Wiring Code Identification Information

WIRE CODE IDENTIFICATION Wire Color Code Chart

Standard Standard
Each wire shown in the diagrams contains a code (Fig. Color Tracer Color Tracer
1) which identifies the main circuit, part of the main Code Color Color Code Color Color
circuit, gauge of wire, and color. The color is shown as a BL BLUE WT OR ORANGE BK
two-letter code, which can be identified by referring to BK BLACK WT PK PINK BK or WT
the Wire Color Code Chart (Fig. 2). BR BROWN WT RD RED WT
DB DARK WT TN TAN WT
A 2 18 LB/YL
BLUE
DG DARK WT VT VIOLET WT
COLOR OF WIRE
GREEN
(Light Blue with Yellow Tracer)
GY GRAY BK WT WHITE BK
GAUGE OF WIRE LB LIGHT BK YL YELLOW BK
(18 Gauge) BLUE
LG LIGHT BK * WITH TRACER
PART OF MAIN CIRCUIT
GREEN
(Varies Depending on Equipment)
Figure 2 – Wire Color Code Chart
MAIN CIRCUIT IDENTIFICATION
CIRCUIT FUNCTION
Figure 1 – Wire Color Code Identification A - Battery Feed
B - Brake Controls
CIRCUIT IDENTIFICATION C - Climate Controls, EBL, Heated Mirror,
Windshield and Seat
All circuits in the diagrams use an alphanumeric code to D - Diagnostic Circuits, Communications,
identify the wire and its function (Fig. 3). To identify Antennas
which circuit code applies to a system; refer to the E - Dimming Illumination Circuits
Circuit Identification Code Chart. This chart shows the
F - Switched Ignition Feeds
main circuits only and does not show the secondary
G - Gauges, Displays, Monitoring, Body
codes that may apply to some models.
Sensors, Resistive Mux'd Switches
H - Open
I - Not Used
J - Open
K - Power Train Control Module
L - Exterior Lighting, Headlamp Leveling
M - Interior and Courtesy Lighting
N - Fuel Pump, Radiator Fan
O - Not Used
P - Power Option, Seats, Recliner, Lumbar,
Mirrors, Door Locks
Q - Power Options, Windows, Vents,
Sunroof, Tops, Trunk, Liftgate, Sliding
Doors
R - Restraint Systems
S - Suspension/Steering
T - Starter, Transmission, Transaxle,
Transfer Case
U - Washer, Wiper
V - Speed Control
W - Open
X - Sound Systems, Horn
Y - Open
Z - Grounds

Figure 3 – Circuit Identification

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 Wiring Code Identification Information
WIRING GUIDELINES FOR 2003
DODGE TRUCK AFTERMARKET/BODY 3. Harness Routing
A. Connectors should be readily accessible, where
BUILDERS feasible, to permit ease of installation and
serviceability. Accessibility to connectors is good
1. Introduction design practice. Examples include fuse blocks,
These guidelines are intended as an aid in wiring relays, modules, electrical components, junction
design. It is not an all-inclusive list or a substitute for blocks and ground blocks.
common sense. It is to be used as a supplement to B. Provide sufficient wire lengths to permit wire
existing good design practices and standards. harness serviceability. However, excess lengths
Additional information is in the Referenced should be kept to a minimum to prevent:
Publications section. Performing a Failure Mode and trapping and pinching during assembly; poor fit
Effects Analysis (FMEA) on each completed wiring and finish; and buzzes, squeaks and rattles.
design is a good practice to confirm the integrity of C. Circuits attached to parts or structures that have
the design. This document will be revised dynamic (moving) properties must consider
periodically, based on advances in technology and adequate “slack” and strain relief to prevent
operating practices. damage. A few examples are the engine block,
door and liftgate harness, shocks, struts and tilt
2. Electrical System steering columns. Endurance testing must be
A. Modification to the existing vehicle wiring should performed to ensure that designs meet life test
be done only with extreme caution. The effects criteria.
on the completed vehicle electrical system must D. Wiring assemblies must not be within one inch
be considered. Any additional circuitry should be (25 mm) of any hot surface or moving
evaluated to ensure that adequate circuit mechanism. Movement due to engine rocking
protection provisions will be in place and that will require a greater distance than one inch.
feedback loops will not be created. Engineering discretion must be used to
B. The following affects the selection of wire gauge determine if heat-protection materials are
for a particular application: needed to protect the wiring assembly. The use
• Wire size selection is affected by circuit of abrasion-protection materials (convoluted
protection requirements, power distribution tubing, fiberglass loom, asphalt loom, friction
requirements and mechanical handling tape, etc.) can be used as an added measure in
requirements the protection of the harness, but should not be
• Wire size selection is affected by long-range relied upon alone to prevent damage to the
heat aging characteristics resulting from wiring assembly. Some examples of hot
current loading surfaces and moving mechanisms are:
C. Circuit Protection
When adding loads to a base vehicle’s protected • Plumbing • Exhaust manifold
circuit; be sure that the total electrical load
through the base vehicle fuse or circuit breaker • Pulleys • Oil and fuel lines
is less than the derated device rating. The total • Catalytic converter • Accelerator, brake and
electrical load is the sum of the base vehicle clutch pedals
circuit current requirement added to the add-on • Parking brake • Auxiliary oil cooler line
component(s) current requirements. Confirm the Mechanisms
load with an ammeter. • Floor pan • Seat track and recliner
• DO NOT increase the rating of a factory- mechanisms
installed fuse or circuit • Choke housing and • Window, door and
• Any added circuitry must be protected by crossover door lock mechanisms
either the base vehicle fuse or circuit • Hinges
breaker or by a similar device installed by
• Belts
the body builder. In-line fuses should be
readily accessible
• All battery circuits, except the starter motor, Wire routings should be away from areas where
must have circuit protection temperatures exceed 180°F and should have a minimum
• Protections devices for high current loads of six inches (152 mm) clearance from exhaust system
such as a winch or snowplow motor must be components. If this is not possible, use heat shields and
connected directly to the vehicle battery and high-temperature insulation to maintain safe operating
not to the vehicle power distribution center temperatures for the wiring.
or other downstream components.
Circuit protection devices are designed to protect the E. If the harness routes over a sharp edge, sheet
wiring. They may not necessarily protect other metal or plastic, the harness must be protected
components in the event of a short circuit. by one or more of the following:

