wiring DODGE TRUCK 1993 Service Repair Manual

24 - 36
HEATING
AND AIR
CONDITIONING

• (9) Remove control.

INSTALLATION
(1) Connect temperature control cable.
(2) Install illumination light.
(3) Install 3 wiring connectors to push button
switch and vacuum harness. (4) Connect blower motor control switch wiring
connector.
(5) Place control unit in place in instrument panel
and secure with attaching screws.
(6) Install faceplate.

VACUUM ACTUATORS
The mode and air circulator actuators are serviced
through the glove box opening after opening the glove box past its stops. The heater/defroster actuator is serviced under the
instrument panel on the left end of the A/C unit.

EVAPORATOR HEATER ASSEMBLY

REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Discharge refrigerant from the A/C system.
(3) Disconnect refrigerant and heater lines from
unit on engine side.
(4) Plug heater hoses and unit and remove conden­
sate tube (Fig. 9).
(5) Move transfer case and/or gear shift levers
away from instrument panel.
(6) Remove right cowl side trim panel, if so
equipped.
(7) Remove glove box by removing mounting
screws at base and swinging out from the bottom to
avoid catch and stops.
(8) Remove structural brace through glove box
opening. Remove screws, loosen nuts.
(9) Remove ash receiver.
(10) Remove right half of lower reinforcement by
removing screws attaching it to the instrument panel and the sctew attaching it to the cowl side trim
panel.
(11) Detach radio ground strap.
(12) Remove center distribution duct.
(13) Remove floor air distribution duct.
(14) Disconnect temperature control cable from
unit through glove box and tape out of way. (15) Disconnect vacuum lines from extension on
control unit and detach vacuum lines from defroster
duct (Fig. 10). (16) Remove wiring connector from resistor block.
(17) Remove blower motor connector on engine

side.
(20) Remove screw that retains the evaporator
heater assembly to cowl side sheet metal.
(21) Remove the evaporator heater assembly. Plas­
tic instrument panel may have to be flexed outward.

Fig.
10 Evaporator Heater
Assembly

DISASSEMBLE
(1) Remove nut that attaches 3 door arms to doors
on the top cover of the unit. Remove the 3 arms (Fig.

11).

ATTACHING
NUTS
RB463

Fig.
11
Door Arms

(2) Remove screws to separate cover from housing.
(3) Slide out evaporator core. (4) Remove mounting screw and slide out heater

core.
(5) Disconnect blower motor feed wire on engine

side.

(6) Remove retaining screws to separate blower
motor from housing.
(7) Separate fan from motor (Fig. 12).
(8) Inspect all parts.

ASSEMBLE
(1) Position the fan onto the motor.
(2) Position the blower motor to the housing.
Tighten the retaining screws. (3) Connect blower motor feed wire on engine side.
(4) Slide the heater core in and install the mount­
ing screws.
(5) Install evaporator core.
(6) Position the cover onto the housing. Install and
tighten the screws. (18) Disconnect vacuum lines on engine side, make
sure grommet is free from dash panel. (19) Remove retaining nuts on engine side.

•

Fig.
12
Blower
Wheel
(7) Install the 3 arms. Install nut that attaches 3
door arms to doors on the top cover of the unit (Fig.
11).

INSTALLATION
(1) Install the evaporator heater assembly. Plastic
instrument panel may have to be flexed outward.
(2) Install and tighten the screw that retains the
evaporator heater assembly to cowl side sheet metal.
(3) Install the retaining nuts on engine side.
(4) Connect vacuum lines on engine side.
(5) Install blower motor connector on engine side.
(6) Remove wiring connector from resistor block.
(7) Connect vacuum lines from extension on con­
trol unit and attach vacuum lines to defroster duct (Fig. 10).
(8) Connect temperature control cable to unit
through glove box. (9) Install floor air distribution duct.
(10) Install center distribution duct.
(11) Attach radio ground strap. (12) Remove right half of lower reinforcement by
removing screws attaching it to the instrument panel and the screw attaching it to the cowl side trim
panel. (13) Install ash receiver.
(14) Install structural brace through glove box
opening. Install screws and loosen nuts. (15) Install glove box by installing mounting
screws. (16) Install right cowl side trim panel, if so
equipped. (17) Position transfer case and/or gear shift levers.
(18) Remove plugs from heater hoses and unit. In­
stall condensate tube (Fig. 9). (19) Connect refrigerant and heater lines to unit
on engine side.
} (20) Connect the negative cable to the battery. (21) Fill the cooling system (refer to Group 7, Cool­
ing System). (22) Evacuate and charge the system.
(23) Check operation of all controls and perfor­
mance of the A/C system.
HEATING
AND AIR
CONDITIONING
24 - 37

