1993 DODGE TRUCK Service Repair Manual

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.

•
IGNITION
SYSTEMS
80 - 27

Fig.
8 Ignition
Switch
Mounting
Pad (7) Check for proper operation of push-to-lock, halo
lighting, Accessory, Lock, Off, Run, Start, column
lock and shift lock (if applicable). IGNITION SWITCH CIRCUITS

.__|.
1
2 3 4 5 6 7

IGNITION
SWITCH CONNECTOR LOOKING
INTO
SWITCH
WIRE
CAVITY WIRE
COLOR APPLICATION

1
YELLOW
STARTER
RELAY
2
DARK
BLUE
IGNITION
RUN/START
3
WHITE
/
BLACK
BRAKE
WARNING
LAMP
4
PINK/BLACK
IGNITION
SWITCH
BATTERY FEED
5
BLACK/ORANGE

OR BLACK/TAN RUN ACCESSORY
6
BLACK
/
WHITE
ACCESSORY

7
RED
IGNITION
SWITCH
BATTERY FEED

J938D-18

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

8E
- 2
INSTRUMENT PANEL
AND
GAUGES

•
TEMPERATURE AND
OIL
INDICATING SYSTEM
(FIG.
3) The operation of the temperature and oil pressure
indicating systems are identical. In the temperature
system the sending unit resistance varies in direct
relationship to the temperature of the coolant. When the engine is cold, the resistance of the tem­
perature sending unit is high and a cold temperature
will be indicated on the gauge. When the engine is hot, the resistance of the tem­
perature sending unit is low and a hot temperature
will be indicated on the gauge. In the oil pressure indicating system the sending
unit resistance is actuated by a diaphragm as the oil
pressure increases or decreases. Low oil pressure causes high resistance. High pressure causes low re­
sistance. 12
VOLTS
TO
GAUGE
TEMPERATURE/
OIL GAUGE
TEMPERATURE/OIL SENDING
UNIT
J908E-48
Fig. 3 Temperature/Oil indicating System

OIL
PRESSURE
WARNING LAMP
The oil pressure warning switch, mounted on the
engine, is controlled by engine oil pressure. When engine oil pressure is normal, the switch is
held in the OFF or OPEN position. This stops cur­
rent from flowing to the oil pressure warning lamp
on instrument panel. When the engine oil pressure is low, the switch is
in the ON or CLOSED position. This allows current
to flow to the oil pressure warning lamp in the in­ strument cluster causing the warning lamp to illumi­

nate.
GENERATOR
INDICATING
SYSTEM
(FIG. 4)
The voltmeter gauge senses the voltage of the elec­
trical system.
VOLTAGE
/*

GAUGE
P/
J908E-49 Fig. 4 Generator Indicating System

SPEEDOMETER/ODOMETER SYSTEM
The speedometer/odometer system consists of an
electric speedometer and pushbutton reset odometer
mounted in the cluster. The system also includes the
wire harness from the cluster to the distance sensor at the transmission, and the adapter and pinion in
the transmission. The speedometer/odometer has the same appearance as a conventional version but it
eliminates the cable-driven mechanical system. A signal is sent from a transmission mounted distance
sensor to the speedometer/odometer circuitry through
the wiring harness. By eliminating the speedometer cable, instrument cluster service and removal is im­
proved. Refer to Group 21 - Transmission for select­ ing the proper pinion, and selecting and indexing the
proper adapter.

DISTANCE
SENSOR

DISTANCE SENSOR TEST For testing of the distance sensor and related com­
ponents refer to the Vehicle Diagnostics Test Proce­ dure Manual.
DISTANCE SENSOR REMOVAL AND INSTALLATION (1) Remove harness connector from sensor. Be sure
weather seal stays on harness connector. (2) Remove sensor by loosening sensor coupling
nut from the pinion gear adapter until sensor is free (Fig. 5).
(3) To install the sensor, reverse the removal pro­
cedures. Tighten coupling nut to 17 N»m (150 in. lbs.)

•

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.