Dodge Lamps Service Manual

DR LAMPS 8L - 1

LAMPS

TABLE OF CONTENTS

page page

LAMPS/LIGHTING - EXTERIOR ............... 1 LAMPS/LIGHTING - INTERIOR............... 24

LAMPS/LIGHTING - EXTERIOR

TABLE OF CONTENTS

page page

LAMPS/LIGHTING - EXTERIOR

DESCRIPTION ..........................2

OPERATION ............................2

DIAGNOSIS AND TESTING - LAMPS/

LIGHTING - EXTERIOR ..................3

STANDARD PROCEDURE

SAFETY PRECAUTIONS .................7

SPECIFICATIONS

EXTERIOR LAMPS .....................7

SPECIAL TOOLS - HEADLAMP ALIGNMENT . . . 7

BACKUP LAMP

REMOVAL .............................7

INSTALLATION ..........................7

BACKUP LAMP SWITCH

DESCRIPTION ..........................7

OPERATION ............................8

DIAGNOSIS AND TESTING - BACKUP LAMP

SWITCH .............................8

BRAKE LAMP

REMOVAL .............................8

INSTALLATION ..........................8

BRAKE LAMP SWITCH

DESCRIPTION ..........................8

OPERATION ............................8

DIAGNOSIS AND TESTING - BRAKE LAMP

SWITCH .............................9

REMOVAL .............................9

INSTALLATION .........................10

CENTER HIGH MOUNTED STOP LAMP

REMOVAL .............................10

INSTALLATION .........................10

CENTER HIGH MOUNTED STOP LAMP UNIT

REMOVAL .............................10

INSTALLATION .........................10

CAB CLEARANCE LAMP

REMOVAL .............................10

INSTALLATION .........................10

FOG LAMP

REMOVAL .............................11

INSTALLATION .........................11

FOG LAMP RELAY

DESCRIPTION .........................11

OPERATION ...........................12

DIAGNOSIS AND TESTING - FRONT FOG

LAMP RELAY .........................12

REMOVAL .............................13

INSTALLATION .........................13

HAZARD SWITCH

DESCRIPTION .........................13

OPERATION ...........................13

HEADLAMP

REMOVAL .............................13

INSTALLATION .........................13

HEADLAMP SWITCH

DESCRIPTION .........................14

OPERATION ...........................14

REMOVAL .............................14

INSTALLATION .........................14

HEADLAMP UNIT

REMOVAL .............................15

INSTALLATION .........................15

ADJUSTMENTS ........................15

LICENSE PLATE LAMP

REMOVAL .............................16

INSTALLATION .........................16

LICENSE PLATE LAMP UNIT

REMOVAL .............................16

INSTALLATION .........................16

MARKER LAMP UNIT

REMOVAL

REMOVAL ...........................16

INSTALLATION

INSTALLATION .......................17

8L - 2 LAMPS/LIGHTING - EXTERIOR DR

MULTI-FUNCTION SWITCH

DESCRIPTION - TURN SIGNAL SYSTEM .....17

OPERATION - TURN SIGNAL SYSTEM .......18

DIAGNOSIS AND TESTING - MULTI-

FUNCTION SWITCH ...................18

REMOVAL .............................18

INSTALLATION .........................19

PARK LAMP RELAY

DESCRIPTION .........................19

OPERATION ...........................19

DIAGNOSIS AND TESTING - PARK LAMP

RELAY ..............................20

REMOVAL .............................20

INSTALLATION .........................21

PARK/TURN SIGNAL LAMP

REMOVAL .............................21

INSTALLATION .........................21

LAMPS/LIGHTING - EXTERIOR

DESCRIPTION

The exterior lighting system for this model include

the following components:

• Backup Lamps

• Brake Lamps

• Daytime Running Lamps

• Front Fog Lamps

• Hazard Warning Lamps

• Headlamps

• Park Lamps

• Turn Signal Lamps

Other components of the exterior lighting system

for this model include:

• Backup Lamp Switch

• Brake Lamp Switch

• Front Control Module

• Front Fog Lamp Relay

• Hazard Switch

• Multi-Function Switch

• Park Lamp Relay

• Trailer Tow Connectors

Some of the interior and exterior lighting functions are governed by the front control module. The headlamp, dome, and door ajar switchs provide signals to the instrument cluster. The instrument cluster sends a J1850 message to the front control module to enable the necessary components for illumination. Hard wired circuitry connects the exterior lighting system components to the electrical system of the vehicle. Refer to the appropriate wiring information.