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• Rolled sheet metal edge 4. Grounding
• Convolute, scroll, loom or braided sleeving The following guideline outlines the general
• Edge protector (pinch welt) requirements for electrical system grounding to
• Wiring clip minimize ground loops, unwanted feedback,
A. Route wires on the surface of sheet metal to coupling of transients and electro-magnetic
avoid “fishing” operations and to avoid sharp interference to ensure proper electrical and
edges. electronic system performance.
B. Where wiring congestion or the possibility of A. General Requirements
pinching wires exists, the harness design should 1) The battery negative terminal shall connect
be a rigid shape and form. This will aid to the body and the engine with the shortest
installation and facilitate fit and finish objectives. length cables as practical.
A good alternative design technique is the use of 2) Each of the following types of ground circuits
a stamped sheet metal or a molded plastic should connect to the body sheet metal as
trough. close as possible to the electrical/electronic
C. Eliminate buzzes, squeaks and rattles (BSR) by device or combination of devices:
the use of: • Electronic devices employing a single
• Cloth tape power ground for electronics and, where
• Direct connections to devices applicable, internal subminiature lamps
• Locating and/or clipping all connectors • Inductive electrical devices and
whether used or unused subsystems, such as motors, solenoids
• Locating and/or clipping wire harnesses and relays (with noisy grounds) unless
• Foam wrap, foam tubes, foam doughnuts on fully internally sup-pressed
clips • The exception to this is high current loads
D. Route wiring away from areas where fasteners such as a winch or snowplow motor which
are driven. should be grounded directly to the vehicle
E. When a wire assembly is routed from the inside battery to prevent overstressing the rest of
to the outside of the vehicle, the transition point the vehicle ground system
must be sealed by: • Lighting grounds — particularly where
• A rubber grommet loop-type coupling into devices with
• A rubber tube and grommet (highly internal lamps would be possible
recommended for doors and liftgates) B. Detailed Requirements
1) The battery to engine ground shall be
• A sealed bulkhead-type connection
sufficient to keep the total external cranking
F. Wires on the outside of the vehicle or in a wet
circuit resistance between the battery and
environment should:
starter terminals, including junctions, at two
• Be routed lower than sealing devices to
milliohms maximum. The battery ground
avoid water intrusion through the wire
from its terminal to body sheet metal shall
harness
not exceed two milliohms at 80°F.
• Have a drip loop in the wiring harness to 2) Lighting grounds should not interconnect
prevent water intrusion into the connector(s) within wiring assemblies to electronic device
G. High current circuits and pulse width modulation and sub system grounds except at the
circuits should not be routed near the radio and attachment of the given wiring assembly to
other sensitive electronic devices. If rerouting is sheet metal.
unavoidable grounded shielding or some other 3) Instrument panel subsystem grounds must
means of isolation may be required. If possible, have a dedicated ground for the A/C blower
high current circuits should be routed at least six circuit. Door and seat actuator grounds are
inches away from the radio. not to pass through the main instrument
H. Wire harnesses should not be routed closer than panel wiring assembly.
one inch (25 mm) from high voltage devices C. Grounding Connections
such as the distributor coil or spark plug wires. 1) Steel ground screws shall have suitable
I. When underbody routing is unavoidable, provide cadmium, tin or zinc dichromate coating.
a special wire jacket or covering, such as 2) Metal surfaces for grounding shall be free of
polyurethane, fiberglass sleeve or loom, for paint and other insulating coatings or will
protection. acquire this condition by using metal cutting
J. Wire harnesses included with modular fasteners.
assemblies, such as headliners and door trim 3) Grounds to vehicle sheet metal shall employ
panels, must be routed and secured by utilizing one of the following fastening methods:
clips, straps or adhesives to ensure proper
• Weld stud and nut/washer assembly using
retention and to prevent buzzes, squeaks or
a serrated eyelet
rattles.
• Weld or pierce nut and paint cutting screw