'H"
VALVE

Fig.
13
Expansion
(H)
Valve
Assembly
ELECTRONIC
TEMPERATURE
CYCLING
SWITCH

REMOVAL
(1) Remove the electrical wires to the switch.
(2) Rotate switch counterclockwise to remove from
pressure switch port. (3) Remove and discard old O-ring.

INSTALLATION
(1) Install new O-ring. Refrigerant oil must be ap­
plied to the new O-ring.
(2) Rotate switch clockwise to install on suction
line pressure switch port. Tighten switch to 5.65 N#m (50 in. lbs.) torque.

CAUTION:
Power
tools
should
not be
used
for in­

stallation
of the switch. The
possibility
of stripping
the
switch
threads
occurs
above
5.88 N*m (52 in.
lbs.)
torque.
(3) Connect wires. (4) Verify operation.

EXPANSION
(H)
VALVE

REMOVAL
The system must be completely discharged before
opening any refrigerant lines. (1) Remove the bolt in center of plumbing sealing
plate (Fig. 13).
(2) Carefully pull refrigerant line assembly to­
wards front of vehicle. Take care NOT to scratch valve sealing surfaces with tube pilots.
(3) Remove the Torx Head screws (Fig. 13). Hold
valve, once cap screws are removed valve is com­
pletely disconnected.
(4) Carefully remove valve.

24
- 38
HEATING
AND AIR
CONDITIONING

INSTALLATION
(1) Remove and replace the aluminum N-gaskets
(1 on evaporator plate and 1 on plumbing plate). (2) Remove sealing cap from H-valve control head
side sealing surface and hold it against evaporator
sealing plate. DO NOT scratch sealing surface. In­
stall the Torx Drive screws and tighten to 11 N-m (100 in. lbs.) torque.
(3) Remove sealing cap from plumbing side sealing
surface and hold plumbing up to valve. Install the
bolt and tighten to 23 N*m (200 in. lbs.) torque.
(4) Connect wires to electronic temperature cycling
switch. (5) After expansion valve is installed and system
charged and leak checked, repeat performance check.

AIR CONDITIONER DISTRIBUTION AND SPOT
COOLER
DUCTS-CENTER

REMOVAL (1) Disconnect the negative cable from the battery.
(2) Open glove box past stops.
(3) Remove right upper air duct by removing
mounting screw and pulling duct out through glove
box opening (Fig. 9).
(4) Remove instrument panel center brace.
(5) Remove right kick pad.
(6) Remove right instrument panel pivot bolt.
(7) Remove instrument panel cluster.
(8) Disconnect shift indicator cable.
(9) Lower steering column.
(10) Remove steering column studs.
(11) Remove radio.
(12) Remove mounting screws and remove scoop
connecting heater unit to center distribution duct. (13) Remove mounting screws and remove center
distribution duct by pulling bottom of instrument
panel out and dropping duct out (Fig. 9).

