open hood DODGE TRUCK 1993 Service User Guide

•

BODY
COMPONENTS
23 - 1
CONTENTS

page
page

CAB/BODY
INTERIOR COMPONENTS
35
FIXED
GLASS
. 29
DOORS
21
PAINT
CODE
CHART
54

EXTERIOR
COMPONENTS
1
REFINISHING
PROCEDURES
54
EXTERIOR COMPONENTS
INDEX

page

Battery
Tray
7

Blower Motor Housing
Insulation
Panel—Diesel
Engine
Only
7

Body
Mouldings, Nameplates
and
Decals .......
9

Cab
. 14

Cab/Body
and
Cargo
Box
Stripes
11

Cargo
Box
19
Cowl
Grille
7
Front
Fenders
8
Fuel
Filler
Door
and
Nozzle/Tubes
12

Grille
and
Grille
Extension Panel
1

Grille
Extension Panel Support Bracket
(With
Diesel Engine Only)
3
page

Grille
Opening Panel (GOP)
and
Radiator Support Panel
3

Hatchgate
and
Components
16

Hood
5

Hood
Inside Release Cable
5

Hood
Latch
4

Labels/Decals/Plates
1

Outside Mirrors
13
Roof
Vent—Ramcharger
. 20

Splash
Shields—Front Fender
9

Sport
Bar
18

Tailgate
14

LABELS/DECALS/PLATES
GENERAL
INFORMATION The labels, decals
and
plates that
are
attached
to

Ram Van
and
Wagon vehicles contain safety
or
oth­ erwise essential information (Figs.
1, 2, 3 and 4).

INSTALLATION
Follow the instructions included with each replace­
ment label, decal
or
plate
to
affix
it to a
panel
or
component.

GRILLE
AND GRILLE EXTENSION PANEL
GRILLE
REMOVAL (1) Remove screws that attach the headlamp bezels
(Fig.
5) to the
grille.

(2)
Separate
the
bezels from
the
headlamps
(Fig.

5).
(3) Raise
and
support
the
hood.
(4) Remove the grille screws from the radiator sup­
port panel
and the
extension panel (Fig.
6).
(5) Remove
the
grille from the front
of
the vehicle.
EMISSION
CONTROL
DRIVE
BELT

INFORMATION
AND
VACUUM
ROUTING
LABEL
HOSE
ROUTING
LABEL
(DIESEL

Fig.
1 Underhood Labels, Decals & Plates
BODY
COMPONENTS

•
BODY
COMPONENTS
23 - 3
GRILLE
EXTENSION
PANEL
INSTALLATION

(1) Position the grille extension panel at the fender
panels and the support bracket. (2) Install the panel screws. Tighten the screws to
23 N*m (200 in. lbs.) torque.
(3) Install the grille. If necessary, refer to the in­
stallation procedure. (4) Remove the support and close the hood.
U-NUT
RADIATOR GRILLE

Fig. 7 Grille Extension Panel
GRILLE EXTENSION PANEL SUPPORT BRACKET

(WITH
DIESEL ENGINE ONLY)

REMOWAL
(1) Remove the grille.
(2) Remove the extension panel.
(3) Remove support bracket-to-grille opening panel
screw. (4) Remove the support bracket-to-radiator support
panel screw (Fig. 8). (5) Remove the support bracket from the vehicle.

INSTALLATION
(1) Position the support bracket at the grille open­
ing panel (GOP) and radiator support panel. (2) Install the support bracket-to-radiator support
panel screw. Tighten the screw to 11 N*m (95 in. lbs.) torque.
(3) Install the support bracket-to-grille opening
panel (GOP) screw. Tighten the screw to 23 N-m (200 in. lbs.) torque.
(4) Install the grille extension panel.
(5) Install the grille.
SCREW
U-NUT
RADIATOR

Fig. 8 Grille Extension Panel Support Bracket—Diesel Engine only
GRILLE OPENING PANEL
(GOP) AND
RADIATOR