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 Wiring Code Identification Information
• Externally serrated eyelet with pierced 4) Unused wiring hole provisions that may
conical hole/depression and double allow moisture, fumes or noise to enter the
threaded paint cutting screw that ensures passenger compartment must be plugged or
high strip to drive torque ratio sealed.
1) The total resistance between ground 5) Screws and clips located in a wet region
terminations and ground surfaces should not must have a sealing provision.
exceed 0.05 milliohms 6) Relays or circuit breakers should not be
2) No more than three wiring eyelet terminals located in moisture splash area without
shall be stacked together under a ground adequate protection.
screw or on a stud 7) Wire harness routing from a wet to a dry
3) Pop-riveted connections are not suitable for environment must have drip loop
grounding wiring terminals construction. Locate the drip loop lower than
the harness grommet; allow water runoff.
5. Sealing and Corrosion Protection
6. Harness Construction
As a first choice, all connectors should be kept away 1) All splices in moisture or splash areas should be
from any splash or wet areas. When connectors are sealed by molding or by heat shrink tubing. This
in a splash or wet area, added protection should be is recommended for dry areas to increase
used to meet endurance requirements. Some reliability.
examples of protection are sealed connectors, grease 2) The following are general guidelines for splices:
in connectors and barriers built to insulate the • Avoid imbalance of circuit size on each side
connector. Orient connectors “horizontally” to help of a splice.
minimize water penetration; avoid “vertical” connector
orientations. • Splices should be staggered by a minimum
of 50 mm center-to-center to avoid electrical
tracking and to minimize harness bulk.
• Greased and/or pre-greased terminals are
not to be used on O2 sensor circuits. • Shielded cable should not be spliced.
• Grease in the connector or the terminals migrate • When used in instrument panel wiring
through the wire strands and contaminate the applications, PVC tape may squeak when in
sensor resulting in false readings contact with some panel plastics. Use foam
or cloth tape harness wrap to prevent
• Greased and/or pre-greased terminals are potential BSR conditions.
not to be used with hypalon insulation. 3) The following are general guidelines for harness
• It causes the insulation to swell and to components:
deteriorate particularly in the presence of heat • Use insulators having secondary terminal
• Greased and/or pregreased terminals are latching (example: wedge-lock) and connector-to
connector latching (example: locking type)
• not to be used on relays. Grease in the
whenever possible. Connector-to- device, such
connector or on the terminals migrates through
as switches, relays, motors, radios, speakers
openings in the relay and contaminates the
and modules, should have a positive latching
internal contacts of the relay resulting in
design
component failure
• Silicon grease is not to be used at all. It can
• Wire color matching and insulator color
matching is NOT a reliable means of insulator
migrate through wire strands and contaminate
polarization. Indexing mating connections and/or
relay or switch contacts. It can also travel to the
keeping similar colored insulators sufficiently
sheet metal destroying the adhesion of vehicle
separated to prevent misassemble are
body paint
recommended practices
1) All metal sockets routed outside the vehicle
must have watertight boots and grease or • Connectors that provide the best terminal
other means of corrosion protection. protection against inadvertent shorting in a
2) All lamp sockets in a wet area must be nonmated connector should be on the vehicle
evaluated for sealing and corrosion side of the wiring assembly. This is usually the
protection. female terminal
3) All grommets used in areas where moisture, • All 10 AWG wires or larger must be soldered to
water splash or exhaust fumes can enter the terminals
into the passenger compartment must seal.
Use applied grommets, sealed tube-and- • Do not use spin-on wire nuts
grommet assemblies, sealed bulkhead Make sure that an adequate mechanical joint exists
connections, or molded grommets. Molded before soldering. Use only rosin core solder
non-rubber grommets are less desirable.