INSTALLATION
(1) Position the center distribution duct through
the bottom of instrument panel (Fig. 9). Install mounting screws.
(2) Position the scoop connecting heater unit to
center distribution duct. Install mounting screws.
(3) Install radio.
(4) Install steering column studs.
(5) Place steering column into position.
(6) Connect shift indicator cable.
(7) Install instrument panel cluster.
(8) Install right instrument panel pivot bolt.
(9) Install right kick pad.
(10) Install instrument panel center brace.
(11) Position the duct in through glove box open­
ing (Fig. 9). Install mounting screw. (12) Close glove box.
(13) Connect the negative cable to the battery.
AIR CONDITIONER DISTRIBUTION AND SPOT

COOLER
DUCTS-RIGHT BI-LEVEL

REMOVAL (1) Disconnect the negative cable from the battery. (2) Open glove box past stops.
(3) Remove right upper air duct by removing
mounting screw and pulling duct out through glove
box opening (Fig. 9).

INSTALLATION
(1) Position the right upper air duct through glove
box opening (Fig. 9). Install mounting screw.
(2) Close glove box.
(3) Connect the negative cable to the battery.

AIR CONDITIONER DISTRIBUTION AND SPOT
COOLER
DUCTS-LEFT BI-LEVEL

REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Remove instrument panel cluster.
(3) Disconnect shift indicator cable.
(4) Remove heater control.
(5) Remove mounting screws and cover that re­
tains instrument panel wiring and let wiring hang

free.

(6) Remove mounting screw and slide left air duct
out through instrument cluster opening (Fig. 9).

INSTALLATION
(1) Slide left air duct in through instrument clus­
ter opening (Fig. 9). Install mounting screw. (2) Position the cover that retains instrument
panel wiring. Install mounting screws.
(3) Install heater control.
(4) Connect shift indicator cable.
(5) Install instrument panel cluster.
(6) Connect the negative cable to the battery.

AIR OUTLET
ASSEMBLIES
RIGHT
SIDE
Both right side outlets are held in place with
spring loaded retaining clips.
REMOVAL (1) With outlet facing out and louver vanes open,
grasp adjusting vane with fingers.
(2) Pull smoothly and firmly to unseat clips and
complete removal toward rear of vehicle.

INSTALLATION
(1) Position outlet assembly in panel opening, f
making sure lettering stamped TOP is up (ribs on
housing match notches on instrument panel).
(2) Press housing assembly until both retaining
clips lock into place.

25 - 20
EMISSION CONTROL SYSTEMS

• engine and tighten to 14 N*m (130 in. lbs.) torque.
Install electrical connector to sending unit.
(5) Clean the intake manifold and EGR valve of
any old gasket material.
(6) Install a new EGR valve gasket to intake man­
ifold. (7) Install EGR valve to intake manifold. Tighten
two mounting bolts to 23 N*m (200 in. lbs.) torque.
(8) Install vacuum lines to EGR valve.
(9) Install spark plug cable loom and plug cables to
valve cover mounting stud.
(10) Install air filter housing.

ELECTRIC EGR TRANSDUCER
(EET) The EGR valve and the EET are serviced as one
unit. Also refer to EGR valve removal/installation.

REMOVAL
(1) Remove air filter housing.
(2) Disconnect wiring connector at EET (Fig. 8). (3) Disconnect hoses at EET. Note position of hoses
for easier installation.
(4) Remove EET from engine.
INSTALLATION (1) Position EET to engine and connect hoses.
(2) Connect wiring connector. (3) Install air filter housing.

ELECTRICAL
CONNECTOR
TRANSDUCER
J9325-15

Fig.
8 Electric EGR Transducer (EET)—Typical

EVAP
CANISTER
The EVAP canister is mounted in the engine com­
partment on the right side wheel well (Fig. 9).

REMOVAL
(1) Remove fuel tubes/lines at EVAP canister.
Note location of tubes/lines before removal for easier
installation. (2) Remove mounting bolt at canister mounting
strap (Fig. 9).
(3) Remove canister and two-piece strap from
mounting bracket.
CANISTER

MOUNTING
STRAPS
CANISTER

MOUNTING
BRACKET RIGHT FRONT
INNER FENDER

MOUNTING
BOLT
EVAP
CANISTER
J9325-36

Fig.
9
EVAP
Canister Removal/Installation INSTALLATION
(1) Position canister to mounting bracket.
(2) Install canister and both mounting straps to
mounting bracket.
(3) Install canister bolt and tighten to 10 N*m (95
in. lbs.) torque.
(4) Install fuel tubes/lines to canister.