SUPPORT
PANEL

REMOVAL
(1) Raise and support the hood. Remove the bat­
tery. (2) Remove the grille.
(3) Remove the extension panel.
(4) If equipped, remove the extension panel sup­
port bracket.
(5) Remove the headlamps from the headlamp re­
ceptacles in the GOP.
(6) Drain the engine coolant from the radiator in a
clean container for reuse. Remove the radiator from
the GOP. If necessary, refer to Group 7—Cooling System for the procedure.
(7) Remove the battery and tray from the GOP.
(8) Remove the horns from the GOP.
(9) Remove the screws, hood latch and the rein­
forcement plate from the radiator support panel. (10) Detach the latch release cable from the clip on
the radiator support panel.
(11) Remove the screws that attach the splash
shields to the GOP (Fig. 9). (12) Remove the cab/body front holddowns from
the front crossmember (Fig. 10). (13) Remove the screws that attach the fenders to
the GOP.
(14) Remove the screws that attach the fenders to
the radiator support panel.
(15) Remove the screws that attach the splash
shield to the right fender inner support panel.
(16) Repeat step (15) for the left fender panel.
(17) Move both fender panels outward at the front.
Remove the GOP and the radiator support panel
from the vehicle.

23
- 4
BODY
COMPONENTS

• INSTALLATION
(1) If necessary, install U-nuts at the GOP lower
flange. (2) Move both fender panels outward at the front.
Position the GOP on the frame rails (Fig. 10).
(3) Move both fender panels inward at the front.
Install the screws to attach the fender splash shields
to the fender inner support panels. Tighten the
screws to 11 N#m (95 in. lbs.) torque.
(4) Install the cab/body front holddown bolts at the
GOP to the front crossmember. Tighten the nuts to
68 Nnn (50 ft. lbs.) torque.
(5) Install the screws at the fenders to the GOP
and radiator support panel. Tighten the screws to 11
N»m (95 in. lbs.) torque. Tighten the radiator support
panel screws to 23 Nnn (200 in. lbs.) torque.
(6) Align the holes and install the splash shield
screws. Tighten the screws to 11 N»m (95 in. lbs.)
torque.
(7) Install the horns on the GOP.
(8) Attach the battery tray to the GOP. If neces­
sary, refer to the installation procedure. Tighten the
screws to 11 Nnn (95 in. lbs.) torque.
(9) Install the radiator on the GOP. Refill the en­
gine with coolant. If necessary, refer to Group 7—Cooling System for the procedures. (10) Attach the hood release cable to the clip on
the radiator support panel.
(11) Adjust the hood latch cable.
(12) Position the shield and the hood latch on the
radiator support panel. Install the screws. Tighten
the screws to 23 Nnn (200 in. lbs.) torque.
(13) Test the hood latch and the release cable for
proper operation.
(14) Install the headlamps in the headlamp recep­

tacles.

(15) Install the extension panel support bracket (if
equipped). Install the grille extension panel and the
grille.
(16) Install the battery and the holddown bracket.
Tighten the holddown rod nuts to 2 Nnn (20 in. lbs.) torque.
(17) Remove the support and close the hood.
(18) If necessary, adjust the headlamp beams.

HOOD
LATCH

REMOVAL
(1) Open and support the hood.
(2) Remove the hood latch and screws from the ra­
diator support panel (Fig. 11). (3) Disconnect release cable from the hood latch.
INSTALLATION If a replacement hood latch is being installed,
lubricate it thoroughly.
SCREW

U-NUT
BUMPER INNER FENDER
SUPPORT PANEL
PANEL
SPLASH

SHIELD

SCREW

U-NUT
REINFORCEMENT PANEL
(4WD
ONLY)
GRILLE
PANEL
J9123-567

Fig.
9
Grille
Opening
Panel
(GOP) & Radiator
Support
Panel

BOLT

(RAMCHARGER)
WASHER
GRILLE OPENING AND RADIATOR SUPPORT PANEL INSULATOR

BOLT

WITH
INSULATOR
(MODELS
30
AND
60)