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 Wiring Code Identification Information
• and duplex heat sink for wiring — never use this path is modified, compliance to this
requirement must be maintained and verified.
acid core solder
• Non-conductive fuel tank filler necks and
7. Electromagnetic Capability (EMC) trapdoor assemblies must be connected to the
• Any electrical/electronic (E/E) device, module, vehicle ground system with less than 1,000,000
ohms (1Mohm) resistance (using a 500V
subsystem or system used on DaimlerChrysler
vehicles shall meet DaimlerChrysler source) to insure discharge before fueling. If
Performance Standards PF-10614 entitled this path is modified, compliance to this
Electromagnetic Compatibility Specifications for requirement must be maintained and verified.
Electrical and Electronic Modules and Motors
and PF-10615 Electrical Specifications for 8. Current Capacity of Wire
Electrical and Electronic Modules and Motors. The following table shows the maximum rated
The relevant tests are performed in accordance current capacity of plastic insulated copper wire.
with DCA LP-388-C, and DaimlerChrysler Temperature affects current capacity of a given wire
Corporation determines pass-fail limits and the type of insulation. This table shows
generally accepted values.
• Vehicles being produced in or for the Canadian
market must meet Canadian regulation ICES Wire Gauge Maximum Current Capacity
002 Issue 2.
10 45 Amperes
• Vehicles being produced for European Union 12 30 Amperes
countries must meet EEC 72/245/EEC as
14 25 Amperes
amended by 95/54/EC dated 10/31/95. Other
European countries must meet broadband RF 16 20 Amperes
Emission regulation ECE Regulation 10.02 18 15 Amperes
2002-02 20 10 Amperes
• Major vehicle metallic components need to be
electrically bonded together to provide for RF • Extending a circuit by splicing — use a wire
shielding and maintain good electrical ground gauge equal to or greater than the wire in the
integrity. The DC resistance between the circuit to be lengthened after the splice
engine, hood, doors, and other major vehicle
body panels to body ground should not exceed
• Adding devices from a base vehicle circuit —
use the above table to determine the wire gauge
250 milliohms (ref: DS-108)
for the required current capacity
• Body panels around the engine compartment or
• Added wiring should have Hypalon, cross-linked
ignition system must not be changed without
polyethylene insulation or a similar type of
verifying that the vehicle still meets the
thermosetting insulation
appropriate Canadian and/or European RF
Emissions regulations. If vehicle body panels
9. Referenced Publications
around the engine compartment are replaced by
The following documents are recommended for
nonmetallic panels, they may need to
further information.
incorporate metallic material to reduce the
amount of RF that will be emitted from the
ANSI Publication. American National
vehicle so it will meet the appropriate standards
Standards Institute, 11 West 42nd Street, 13th
• Care must be exercised in installing two-way Floor, New York, NY 10036
communication radio transmitters in vehicles so
they do not cause degradation of ANSI/RVIA 12V Low Voltage Systems in
preference/operation of the vehicle. Two-way Conversion Vehicles
radio installation guidance is provided by ANSI A119.2 – 1995, Standard for
DaimlerChrysler Technical Service Bulletin TSB Recreational Vehicles
08-023-99
• Electrical circuits added to the vehicle shall be SAE Publication. Society of Automotive
designed with separate power leads protected Engineers, Inc., 400 Commonwealth Drive,
by appropriately sized wiring, fuse links, circuit Warrendale, PA 15096
breakers and/or fuses
SAE J554 – 1987, Standard for Electric Fuses
• Conductive fuel tank filler necks and trapdoor (Cartridge Type)
assemblies must be connected to the vehicle
ground system with less than 100ohms SAE J551-4 – 1994, Test Limits and Methods of
resistance to insure discharge before fueling. If Measurement of Radio Disturbance
Characteristics of Vehicles and Devices,

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SAE J561 – 1993, Electrical Terminals – Eyelet

and Spade Types

SAE J2223/3 – 1994, Electrical Terminals –

Blade Type

SAE J928 – 1989, Electrical Terminals – Pin and

Receptacle Type

SAE J1284 – 1988, Electrical Terminals –

Standard for Blade-Type Electric Fuses

SAE J2077 – 1990, Miniature Blade-Type

Electric Fuses

SAE J1888 – 1990, High Current Time Lag

Electric Fuses
SAE J1292 – 1981, Automobile, Truck, Truck
Tractor, Trailer, and Motor Coach Wiring

SAE J562 – 1986, Nonmetallic Loom

SAE J573 – 1989, Miniature Lamp Bulbs

SAE FMEA plus For Windows, Failure Modes

and Effects Analysis Software

DaimlerChrysler Corporation

PF 10614 Performance Standard –

Electromagnetic Compatibility Specification for
Electrical and Electronic Modules and Motors

PF 10615 Performance Standard – Electrical

Specifications for Electrical and Electronic
Modules and Motors

Technical Service Bulletin 08-023-99:

Installation of Radio Transmitting Equipment

Lab Procedure – LP 388-C-xy:

Electrical and EMC

DS-108 – Grounding Guidelines

Additional Referenced Documents

Industry Canada ICES-002 Issue 2

European Union 72/245/EEC as amended by
95/54/EC dated 10/31/95
ECE Regulation 10.02 2002 - 02

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