ad blue DODGE TRUCK 1993 Service Owner's Manual

CAV

WIRE

COLOR DESCRIPTION
CAV
WIRE

COLOR DESCRIPTION

1 DG/RD*
MAP SENSOR 37
BK/OR OVERDRIVE LAMP
2 TN/BK*
ENGINE COOLANT TEMPERATURE SENSOR 38 PK/BK INJECTOR DRIVE
#5

3 RD/WT DIRECT BATTERY 39 GY/RD IAC MOTOR
#4

4
BK/LB*

SENSOR RETURN 40 BR/WT
IAC MOTOR
#2

5 BK/WT SIGNAL GROUND 41
BK/DG* OXYGEN SENSOR SIGNAL
6 VT/WT
5-VOLT
OUTPUT
(MAP AND TPS)
42
7 OR

8-VOLT
OUTPUT (DISTRIBUTOR PICK-UP) 43

GY/LB*
TACHOMETER SIGNAL OUTPUT (VEHICLES W/TACHOMETER)
8 44 GY CAMSHAFT POSITION SENSE
9 DB
J2-IGNITION FEED 45
LG SCI RECIEVE
10 R/WT OVERDRIVE OVERRIDE
46 CCD
(-)

11 BK/TN POWER GROUND 47 WT/OR* SPEED SENSOR SIGNAL
12 BK/TN POWER GROUND 48 BR/RD* SPEED CONTROL
SET
SWITCH
13 LB/BR
INJECTOR DRIVER
#4
49
YL/RD* SPEED CONTROL ON/OFF SWITCH
14 YL/WT
INJECTOR DRIVER
#3
50 WT/LG* SPEED CONTROL RESUME SWITCH
15 TN INJECTOR DRIVER
#2
51 DB/YL*
AUTO SHUTDOWN
(ASD)
RELAY
-
RETURN
16
WT/DB*

INJECTOR DRIVER
#1
52 PK/BK
EVAP CANISTER PURGE SOLENOID
17 DB/TN INJECTOR DRIVER
#7
(V-8
ONLY) 53 LG/RD* SPEED CONTROL VENT SOLENOID
18 DB/GY
INJECTOR DRIVER
#8
(V-8
ONLY) 54
OR/BK* SHIFT INDICATOR LIGHT (MANUAL TRANSMISSION ONLY)
19 BK/GY*
IGNITION COIL DRIVER 54
OR/BK* CONVERTOR CLUTCH SOLENOID (AUTO TRANSMISSION)
20 DG
GENERATOR FIELD CONTROL 55
OR/WT OVERDRIVE SOLENOID (AUTO TRANSMISSION ONLY)
21 BK/RD
CHARGE TEMPERATURE SENSOR 56
GY/PK SRI LAMP
(5.9L HDC
ENGINE)
22
OR/DB*

THROTTLE POSITION SENSOR
(TPS)
57
DG/OR ASD SENSE
23 TN/WT
OXYGEN SENSOR SIGNAL
(5.9L HDC
ENGINE) 58 LG/BK
INJECTOR DRIVER
#6

24 GY/BK IGNITION (CAMSHAFT POSITION SENSOR) 59
VT/BK IAC MOTOR
#1

25 PK
,
SCI
TRANSMIT 60
YL/BK* IAC MOTOR
#3

26 CCD
(-:-)
WIRE COLOR CODES LB
LIGHT BLUE
VT VIOLET

27 BR
A/C SWITCH SENSE BK BLACK
LG LIGHT GREEN
WT

WHITE
28 VT A/C SELECT BR BROWN
OR ORANGE
YL YELLOW
29 WT/PK* BRAKE SWITCH
-
DB DARK BLUE PK
PINK *
WITH TRACER
30 BY/YL*
PARK/NEUTRAL SWITCH DG DARK GREEN
RD
RED
31 GY
GRAY TN TAN
32 BK/PK*
MALFUNCTION INDICATOR LAMP
33 TN/RD*
SPEED CONTROL VACUUM SOLENOID CONNECTOR
34 DB/OR* A/C CLUTCH RELAY TERMINAL

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oooooooooojj
35 GY/YL*
EGR SOLENOID SHOWN W'41
30
50«M#5l31
604

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36 J9314-171
Fig.
17 PCM
Connector—Gas
Powered
Engines

(3) Check for battery voltage at both intake air
heater terminals. The heaters will only be ener­ gized for 10 to 20 seconds. Refer to the Preheat Cycle Time Interval Chart.