FRAME
RAIL
WASHER NUT
SPACER

WASHER
(4
FOR ADI)
INSULATOR
^

BOLT
RETAINER
.
FRAME

— "
"
CROSSMEMBER
J9113-19

Fig.
10
Cab/Body
Front
Holddowns

(1) Position the hood latch on the radiator support
panel. Install the screws. Tighten the screws to 23 Nnn (200 in. lbs.) torque. (2) Connect latch release cable to the hood latch. (3) Adjust the hood latch cable.
(4) Test the hood latch and release cable for proper
operation.

•

BODY
COMPONENTS
23 - 5
(5)
If
necessary, align
the
hood,
the
latch,
and the

striker. Refer
to
Fore/Aft
And
Latch/Striker Adjust­
ment.
BOLT

CABLE

SHIELD

RADIATOR

GRILL SUPPORT

RB1346

Fig.
11
Hood
Latch
&
Release
Cable

HOOD
INSIDE
RELEASE
CABLE
REMOWAL
(1) Open
and
support
the
hood.
(2) Disconnect release cable from
the
hood latch.
(3) Detach
the
release cable from
the
clip
in the

engine compartment
(Fig. 12).

(4)
Separate
the
release cable grommet from
the

dash panel hole.
(5) From inside
the
vehicle, remove
the
screws.
Re­

move
the
release cable handle bracket from
the
bot­
tom
of the
instrument panel.
(6) Route
the
hood release cable through
the
dash
panel hole. Remove
it via the
inside
of the
vehicle.
INSTALLATION (1) Route
the
hood release cable through
the
hole
in
the
dash panel.
(2) Position
the
release cable handle
at the
bottom
of
the
instrument panel. Install
the
screws. Tighten
the screws
to 11 Nem (95 in. lbs.)
torque.
(3) Install
the
cable grommet
in the
dash panel
hole
(Fig. 12).

(4)
Attach
the
cable
to the
rear clip
in the
engine
compartment. (5) Route
the
cable under
the
radiator support
panel flange. Attach
it to the
clip
and
then connect
it

to
the
hood latch.
(6) Adjust
the
latch cable.
(7) Test
the
hood latch release cable
for
proper
op­

eration.
RELEASE

CABLE

HANDLE

BRACKET

HOOD
LATCH
RADIATOR
BAFFLE PANEL
J9123-376

Fig.
12
Release
Cable Removal/Installation
LOCATOR
CLIP

HOOD
LATCH

RELEASE
CABLE

BRACKET
INSTRUMENT

PANEL
LOWER
REINFORCEMENT
BRACKET

RWAL BRAKE
TEST CONNECTOR
J9123-360

Fig.
13
Release
Cable Handle Bracket
&
RWAL

Brake
Test
Connector
HOOD

POSITION ADJUSTMENT The hood hinge bolt holes
are
oversize
and
elon­
gated
for
ease
of
adjustment
(Fig. 15).
Loosen
the

hinge bolts
at the
fender
for
up/down adjustment.
Loosen
the
hinge bolts
at the
hood
for
front/back
ad­

justment.
REMOVAL (1) Raise
and
support
the
hood
at the
full-open
po­

sition. (2)
If
equipped, disconnect
the
underhood lamp
wire connector
(Fig. 16).

(3) With
the aid of an
assistant, remove
the
hinge
arm-to-hood bolts. Remove
the
hood from vehicle.

23
- 6
BODY
COMPONENTS

•

INSTRUMENT
PANEL

COWL

PANEL

REGULATOR
BRACKET
J9123-437

Fig.
14 Release Cable Handle Bracket &
Diesel
Engine
Speed
Control Regulator Bracket (4) If a replacement hood is being installed, trans­
fer the underhood lamp and the insulator panel (Fig.
17).
(5) Test the hood hinges for correct operation.
(6) Lubricate the hood hinges with engine oil.

