Wiring Code Identification InformationWIRE CODE IDENTIFICATIONEach wire shown in the diagrams contains a code (Fig.1) which identifies the main circuit, part of the maincircuit, gauge of wire, and color. The color is shown as atwo-letter code, which can be identified by referring tothe Wire Color Code Chart (Fig. 2).A 2 18 LB/YLCOLOR OF WIRE(Light Blue with Yellow Tracer)GAUGE OF WIRETracer Wire Color Code HTYLYELLOWBLUELGLIGHTGREEN(18 Gauge)PART OF MAIN CIRCUIT(Varies Depending on Equipment)MAIN CIRCUIT IDENTIFICATIONFigure 1 – Wire Color Code IdentificationCIRCUIT IDENTIFICATIONAll circuits in the diagrams use an alphanumeric code toidentify the wire and its function (Fig. 3). To identifywhich circuit code applies to a system; refer to theCircuit Identification Code Chart. This chart shows themain circuits only and does not show the secondarycodes that may apply to some models.Base Wire Color Code Figure 2 – Wire Color Code ChartsCIRCUITFUNCTIONA- Battery FeedB- Brake ControlsC- Climate Controls, EBL, Heated Mirror,Windshield and SeatD- Diagnostic Circuits, Communications,AntennasE- Dimming Illumination CircuitsF- Switched Ignition FeedsG- Gauges, Displays, Monitoring, BodySensors, Resistive Mux'd SwitchesH- OpenI- Not UsedJ- OpenK- Power Train Control ModuleL- Exterior Lighting, Headlamp LevelingM- Interior and Courtesy LightingN- Fuel Pump, Radiator FanO- Not UsedP- Power Option, Seats, Recliner, Lumbar,Mirrors, Door LocksQ- Power Options, Windows, Vents,Sunroof, Tops, Trunk, Liftgate, SlidingDoorsR- Restraint SystemsS- Suspension/SteeringT- Starter, Transmission, Transaxle,Transfer CaseU- OpenV- Speed ControlW- Washer, WiperX- Sound Systems, HornY- OpenZ- GroundsFigure 3 – Circuit Identification
Wiring Code Identification InformationCONNECTORSConnectors shown in the diagrams are identified usingthe international standard arrows for male and femaleterminals (Fig. 4). A connector identifier is placed next tothe arrows to indicate the connector number (Fig. 4).For viewing connector pin outs, with two terminals orgreater, refer to section 8W-80. This section identifiesthe connector by number and provides terminalnumbering, circuit identification, wire colors andfunctions.All connectors are viewed from the terminal end unlessotherwise specified. To find the connector location in thevehicle, refer to section 8W-90. This section uses theconnector identification number from the wiring diagramsto provide a figure number reference.TAKE OUTSFigure 4 – Electrostatic Discharge SymbolThe abbreviation T/O is used in the component locationsection to indicate a point in which the wiring harnessbranches out to a component.ELECTROSTATIC DISCHARGE (ESD)SENSITIVE DEVICESAll ESD sensitive components are solid state and asymbol (Fig. 5) is used to indicate this. When handlingany component with this symbol, comply with thefollowing procedures to reduce the possibility ofelectrostatic charge buildup on the body and inadvertentdischarge into the component. If it is not known whetherthe part is ESD sensitive, assume that it is.1) Always touch a known ground before handling thepart. This should be repeated while handling the partand more frequently after sliding across a seat,sitting down from a standing position or walking adistance.2) Avoid touching electrical terminals of the part, unlessinstructed to do so by a written diagnosticprocedure.3) When using a voltmeter, be sure to connect theground lead first.4) Do not remove the part from its protective packinguntil it is time to install the part.5) Before removing the part from its package, groundthe package to a known good ground on the vehicle.Figure 5 – Electrostatic Discharge Symbol
Wiring Code Identification InformationWIRING GUIDELINES FOR 2013RAM TRUCK AFTERMARKET/BODYBUILDERS1. IntroductionThese guidelines are intended as an aid in wiringdesign. It is not an all-inclusive list or a substitute forcommon sense. It is to be used as a supplement toexisting good design practices and standards.Additional information is in the ReferencedPublications section. Performing a Failure Mode andEffects Analysis (FMEA) on each completed wiringdesign is a good practice to confirm the integrity ofthe design. This document will be revisedperiodically, based on advances in technology andoperating practices.2. Electrical SystemA. Modification to the existing vehicle wiring shouldbe done only with extreme caution. The effectson the completed vehicle electrical system mustbe considered. Any additional circuitry should beevaluated to ensure that adequate circuitprotection provisions will be in place and thatfeedback loops will not be created.B. The following affects the selection of wire gaugefor a particular application:Wire size selection is affected by circuitprotection requirements, power distributionrequirements and mechanical handlingrequirementsWire size selection is affected by long-rangeheat aging characteristics