TAIL LAMP

REMOVAL .............................21

INSTALLATION .........................21

TAIL LAMP UNIT

REMOVAL .............................21

INSTALLATION .........................21

TRAILER TOW WIRING

DESCRIPTION .........................22

TURN LAMP

REMOVAL .............................22

INSTALLATION .........................22

UNDERHOOD LAMP

REMOVAL .............................22

INSTALLATION .........................22

UNDERHOOD LAMP UNIT

REMOVAL .............................22

INSTALLATION .........................23

OPERATION

DAYTIME RUNNING LAMPS

Power is reduced using pulse-width modulation to the high beams, where by the power is switched on and off rapidly instead of remaining on continuously. The duration and interval of the power pulses is programmed into the Front Control Module (FCM).

HEADLAMP SYSTEM

The instrument cluster monitors both the multiplexed headlamp and multifunction switches. The instrument cluster transmits a J1850 bus message to the front control module (FCM) to activate the headlamps. The headlamp system will default to headlamps ON position when ignition switch is ON and when an open or short circuit failure occurs on the headlamp switch input to the instrument cluster. The system will return to normal operation when the open or short is repaired. A fault will be reported by the Instrument Cluster when a failure occurs on the dimmer or headlamp switch input.

If the exterior lamps are ON, and the headlamp switch is in any position other than OFF, with the ignition switch OFF (LOCK) after 5 minutes, the Instrument Cluster transmits a message via J1850 informing the the FCM. The FCM will then turn off the headlamps, park lamps and fog lamps. This feature (load shed) prevents the vehicle battery from being discharged when the vehicle lights have been left ON.

HEADLAMP TIME DELAY SYSTEM

The headlamp time delay system is activated by turning the headlamps ON (high or low beam) while the engine is running, turning the ignition switch OFF, and then turning the headlamp switch OFF

DR LAMPS/LIGHTING - EXTERIOR 8L - 3

LAMPS/LIGHTING - EXTERIOR (Continued)

within 45 seconds. The system will not activate if more than 45 seconds elapse between ignition switch OFF and headlamp switch OFF. The FCM will allow the headlamps to remain ON for 60 seconds (configurable) before they automatically turn off (If the key is in the ignition during the headlamp time delay mode, then the headlamps including panel dimming will be ON).

LAMP OUTAGE

If one or more of the following lamps (Low and/or High beams, Brake and/or Turn Signal) are out, then a “lamps out” indicator located in the cluster will illuminate.

OPTICAL HORN/HIGH BEAMS

When the multiplexed multifunction switch is pulled to the first detent (optical horn) signal, the headlamps are ON, the Instrument Cluster shall send a message via J1850 to the FCM to turn on the headlamps drivers to illuminate all four filaments (Low and High beams). When the multifunction switch is pulled to the second detent (high beam) signal and the headlamps are ON, the Instrument Cluster shall send a message via J1850 to the FCM to turn on the headlamps drivers. The High Beams are illuminated and the Low Beams and Fog Lamps (if ON) are extinguished. If the headlamps were in the high beam configuration when power was removed from the headlamps, the headlamps will return to their last state prior to being shut off.

DIAGNOSIS AND TESTING - LAMPS/LIGHTING

- EXTERIOR

WARNING: EYE PROTECTION SHOULD BE USED WHEN SERVICING GLASS COMPONENTS. PERSONAL INJURY CAN RESULT.

CAUTION: Do not touch the glass of halogen bulbs with fingers or other possibly oily surface, reduced bulb life will result. Do not use bulbs other than those indicated in the Bulb Application table. Damage to lamp and/or Daytime Running Lamp Module can result. Do not use fuses, circuit breakers or relays having greater amperage value than indicated on the fuse panel or in the Owners Manual.

When a vehicle experiences problems with the headlamp system, verify the condition of the battery connections, fuses, charging system, headlamp bulbs, wire connectors, relay, multifunction switch, and headlamp switch. Refer to the appropriate wiring information.

Each vehicle is equipped with various lamp assemblies. A good ground is necessary for proper lighting operation. Grounding is provided by the lamp socket when it comes in contact with the metal body, or through a separate ground wire.

When changing lamp bulbs check the socket for loose pin connections and corrosion. Repair as necessary.

When it is necessary to remove components to service another, it should not be necessary to apply excessive force or bend a component to remove it. Before damaging a trim component, verify hidden fasteners or captured edges are not holding the component in place.