INSTALLATION
(1) With the aid of an assistant, position the hood
on the vehicle. Align the hood bolt holes with the
hinge arm holes. Install and finger-tighten the bolts. (2) Align the hood, the latch, and the striker.

HINGE
REPLACEMENT

REMOVAL
If both hinges are being replaced, remove the
hood and both hinges as a unit. If only one
hinge is being replaced, use the following proce­ dure. (1) Raise and support the hood at the full-open po­
sition. (2) Mark the position of the hinge bolts. Loosen
the bolts (Fig. 15). (3) Support the hood at the side being removed.
Remove the bolts and hinge from the hood and
fender panel.

INSTALLATION
(1) Position the replacement hinge against the
fender panel. Install and finger-tighten the bolts. (2) Align the hood bolt holes with the marks.
(3) Tighten the hinge bolts to 23 N-m (200 in. lbs.)
torque.
LATCH STRIKER
LATCH SAFETY SUPPORT HOOD

STRIKER
LATCH PANEL HINGE
J9123-375

Fig.
16
Underhood
Lamp
INSTALLATION

(1) Position the striker on the hood.
(2) Install and tighten the screws.
HOOD SUPPORT ROD

REMOVAL
(1) Raise and support the hood.
(2) Drill out the support rod rivet from the radia­
tor support panel. (3) Remove the support rod from the radiator sup­
port panel.

INSTALLATION
(1) Position the support rod on the radiator support
panel. (2) Install the rivet to attach the rod to the panel.

REMOVAL
(1) Raise and support the hood.
(2) Remove the screws and the latch striker from
the hood.

24 - 10
HEATING
AND AIR
CONDITIONING

•
(3) Add 50 ml (1.7 oz.) of clean refrigerant oil
through the suction port.
(4) Install compressor.
(5) Install the suction and discharge lines to the
compressor. Use new gaskets to prevent leakage.
Tighten the line nuts to 23 N*m (200 in. lbs.) torque.

(6)
Evacuate and charge system.

OVER-ALL
PERFORMANCE
TEST
Humidity has an important bearing on the temper­
ature of the air delivered to the vehicle's interior.
This is true of all air conditioning systems It is im­
portant to understand the effect humidity has on the
performance of the system. When humidity is high,
the evaporator has to perform a double duty. It must lower the air temperature and the temperature of the
moisture carried in the air. Condensing the moisture
in the air transfers a great deal of heat energy into
the evaporator fins and tubing. This reduces the amount of heat the evaporator can absorb from the
air.
Evaporator capacity used to reduce the amount of
moisture in the air is not wasted. Wringing some of
the moisture out of the air entering the vehicle adds
to the comfort of the passengers. However, an owner may expect too much from their air conditioning sys­
tem on humid days. A performance test is the best
way to determine whether or not the system is per­
forming up to standard. This test also provides valu­ able clues to the possible cause of trouble.
To perform the test the air temperature in the test
room must be 21°C (70°F) minimum. (1) Connect a tachometer and manifold gauge set
(Fig. 5).
(2) Set A/C controls to MAX A/C, temperature le­
ver on full cool and blower on HIGH. (3) Start engine and adjust rpm to 1,000 RPM with
A/C clutch engaged.
(4) Engine should be warmed up with doors, win­
dows and hood closed.
(5)
Insert a thermometer in the left center A/C
outlet and operate the engine for 5 minutes. The A/C
clutch may cycle depending on ambient conditions.