resulting fromcurrent loadingC. Circuit ProtectionWhen adding loads to a base vehicle’s protectedcircuit; be sure that the total electrical loadthrough the base vehicle fuse or circuit breakeris less than the derated device rating. The totalelectrical load is the sum of the base vehiclecircuit current requirement added to the add-oncomponent(s) current requirements. Confirm theload with an ammeter.DO NOT increase the rating of a factoryinstalled fuse or circuitAny added circuitry must be protected byeither the base vehicle fuse or circuitbreaker or by a similar device installed bythe body builder. In-line fuses should bereadily accessibleAll battery circuits, except the starter motor,must have circuit protectionProtections devices for high current loadssuch as a winch or snowplow motor must beconnected directly to the vehicle battery andnot to the vehicle power distribution centeror other downstream components.Circuit protection devices are designed toprotect the wiring. They may not necessarilyprotect other components in the event of a shortcircuit.3. Harness RoutingA. Connectors should be readily accessible, wherefeasible, to permit ease of installation andserviceability. Accessibility to connectors is gooddesign practice. Examples include fuse blocks,relays, modules, electrical components, junctionblocks and ground blocks.B. Provide sufficient wire lengths to permit wireharness serviceability. However, excess lengthsshould be kept to a minimum to prevent:trapping and pinching during assembly; poor fitand finish; and buzzes, squeaks and rattles.C. Circuits attached to parts or structures that havedynamic (moving) properties must consideradequate “slack” and strain relief to preventdamage. A few examples are the engine block,door and liftgate harness, shocks, struts and tiltsteering columns. Endurance testing must beperformed to ensure that designs meet life testcriteria.D. Wiring assemblies must not be within one inch(25 mm) of any hot surface or movingmechanism. Movement due to engine rockingwill require a greater distance than one inch.Engineering discretion must be used todetermine if heat-protection materials areneeded to protect the wiring assembly. The useof abrasion-protection materials (convolutedtubing, fiberglass loom, asphalt loom, frictiontape, etc.) can be used as an added measure inthe protection of the harness, but should not berelied upon alone to prevent damage to thewiring assembly. Some examples of hotsurfaces and moving mechanisms are:PlumbingExhaust manifoldPulleysOil and fuel linesCatalytic converterAccelerator, brake andclutch pedalsAuxiliary oil cooler lineParking brakeMechanismsFloor panChoke housing andcrossoverHingesSeat track and reclinermechanismsWindow, door anddoor lock mechanismsBeltsWire routings should be away from areas wheretemperatures exceed 180 F and should have a minimumof six inches (152 mm) clearance from exhaust systemcomponents. If this is not possible, use heat shields andhigh-temperature insulation to maintain safe operatingtemperatures for the wiring.
Wiring Code Identification InformationA.B.C.D.E.F.G.H.I.J.Hole linerRolled sheet metal edgeConvolute, scroll, loom or braided sleevingEdge protector (pinch welt)Wiring clipRoute wires on the surface of sheet metal toavoid “fishing” operations and to avoid sharpedges.Where wiring congestion or the possibility ofpinching wires exists, the harness design shouldbe a rigid shape and form. This will aidinstallation and facilitate fit and finish objectives.A good alternative design technique is the use ofa stamped sheet metal or a molded plastictrough.Eliminate buzzes, squeaks and rattles (BSR) bythe use of:Cloth tapeDirect connections to devicesLocating and/or clipping all connectorswhether used or unusedLocating and/or clipping wire harnessesFoam wrap, foam tubes, foam doughnuts onclipsRoute wiring away from areas where fastenersare driven.When a wire assembly is routed from the insideto the outside of the vehicle, the transition pointmust be sealed by:A rubber grommetA rubber tube and grommet (highlyrecommended for doors and liftgates)A sealed bulkhead-type connectionWires on the outside of the vehicle or in a wetenvironment should:Be routed lower than sealing devices toavoid water intrusion through the wireharnessHave a drip loop in the wiring harness toprevent water intrusion into the connector(s)High current circuits and pulse width modulationcircuits should not be routed near the radio andother sensitive electronic devices. If rerouting isunavoidable grounded shielding or some othermeans of isolation may be required. If possible,high current circuits should be routed at least sixinches away from the radio.Wire harnesses should not be routed closer thanone inch (25 mm) from high voltage devicessuch as the distributor coil or spark plug wires.When underbody routing is unavoidable, providea special wire jacket or covering, such aspolyurethane, fiberglass