turn clamp counterclockwise and remove.
(5) Remove shell through front of housing.

INSTALLATION
(1) Insert shell through front of housing.
(2) Install clamp on shell, turn clockwise and
tighten securely.
(3) Connect wiring to shell.
(4) Install lighter element.
(5) Install wires and close ash receiver.
ASH
TRAY
(Fig. 8)
TRAY

REMOVAL
(1) Open ash tray.
(2) Remove ash tray bin.

INSTALLATION
(1) Install ash tray bin.
(2) Push ash tray inward to closed position.
HOUSING

REMOVAL
(1) Remove ash tray bin. (2) Disconnect electrical leads from cigar lighter.
(3) Remove 6 screws retaining housing to panel.
(4) Remove cigar lighter from housing.

INSTALLATION
(1) Install cigar lighter in housing.
(2) Connect electrical leads to cigar lighter. (3) Position housing to panel and install six
mounting screws.
(4) Install ash tray bin. Fig. 8
Cigar
Lighter and Ash
Tray

8H
- 12
VEHICLE SPEED CONTROL SYSTEM

•
SERVO
THROTTLE CABLE ASSEMBLY—DIESEL
ENGINE

REMOVAL (1) Remove hairpin clip and washer retaining ca­
bles on bellcrank. Remove servo throttle cable from bellcrank.
(2) Remove servo throttle cable from cable support
bracket.
(3) Remove 2 nuts from servo mounting bracket.
(4) Pull servo away from mounting bracket.
(5) Remove and discard push nuts on servo studs. (6) Pull speed control cable away from servo to ex­
pose cable retaining clip. (7) Remove clip attaching cable to servo.
(8) Disconnect cable at servo and remove cable as­
sembly.
INSTALLATION (1) Locate cable through servo mounting bracket.
(2) Connect cable sleeve to servo stud, align holes,
and install hairpin clip.
(3) Insert servo studs through holes in cable.
(4) Install new push nuts on servo studs.
(5) Insert servo studs through holes in bracket. In­
stall nut washers and torque to 6 N*m (50 in. lbs.).
(6) Route cable from servo, to cable support
bracket, (7) Install cable end on bellcrank rod.
(8) Adjust cable as described under speed control
cable adjustment. (9) Install washer and hairpin clip on end of bell­
crank rod.

SPEED
CONTROL
SWITCH
REPLACEMENT
(1) Disconnect negative cable from battery.
(2) From underside of steering wheel, remove horn
pad mounting screws (Fig. 2).
(3) Pull pad up from wheel and disconnect electri­
cal leads.
(4) Remove pad.
(5) Unplug 4-way electrical connector from clock-
spring. (6) Remove 4 screws holding switches and remove
switches (Fig. 3) (7) Install new switches with 4 screws.
(8) Connect 4-way electrical connector from clock-
spring to switches. (9) Connect electrical leads to horn pad.
(10) Install horn pad with 3 screws.
HORN
PAD
Fig. 2 Sport Steering Wheel
CLOCKSPRING

Fig. 3 Speed Control Switches

SPEED
CONTROL VACUUM RESERVOIR
REPLACEMENT-GAS
ENGINE

REMOVAL (1) Disconnect all hoses.
(2) Remove nuts and slide vacuum reservoir off

studs.

INSTALLATION (1) Install vacuum reservoir onto bracket studs.
(2) Install nut washers and torque to 6 Nrn (50 in.

lbs.).

(3) Connect vacuum hoses.

VACUUM PUMP-DIESEL ENGINE
Refer to Group 5 - Brakes for removal and instal­
lation of the vacuum pump.