(6)
After 5 minutes note the discharge air temper­
ature. (If the clutch cycles take the reading before
the clutch disengages).
(7) Open the hood and disconnect the gray vacuum
line going to the heater water control valve. Observe
the valve arm for movement as the line is discon­ nected. If it does not move refer to the heater valve
controls sections of this group. Plug the vacuum line
to prevent leakage.
(8) Operate the A/C for 2 more minutes and take
the discharge air temperature reading again. If the
temperature increased by more than 2°C (5°F), check
LEFT
SUCTION
RIGHT

J9124-109

Fig.
5 Manifold
Gauge
Tester
Connections

the blend air door cable for correct operation. If tem­
perature does not increase more than 2°C
(5°F),
com­
pare discharge air temperature, suction and discharge pressures with Performance Temperature Chart. Connect the gray vacuum line.
(9) If the discharge air temperature fails to meet
the specifications in the Performance Temperature Chart, refer to the diagnostic analysis charts for fur­
ther test information.

24-12
HEATING
AND AIR
CONDITIONING

PERFORMANCE TEMPERATURE CHART

Garage
Ambient
Temperature
21
°C

(70°F) 26.5°C
(80°F) 32°C
(90°F) 3/.5°'J
(100T) 43°C
(110°F)

Discharge
Air Temperature
3-10°C
(38-50°F) 6-12°C
(42-54'F) 8-14°C
(46-58°F) 10-17°C
(50-62°F) 12-19°C
(54-66°F)

Compressor
Discharge Pressure
1344 a
1620 a
1861 kPag 2103 a 1379kPcg
2344 a

Compressor
Discharge Pressure

120 •
195 PS'9 160 .
235 PS'9 200 .
270 PS'9 240 .
305 PS'9 280 .
340 PS'9

Evaporator
Suction Pressure
124 kPag
207 a 138 kPag
241 J 269 kPag III kP°9
296 179 ,D
324 kPag

Evaporator
Suction Pressure

18 .
30 PS'9 20 .
35 pS'g 22
39 pS,g
25 .
43 pS'g 26 .
47 pS'9
J9124-97 pressure must drop to below -50 kPag (15 inch of vacu­

um).
If the condition is not met the H-valve is stuck
open and should be replaced. Remove Liquid C02 and
watch evaporator suction pressure; it should increase to a minimum of 262 kPag (38 psig) and then stabilize to a
pressure of 172-240 kPag (25-35 psig). Any H-valve
which does not produce this response is stuck open and should be replaced.
(4) Connect A/C water valve vacuum hose (gray)
and set temperature control in cool position.
(5) Set engine speed at 1,000 RPM and blower on

HI.
The evaporator suction pressure should be in the
range of 138-207 kPag (20-30 psig). If compressor dis­ charge is higher than 1 656 kPag (240 psig), check
for restricted discharge line, radiator overheating, air in system or faulty viscous fan drive. If discharge
pressure is less than 966 kPag (140 psig), check com­
pressor head gaskets and discharge reeds.
(6) Connect the electrical wires to the electronic
temperature cycling clutch switch.
VACUUM CONTROL SYSTEM ADJUSTMENTS
AND TESTS To keep the vacuum harness in place, common vi­
nyl tape (sometimes called plastic tape of electri­
cian's tape) cannot be used. It will cause the tube to
deteriorate directly under the tape, when high under­
hood temperatures are involved. A compatible nylon type of tape such as MS CH69 (#281) or an equiva­lent must be used.
The test of the push button switch operation deter­
mines whether or not the vacuum and electrical cir­ cuits are properly connected and the controls are
functioning properly. However, it is possible that this system operating perfectly at engine idle during high
manifold vacuum, may not function properly at high engine speeds. Before starting this test, stop engine and make certain the vacuum source hose at engine
intake manifold is tight on its connector.
EXPANSION (H) VALVE TEST
Test must be made at ambient temperature of
21°C-29°C (70°F-85°F).
After performing all previously mentioned tests,
conduct the H-valve test as follows:
(1) Operate the engine at 1,000 RPM with the win­
dows closed. Set air conditioning controls for MAX
A/C,
high blower, temperature control lever in full
reheat position and cycling clutch switch electrically
bypassed. Disconnect and plug the water valve vac­ uum hose in the engine compartment. (2) Operate the system for at least 5 minutes in or­
der to obtain partial stabilization and sufficient re­
heat to load the system. Pressure at the discharge service port should reach 966-1 656 kPag (140-240
psig) (Fig. 6). If head pressure of 966-1 656 kPag (140-240 psig) cannot be obtained, check system
charge level.