sleeve or loom, forprotection.Wire harnesses included with modularassemblies, such as headliners and door trimpanels, must be routed and secured by utilizingclips, straps or adhesives to ensure properretention and to prevent buzzes, squeaks orrattles.4. GroundingThe following guideline outlines the generalrequirements for electrical system grounding tominimize ground loops, unwanted feedback,coupling of transients and electro-magneticinterference to ensure proper electrical andelectronic system performance.A. General Requirements1) The battery negative terminal shall connectto the body and the engine with the shortestlength cables as practical.2) Each of the following types of ground circuitsshould connect to the body sheet metal asclose as possible to the electrical/electronicdevice or combination of devices:Electronic devices employing a singlepower ground for electronics and, whereapplicable, internal subminiature lampsInductive electrical devices andsubsystems, such as motors, solenoidsand relays (with noisy grounds) unlessfully internally sup-pressedThe exception to this is high current loadssuch as a winch or snowplow motor whichshould be grounded directly to the vehiclebattery to prevent overstressing the rest ofthe vehicle ground systemLighting grounds — particularly whereloop-type coupling into devices withinternal lamps would be possibleB. Detailed Requirements1) The battery to engine ground shall besufficient to keep the total external crankingcircuit resistance between the battery andstarter terminals, including junctions, at twomilliohms maximum. The battery groundfrom its terminal to body sheet metal shallnot exceed two milliohms at 80 F.2) Lighting grounds should not interconnectwithin wiring assemblies to electronic deviceand sub system grounds except at theattachment of the given wiring assembly tosheet metal.3) Instrument panel subsystem grounds musthave a dedicated ground for the A/C blowercircuit. Door and seat actuator grounds arenot to pass through the main instrumentpanel wiring assembly.C. Grounding Connections1) Steel ground screws shall have suitablecadmium, tin or zinc dichromate coating.2) Metal surfaces for grounding shall be free ofpaint and other insulating coatings or willacquire this condition by using metal cuttingfasteners.3) Grounds to vehicle sheet metal shall employone of the following fastening methods:Weld stud and nut/washer assembly usinga serrated eyeletWeld or pierce nut and paint cutting screw
Wiring Code Identification InformationExternally serrated eyelet with piercedconical hole/depression and doublethreaded paint cutting screw that ensureshigh strip to drive torque ratio1) The total resistance between groundterminations and ground surfaces should notexceed 0.05 milliohms2) No more than three wiring eyelet terminalsshall be stacked together under a groundscrew or on a stud3) Pop-riveted connections are not suitable forgrounding wiring terminals5. Sealing and Corrosion ProtectionAs a first choice, all connectors should be kept awayfrom any splash or wet areas. When connectors arein a splash or wet area, added protection should beused to meet endurance requirements. Someexamples of protection are sealed connectors, greasein connectors and barriers built to insulate theconnector. Orient connectors “horizontally” to helpminimize water penetration; avoid “vertical” connectororientations.Greased and/or pre-greased terminals arenot to be used on O2 sensor circuits.Grease in the connector or the terminals migratethrough the wire strands and contaminate thesensor resulting in false readingsGreased and/or pre-greased terminals arenot to be used with hypalon insulation.It causes the insulation to swell and todeteriorate particularly in the presence of heatSilicon grease is not to be used at all. It canmigrate through wire strands and contaminaterelay or switch contacts. It can also travel to thesheet metal destroying the adhesion of vehiclebody paint1) All metal sockets routed outside the vehiclemust have watertight boots and grease orother means of corrosion protection.2) All lamp sockets in a wet area must beevaluated for sealing and corrosionprotection.3) All grommets used in areas where moisture,water splash or exhaust fumes can enterinto the passenger compartment must seal.Use applied grommets, sealed tube-andgrommet assemblies, sealed bulkheadconnections, or molded grommets. Moldednon-rubber grommets are less desirable.4) Unused wiring hole provisions that mayallow moisture, fumes or noise to enter thepassenger compartment must be plugged orsealed.5) Screws and clips located in a wet regionmust have a sealing provision.6) Relays or circuit breakers should not belocated in moisture splash area withoutadequate protection.7) Wire harness routing from a wet to a dryenvironment must have drip loopconstruction. Locate the drip loop lower thanthe harness grommet; allow water runoff.6. Harness