8L - 4 LAMPS/LIGHTING - EXTERIOR DR

LAMPS/LIGHTING - EXTERIOR (Continued)

HEADLAMP DIAGNOSIS

CONDITION POSSIBLE CAUSES CORRECTION

HEADLAMPS ARE DIM WITH ENGINE IDLING OR IGNITION TURNED OFF

HEADLAMP BULBS BURN OUT FREQUENTLY

HEADLAMPS ARE DIM WITH ENGINE RUNNING ABOVE IDLE

1. Loose or corroded battery cables.

2. Loose or worn generator drive belt.

3. Charging system output too low. 3. Test and repair charging system, refer to

4. Battery has insufficient charge. 4. Test battery state-of-charge, refer to

5. Battery is sulfated or shorted. 5. Load test battery, refer to Electrical, Battery

6. Poor lighting circuit ground. 6. Test for voltage drop across ground circuits,

1. Integrated Control Module (ICM) not controlling voltage.

2. Loose or corroded terminals or splices in circuit.

1. Charging system output too low. 1. Test and repair charging system, refer to

2. Poor lighting circuit ground. 2. Test for voltage drop across ground circuits,

3. High resistance in headlamp circuit.

1. Clean and secure battery cable clamps and posts.

2. Adjust or replace generator drive belt.

Electrical, Charging

Electrical, Battery System.

System.

refer to Electrical, Wiring Diagram Information.

1. Test and repair Integrated Control Module.

2. Inspect and repair all connectors and splices. Refer to Electrical, Wiring Information.

Electrical, Wiring Information.

refer to Electrical, Wiring Information.

3. Test amperage draw of headlamp circuit.

HEADLAMPS FLASH RANDOMLY

1. Poor lighting circuit ground. 1. Test for voltage drop across ground locations, refer to Electrical, Wiring Information.

2. Variable resistance in headlamp

circuit.

3. Loose or corroded terminals or

splices in circuit.

4. Faulty headlamp switch. 4. Replace headlamp switch.

5. Front Control Module

Malfunction.

2. Test amperage draw of headlamp circuit.

3. Inspect and repair all connectors and splices, refer to Electrical, Wiring Information.

5. Refer to appropriate ICM/FCM diagnostics.

DR LAMPS/LIGHTING - EXTERIOR 8L - 5

LAMPS/LIGHTING - EXTERIOR (Continued)

CONDITION POSSIBLE CAUSES CORRECTION

HEADLAMPS DO NOT ILLUMINATE

HEADLAMPS ON WITH IGNITION IN RUN, WITH HEADLAMP SWITCH OFF

1. No voltage to headlamps. 1. Repair open headlamp circuit, refer to Electrical, Wiring Information.

2. No ground at headlamps. 2. Repair circuit ground, refer to Electrical, Wiring Information.

3. Broken connector terminal or

wire splice in headlamp circuit.

4. Faulty or burned out bulb. 4. Replace headlamp bulb(s).

5. Integrated Control Module

malfunction.

6. J1850 Bus Communication 6. Verify messages being transmitted by

7. Front Control Module

Malfunction.

1. Faulty headlamp switch. 1. Replace headlamp switch (review Instrument

2. Diagnostic tool indicates (4.7 -

5.0V) on headlamp switch input to

Instrument Cluster.

3. J1850 Bus Communication. 3. Verify messages being transmitted by

4. Front Control Module

Malfunction.

3. Repair connector terminal or wire splice.

5. Refer to appropriate Body Control Module diagnostics.

Instrument Cluster and received by FCM.

7. Refer to appropriate ICM/FCM diagnostics.

Cluster logged faults).

2. Inspect and repair terminals, connectors and open circuits.

Instrument Cluster and received by FCM.

4. Refer to appropriate ICM/FCM diagnostics.

CONDITION POSSIBLE CAUSES CORRECTION

FOG LAMPS ARE DIM WITH ENGINE IDLING OR IGNITION TURNED OFF.

FOG LAMP BULBS BURN OUT FREQUENTLY

FOG LAMP DIAGNOSIS

1. Loose or corroded battery

cables.

2. Loose or worn generator drive

belt.

3. Charging system output too low. 3. Test and repair charging system. Refer to

4. Battery has insufficient charge. 4. Test battery state-of-charge. Refer to

5. Battery is sulfated or shorted. 5. Load test battery. Refer to Electrical, Battery

6. Poor lighting circuit ground. 6. Test for voltage drop across ground

1. Charging system output too

high.