Fig.
6
Expansion
(H)
Valve
Test

WARNING:
EXTREME
CARE
MUST
BE
USED
WHEN
HANDLING
LIQUID
C02 AS
SKIN
INJURY
CAN OC­

CUR
IF
PROTECTIVE
GLOVES
ARE NOT
WORN.
(3) Put Liquid C02 on control head (completely cover
head) for a minimum of 30 seconds. Evaporator suction

•

HEATING
AND AIR
CONDITIONING
24 - 21 (a) Loosen both test hoses at the manifold gauge
set. Tighten the hoses as soon as the air is purged. (b) Loosen charging hose connection at manifold
gauge set. This will purge air from the charging

hose.
Tighten connection as soon as air is purged.
(9) With vehicle windows open and hood up, oper­
ate engine at 1,300 RPM. (10) Place air conditioner control on A/C and place
the fan switch on high. (11) If necessary, block the condenser to maintain
a discharge pressure of 1 550-1 725 kPag (225-250

psig).
System must be charged through the evapora­
tor suction service ports as follows:
(a) Slowly open the suction service gauge valve.
Meter flow of refrigerant by adjusting the suction service gauge valve so the pressure registered at
the suction service gauge does not exceed 345 kPag

COMPRESSOR
J
(50
psig). Keep refrigerant container upright.
(b) Add refrigerant gas until there is no foam visi­
ble at the sight glass. As soon as all foam clears, note the weight registered on the refrigerant scale.
(c) Watch the refrigerant weighing scale and add
437 g (14 oz.) of refrigerant (equivalent to 1 can).
(d) Close the suction gauge valve.

CAUTION:
TOO
much
refrigerant
in the
system
can

cause
abnormally high discharge pressures. Care
must
be
used
so the
exact recommended amount
of
refrigerant
is
added
after
foam clears
in the
sight

glass.

(e) Close dispensing manifold valve. Remove test
hoses and adapters from the service ports of com­
pressor and install protective caps at service ports.

RVICE (SD-709)

INDEX

page

Compressor
21

Compressor
Shaft Seal
.................... 25
The A/C system uses a 7 piston design Sanden SD-
709 compressor. Designated the SD-709, the compres­
sor is mounted on the front right side of the engine
and is driven by a serpentine belt.
System lubrication is provided by 135cc ±15cc (4.6
cu. in. ±0.5 cu. in.) of 500 viscosity refrigerant oil.
The clutch used on the compressor consists of 3 ba­
sic components:
(1) The pulley.
(2) The front plate. (3) The field coil.
The pulley and field coil are attached to the front
head of the compressor with snap rings. The hub is keyed to the compressor shaft and is retained on the
shaft with a self-locking nut. Special service tools are
required to remove and install the clutch plate on
the compressor shaft.

COMPRESSOR
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Disconnect the clutch lead wire.
(3) Remove the discharge and inlet (suction) ser­
vice valves from the compressor. Plug or tape all the
openings.
(4) Refer to Group 7, Cooling System and remove
the drive belt(s). (5) Remove the bolts and lift the compressor from
the mounting bracket (Fig. 1).
page

Cylinder Head
/
Valve Plate
27
Magnetic
Clutch
22

Fig.
1
Compressor
Mounting

INSTALLATION
If a replacement compressor is being installed,
check the oil level. Add or subtract oil as necessary.
Install the magnetic clutch on the compressor.
(1) Install the compressor on the mounting bracket.
Tighten the bolts to 27 N*m (20 ft. lbs.) torque.
(2) Refer to Group 7, Cooling System and install
the drive belt(s).
(3) Check the belt tension.
@ New drive belt-800-900 N (180-200 lbs-f).
• Used belt-623-712 N (140-160 lbs-f).