Construction1) All splices in moisture or splash areas should besealed by molding or by sealed heat shrinktubing. See the Service Kit Part Numberschapter of the Technical Information section ofthis Body Builder Guide for recommended heatshrink tubing available from Mopar. This heatshrink tubing has a built in sealing compoundwhich flows upon heat application. This is alsorecommended for dry areas to increasereliability.2) The following are general guidelines for splices:Avoid imbalance of circuit size on each sideof a splice.Splices should be staggered by a minimumof 50 mm center-to-center to avoid electricaltracking and to minimize harness bulk.Shielded cable should not be spliced.When used in instrument panel wiringapplications, PVC tape may squeak when incontact with some panel plastics. Use foamor cloth tape harness wrap to preventpotential BSR conditions.3) The following are general guidelines for harnesscomponents:Use insulators having secondary terminallatching (example: wedge-lock) and connector-toconnector latching (example: locking type)whenever possible. Connector-to- device, suchas switches, relays, motors, radios, speakersand modules, should have a positive latchingdesignWire color matching and insulator colormatching is NOT a reliable means of insulatorpolarization. Indexing mating connections and/orkeeping similar colored insulators sufficientlyseparated to prevent misassemble arerecommended practicesConnectors that provide the best terminalprotection against inadvertent shorting in anonmated connector should be on the vehicleside of the wiring assembly. This is usually thefemale terminalAll 10 AWG wires or larger must be soldered tothe terminalsDo not use spin-on wire nutsMake sure that an adequate mechanical jointexists before soldering. Use only rosin core solder
Wiring Code Identification Information7. Electromagnetic Capability (EMC)Any electrical/electronic (E/E) device, module,subsystem or system used on Chrysler GroupLLC vehicles shall meet Chrysler Group LLCPerformance Standards PF-10614 entitledElectromagnetic Compatibility Specifications forElectrical and Electronic Modules and Motorsand PF-10615 Electrical Specifications forElectrical and Electronic Modules and Motors.The relevant tests are performed in accordancewith DCA LP-388-C, and Chrysler Group LLCdetermines pass-fail limitsVehicles being produced in or for the Canadianmarket must meet Canadian regulation ICES002 Issue 2.Vehicles being produced for European Unioncountries must meet EEC 72/245/EEC asamended by 95/54/EC dated 10/31/95. OtherEuropean countries must meet broadband RFEmission regulation ECE Regulation 10.022002-02Major vehicle metallic components need to beelectrically bonded together to provide for RFshielding and maintain good electrical groundintegrity. The DC resistance between theengine, hood, doors, and other major vehiclebody panels to body ground should not exceed250 milliohms (ref: DS-108)Body panels around the engine compartment orignition system must not be changed withoutverifying that the vehicle still meets theappropriate Canadian and/or European RFEmissions regulations. If vehicle body panelsaround the engine compartment are replaced bynonmetallic panels, they may need toincorporate metallic material to reduce theamount of RF that will be emitted from thevehicle so it will meet the appropriate standardsCare must be exercised in installing two-waycommunication radio transmitters in vehicles sothey do not cause degradation ofpreference/operation of the vehicle. Two-wayradio installation guidance is provided byChrysler Group LLC Technical Service BulletinTSB 08-023-99Electrical circuits added to the vehicle shall bedesigned with separate power leads protectedby appropriately sized wiring, fuse links, circuitbreakers and/or fusesConductive fuel tank filler necks and trapdoorassemblies must be connected to the vehicleground system with less than 100ohmsresistance to insure discharge before fueling. Ifthis path is modified, compliance to thisrequirement must be maintained and verified.Non-conductive fuel tank filler necks andtrapdoor assemblies must be connected to thevehicle ground system with less than 1,000,000ohms (1Mohm) resistance (using a 500Vsource) to insure discharge before fueling. Ifthis path is modified, compliance to thisrequirement must be maintained and verified.8. Current Capacity of WireThe following table shows the maximum ratedcurrent capacity of plastic insulated copper wire.Temperature affects current capacity of a given wireand the type of insulation. This table showsgenerally accepted values.Wire Gauge Maximum Current Capacity10121416182045 Amperes30 Amperes25 Amperes20 Amperes15 Amperes10 AmperesExtending a circuit by splicing — use a wiregauge equal to or greater than the wire in thecircuit to be lengthened after the spliceAdding devices from a base vehicle circuit —use the above table to determine the wire gaugefor th