EVAP
CANISTER PURGE SOLENOID
REMOVAL
(1) Remove air filter housing.
(2) Disconnect wiring connector at solenoid (Fig.

10). BRACKET
MOUNTING

NUT
ELECTRICAL
CONNECTOR
CANISTER PURGE
SOLENOID/BRACKET VACUUM
CONNECTOR

J9214-50

Fig.
10
EVAP
Canister
Purge
Solenoid—
Typical

(3) Disconnect vacuum harness at solenoid (Fig.

10).

•
EMISSION CONTROL SYSTEMS 25 - 21 (4) Remove solenoid and its support bracket from
intake manifold (one bolt—5.2L/5.9L engine, one
nut—3.9L engine). (5) Remove EVAP canister purge solenoid from en­

gine.

INSTALLATION
(1) Install EVAP canister purge solenoid and its
mounting bracket to intake manifold.
(2) Connect vacuum harness and wiring connector.
(3) Install air filter housing.
FUEL TANK FILLER TUBE CAP If replacement of the fuel filler tube cap (Fig. 11) is
necessary, it must be replaced with an identical cap
to be sure of correct system operation.

CAUTION:
Remove
the
fuel
tank
filler
tube
cap to
relieve
fuel
tank
pressure.
The cap
must
be re­
moved
prior
to
disconnecting
any
fuel
system
com­

ponent
or
before
draining
the
fuel
tank.
PLASTIC

GASKET
RN348
Fig.
11
Fuel
Tank
Filler
Tube Cap—Typical
OXYGEN (02) SENSOR For description, operation, diagnosis and removal/
installation procedures of the 02 sensor, refer to Group 14, Fuel Systems. POWERTRAIN CONTROL MODULE (PCM)
For removal and installation procedures, refer to
Group 14, Fuel Systems.
PRESSURE RELIEF/ROLLOWER WALWE For removal and installation procedures, refer to
the Fuel Tank section of Group 14, Fuel Systems.