2. Loose or corroded terminals or

splices in circuit.

1. Clean and secure battery cable clamps and posts.

2. Adjust or replace generator drive belt.

Electrical, Charging,

Electrical, Battery System.

System.

locations. Refer to Electrical, Wiring Information.

1. Test and repair charging system. Refer to Electrical, Charging.

2. Inspect and repair all connectors and splices. Refer to Electrical, Wiring Information.

8L - 6 LAMPS/LIGHTING - EXTERIOR DR

LAMPS/LIGHTING - EXTERIOR (Continued)

CONDITION POSSIBLE CAUSES CORRECTION

FOG LAMPS ARE DIM WITH ENGINE RUNNING ABOVE IDLE

FOG LAMPS FLASH RANDOMLY

1. Charging system output too low. 1. Test and repair charging system. Refer to

Electrical, Charging.

2. Poor lighting circuit ground. 2. Test for voltage drop across ground

locations. Refer to Electrical, Wiring Information.

3. High resistance in fog lamp

circuit.

1. Poor lighting circuit ground. 1. Test for voltage drop across ground

2. Variable resistance in fog lamp

circuit.

3. Faulty fog lamp switch (part of

headlamp switch).

4. Loose or corroded terminals or

splices in circuit.

5. Is relay engaging properly? 5. Verify function of fog lamp relay in IPM.

6. J1850 Bus Communication. 6. Verify J1850 message (fog lamp info)

3. Test amperage draw of fog lamp circuit.

locations. Refer to Electrical, Wiring Information.

2. Test amperage draw of fog lamp circuit.

3. Replace headlamp switch.

4. Inspect and repair all connectors and splices. Refer to Electrical, Wiring Information.

transmitted from Instrument Cluster and received by FCM.

FOG LAMPS DO NOT ILLUMINATE

CONDITION POSSIBLE CAUSES CORRECTION

DAYTIME RUNNING LAMPS DO NOT OPERATE

1. Blown fuse for fog lamp. 1. Replace fuse. Refer to Electrical, Wiring

Information.

2. No ground at fog lamps. 2. Repair circuit ground. Refer to Electrical,

Wiring Information.

3. Faulty fog lamp switch (part of

headlamp switch).

4. Broken connector terminal or

wire splice in fog lamp circuit.

5. Faulty or burned out bulb. 5. Replace bulb.

6. Is relay engaging? 6. Verify function of fog lamp relay in IPM.

7. J1850 Bus Communication. 7. Verify J1850 message (fog lamp info)

3. Replace headlamp switch.

4. Repair connector terminal or wire splice.

transmitted from Instrument Cluster and received by FCM.

DAYTIME RUNNING LAMP (CANADA ONLY) DIAGNOSIS

1. Parking brake engaged. 1. Disengage parking brake.

2. Parking brake circuit shorted to ground.

3. Headlamp circuit shorted to ground.

4. FCM, Instrument Cluster not programed with Canadian country code.

2. Check cluster telltale, refer to the appropriate wiring information.

3. Refer to the appropriate wiring information.

4. Check country code.

DR LAMPS/LIGHTING - EXTERIOR 8L - 7

LAMPS/LIGHTING - EXTERIOR (Continued)

STANDARD PROCEDURE

SAFETY PRECAUTIONS

WARNING: EYE PROTECTION SHOULD BE USED WHEN SERVICING GLASS COMPONENTS. PERSONAL INJURY CAN RESULT.

CAUTION: Do not touch the glass of halogen bulbs with fingers or other possibly oily surface, reduced bulb life will result.Do not use bulbs with higher candle power than indicated in the Bulb Application table . Damage to lamp and/or Daytime Running Lamp Module can result.Do not use fuses, circuit breakers or relays having greater amperage value than indicated on the fuse panel or in the Owners Manual.

SPECIFICATIONS

EXTERIOR LAMPS

CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. Do not touch halogen bulbs with fingers or other oily surfaces. Bulb life will be reduced.

The following Bulb Application Table lists the lamp title on the left side of the column and trade number or part number on the right.

BULB APPLICATION TABLE

LAMP BULB

Back-up 3157

Center High Mounted Stop lamp

Fog lamp 9006LL

Front Park/Turn Signal 4157NAK

Head lamp 9007

License Plate 7F69

Tail, Brake, Turn Signal 3157

Side Marker, Tail Gate,

Cab Clearance

912

168

SPECIAL TOOLS - HEADLAMP ALIGNMENT

Headlamp Aiming Kit C-4466–A

BACKUP LAMP

REMOVAL

(1) Remove and isolate the negitive battery cable.