CLUSTER
AND
GAUGE SERVICE PROCEDURES
. . . 8E-12

CLUSTER
AND
GAUGE TEST PROCEDURES
8E-5

GENERAL INFORMATION
8E-1

MESSAGE
CENTER-DIESEL ENGINE
8E-4

MESSAGE
CENTER-GAS ENGINE
8E-3

SWITCH
AND
PANEL COMPONENT SERVICE
8E-16

INTRODUCTION
lntro.-1
DESIGNATIONS, LABELS/PLATES/DECALS, CODES AND DIMENSIONS/WEIGHTS
Intro.-1

MEASUREMENT
AND
TORQUE SPECIFICATIONS
lntro.-11

LAMPS
8L-1
BULB APPLICATION
8L-11

EXTERIOR LAMPS
8L-1

EXTERIOR LAMPS SERVICE PROCEDURES
8L-3
INTERIOR LAMPS
8L-10

LUBRICATION
AND
MAINTENANCE
0-1
CHASSIS
AND
BODY
0-28
DRIVETRAIN
0-22

ENGINE MAINTENANCE
0-14

GENERAL INFORMATION
0-1

POWER DOOR LOCKS
8P-1
SERVICE
PROCEDURES
8P-2

TEST PROCEDURES
8P-1

POWER MIRRORS
8T-1
SERVICE
PROCEDURES
8T-2

TEST PROCEDURES
8T-1

POWER WINDOWS
8S-1
SERVICE
PROCEDURES
8S-3

TEST PROCEDURES
8S-1

PROPELLER SHAFTS
16-1
GENERAL INFORMATION
16-1
PROPELLER SHAFT REPLACEMENT
16-8

SERVICE
DIAGNOSIS/PROCEDURES
16-3

TORQUE SPECIFICATIONS
16-15
UNIVERSAL
JOINT
REPLACEMENT
16-10

REAR
SUSPENSION
AND
AXLE
3-1
8
3/8 and 9 1/4
AXLE
3-11

GENERAL INFORMATION
3-1

MODEL
60 and 70
AXLES
3-29

POWER-LOK DIFFERENTIAL
3-55

REAR
SUSPENSION—2WD
and 4WD
VEHICLES
.... 3-3

SERVICE
DIAGNOSIS
3-6

SPECIFICATIONS
3-27

SURE-GRIP
DIFFERENTIAL SERVICE
3-28

TORQUE SPECIFICATIONS
3-59

TRAC-LOK DIFFERENTIAL
3-51

REAR
WINDOW DEFOGGER
8N-1
REPAIR PROCEDURES (GRID LINES, TERMINALS,
AND PIGTAILS)
8N-3

SERVICE
PROCEDURES
8N-4

TEST PROCEDURES
8N-1

STEERING
19-1
GENERAL INFORMATION
19-1
POWER STEERING PUMP
19-11
POWER STEERING SYSTEM DIAGNOSIS
19-2

RECIRCULATING BALL POWER STEERING GEAR
. . 19-20

STEERING COLUMN
19-35

STEERING LINKAGE
19-17

TORQUE SPECIFICATIONS
19-40

TRANSMISSION
AND
TRANSFER CASE
21-1

AUTOMATIC TRANSMISSION DIAGNOSIS
AND

TESTING
21-85

AUTOMATIC TRANSMISSION REMOVAL
AND
INSTALLATION
21-142

AUTOMATIC TRANSMISSION—32RH/36RH/37RH/
42RH/46RH
21-73

G360
MANUAL TRANSMISSION
21-46

G360
TRANSMISSION OVERHAUL
21-53

GENERAL INFORMATION-32RH/36RH/37RH
21-73

GENERAL INFORMATION—42RH/46RH
. . . 21-78

IN-VEHICLE SERVICE—32RH/36RH/37RH/ 42RH/46RH
21-130

NP205
TRANSFER CASE
21-342

NP241
TRANSFER CASE
21-350
NV4500
MANUAL TRANSMISSION
21-1

NV4500
TRANSMISSION OVERHAUL
21-6

OVERDRIVE
UNIT
OVERHAUL—42RH/46RH
21-324

TRANSMISSION OVERHAUL—32RH
21-152

TRANSMISSION OVERHAUL—36RH/37RH
21-192
TRANSMISSION OVERHAUL—42RH
21-233

TRANSMISSION OVERHAUL—46RH
21-278

TRANSMISSION/TRANSFER CASE SPECIFICATIONS
21-364

TURN SIGNALS
AND
HAZARD WARNING FLASHER
. . . 8J-1
GENERAL INFORMATION
8J-1
MULTIFUNCTION SWITCH SERVICE PROCEDURES.
. 8J-3

MULTIFUNCTION SWITCH TESTING PROCEDURES.
. 8J-2

VEHICLE
SPEED
CONTROL SYSTEM
8H-1
SERVICE
PROCEDURES
8H-11

TEST PROCEDURES
8H-7

WHEELS
AND
TIRES
22-1
TIRES
22-1

TORQUE SPECIFICATIONS
22-13
VEHICLE VIBRATION
22-11
WHEELS
22-6

WINDSHIELD WIPER
AND
WASHER
SYSTEMS
8K-1
INTERMITTENT WINDSHIELD WIPER FUNCTION
AND
SWITCH TESTING PROCEDURES
8K-6

TWO
SPEED
WINDSHIELD WIPER MOTOR
AND
SWITCH TESTING PROCEDURES
8K-1

WINDSHIELD WASHERS
8K-10

WINDSHIELD WIPER SYSTEM SERVICE
PROCEDURES
8K-7

WIRING DIAGRAMS
8W-1
COMPONENT IDENTIFICATION
8W-9

GENERAL INFORMATION
8W-1

SPLICE
LOCATIONS
8W-29

WIRING DIAGRAMS AD-BODY
8W-37