(2) Remove the taillamp unit (Refer to 8 - ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/TAIL LAMP UNIT - REMOVAL).

(3) Remove the bulb back plate from the tail lamp unit.

(4) Separate the bulb from the socket.

INSTALLATION

(1) Install the bulb into the socket.

(2) Install the bulb back plate to the tail lamp unit.

(3) Install the tail lamp unit (Refer to 8 - ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/TAIL LAMP UNIT - INSTALLATION).

(4) Reconnect the negative battery cable.

BACKUP LAMP SWITCH

DESCRIPTION

Vehicles equipped with a manual transmission have a normally open, spring-loaded plunger type back-up lamp switch (Fig. 1). The backup lamp switch is located in a threaded hole on the side of the manual transmission housing. The backup lamp switch has a threaded body and a hex formation near the plunger end of the switch, and an integral connector at the opposite end of the switch. When installed, only the connector and the hex formation are visible on the outside of the transmission housing. Vehicles with an optional electronic automatic transmission have a Transmission Range Sensor (TRS) that is used to perform several functions, including that of the backup lamp switch. The TRS is described in further detail elsewhere in this service information. The backup lamp switch cannot be adjusted or repaired and, if faulty or damaged, the entire switch unit must be replaced.

8L - 8 LAMPS/LIGHTING - EXTERIOR DR

BACKUP LAMP SWITCH (Continued)

BRAKE LAMP

REMOVAL

(1) Disconnect and isolate the negative battery cable.

(2) Remove the tail lamp unit (Refer to 8 - ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/TAIL LAMP UNIT - REMOVAL).

(3) Remove the bulb back plate from the tail lamp unit.

(4) Remove the bulb from the back plate.

INSTALLATION

(1) Install the bulb into the back plate.

(2) Install the bulb back plate to the tail lamp unit.

(3) Install the tail lamp unit (Refer to 8 - ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/TAIL

Fig. 1 Backup Lamp Switch - Typical

1 - MANUAL TRANSMISSION 2 - BACKUP LAMP SWITCH 3 - ENGINE WIRE HARNESS

LAMP UNIT - INSTALLATION).

(4) Connect the negative battery cable.

BRAKE LAMP SWITCH

OPERATION

The backup lamp switch controls the flow of battery voltage to the backup lamp bulbs through an output on the back-up lamp feed circuit. The switch plunger is mechanically actuated by the gearshift mechanism within the transmission, which will depress the switch plunger and close the switch contacts whenever the reverse gear has been selected. The switch receives battery voltage through a fuse in the Integrated Power Module (IPM) on a fused ignition switch output (run) circuit whenever the ignition switch is in the On position. A take out of the engine wire harness connects the backup lamp switch to the vehicle electrical system. The backup lamp switch and circuits can be tested using conventional diagnostic tools and methods.

DIAGNOSIS AND TESTING - BACKUP LAMP SWITCH

(1) Disconnect and isolate the battery negative cable.

(2) Raise and support the vehicle.

(3) Locate and disconnect the engine wire harness connector for the backup lamp switch.

(4) Check for continuity between the two terminal pins in the backup lamp switch connector.

(a) With the gear selector lever in the Reverse

position, there should be continuity.

(b) With the gear selector lever in any position

other than Reverse, there should be no continuity.

DESCRIPTION

The plunger type brake lamp switch is mounted on a bracket attached to the base of the steering column, under the instrument panel.

CAUTION: The switch can only be adjusted during initial installation. If the switch is not adjusted properly a new switch must be installed.

OPERATION

The brake lamp switch is hard wired to the Center High Mount Stop Lamp (CHMSL) and also monitored by the Instrument Cluster for use by the brake lamp, speed control brake sensor circuits and electronic brake distribution (EBD). The brake lamp circuit is open until the plunger is depressed. The speed control and brake sensor circuits are closed until the plunger is depressed. When the brake lamp switch transitions, the CHMSL transitions and instrument cluster transmits a brake applied/released message on the bus. The Integrated Power Module (IPM) will then transition the brake lamps.

When the brake light switch is activated, the Powertrain Control Module (PCM) receives an input indicating that the brakes are being applied. After receiving this input, the PCM maintains idle speed to a scheduled rpm through control of the Idle Air Control (IAC) motor. The brake switch input is also used to disable vent and vacuum solenoid output signals to the speed control servo.

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