PREHEAT
CYCLE
TIME
INTERVAL
SENSOR
MOUNTING
BOLTS

Intake

Manifold

temperature
Preheat
Cycle
Time

Ignition
Key ON

Engine
Net
Running
Pestheat
Cycle

Ignition
Key ON Ingin©
Running

Above 15 °C (59
°F)
0 Seconds
No
-8°C{18°F)*o 15°C(59
°F)
10 Seconds
Yes
-17°C{1 °F) •9°C(16°F) 15 Seconds

Yes

-26°C(-15°F) fo-18°C (0
°F)
17.5 Seconds
Yes
Below
-26
°C
(15T) 20 Seconds

Yes

J9114-239
AIR INTAKE HEATER TEST (1) Disconnect negative battery cable.
(2) Note wire positions on heater terminals for as­
sembly. Disconnect wires from heater.
(3) Use an ohmmeter to test resistance from each
heater terminal to ground. The resistance should be
zero (0). If the resistance is not to specifications, in­ spect for corroded or dirty connections. Clean or re­
pair the connections and retest before replacing
heaters.

ENGINE
SPEED
SENSOR
The engine speed sensor (sometimes referred to as
the crankshaft position sensor) is located on the front
of engine (Fig. 12). To perform a complete test of the engine speed sen­
sor and its circuitry, refer to the DRB II scan tool.
Also refer to the appropriate Powertrain Diagnostics
Procedures manual.

FUEL
HEATER
A malfunctioning fuel heater can cause a wax
build-up in the fuel/water separator (Fig. 13). Wax
build-up in the fuel/water separator can cause engine starting problems and prevent the engine from rev­
ving up. It can also cause miss fire under load and
blue or white fog like exhaust. Voltage to operate the fuel heater is supplied
through the ignition switch. The heater operating
range is from 6° - 13.5°C (43° - 53°). A minimum of 7
VIBRATION

DAMPER
J9214-69

Fig.
12
Engine
Speed
Sensor
volts is required to operate the fuel heater. The re­
sistance value of the heater unit is 2.5 - 3.0 ohms.
««.
* rr ,,

J9114-84

Fig.
13
Fuel
Heater

FUEL
INJECTION
PUMP
The fuel solenoid is the only serviceable component
of the fuel injection pump. The injection pump is
not to be serviced or the warranty may be
voided. If the injection pump requires service,
the complete assembly must be replaced. Incorrect injection pump timing can cause poor per­
formance, excessive smoke and emissions and poor
fuel economy. Refer to the 5.9L Diesel Service Proce­
dures section of this manual for injection pump tim­
ing.

14-92
FUEL
SYSTEM

• A broken injection pump timing mechanism spring
will cause the timing to be fully advanced resulting
in torque loss, a fuel knock and possible engine over­
heating.
An improperly operating KSB (cold start) solenoid
will cause white smoke during engine warm-up. The
KSB solenoid is not serviceable.
A defective or non-adjustable fuel injection pump
can cause starting problems or prevent the engine
from revving up. It can also cause:
• Engine surge at idle • Rough idle (warm engine)
• Engine miss under load
• Low power
• Excessive fuel consumption
• Poor performance
• Low power
• Black smoke from the exhaust • Blue or white fog like exhaust
• Incorrect idle or maximum speed A worn fuel injection pump plunger can effect fuel
pressure and the amount of fuel injected. This results in reduced engine power. In most cases, if the injec­
tion pump is delivering fuel from one outlet, it will deliver fuel from all outlets. If the internal plunger is defective, the fuel injection pump must be re­
placed.
Engine power is also effected by the governor set­
ting and performance. Do not attempt to adjust the governor. If the governor seals on the external adjustment screw are broken, the fuel rate may
be out of adjustment. The warranty of the injec­ tion pump and the engine may be void if the
seals have been tampered with or removed.

FUEL
INJECTORS
A leaking fuel injector can cause fuel knock, poor
performance, black smoke, poor fuel economy and
rough engine idle. If the fuel injector needle valve
does not operate properly, the engine may misfire and produce low power. A leak in the injection pump-to-injector high pres­
sure fuel line can cause many of the same symptoms as a malfunctioning injector. Inspect for a leak in the
high pressure lines before checking for a malfunc­
tioning fuel injector.

WARNING:
THE
INJECTION PUMP SUPPLIES HIGH
PRESSURE
FUEL
OF
APPROXIMATELY
59,000
KPA

(8,000
PSI) TO
EACH INDIVIDUAL INJECTOR
THROUGH THE HIGH
PRESSURE
LINES. FUEL UN­
DER
THIS AMOUNT
OF
PRESSURE
CAN
PENE­
TRATE THE SKIN AND CAUSE PERSONAL INJURY,
WEAR
SAFETY GOGGLES
AND
ADEQUATE PRO­
TECTIVE CLOTHING. AVOID CONTACT
WITH
FUEL
SPRAY
WHEN BLEEDING HIGH
PRESSURE
FUEL
LINES.
WARNING:
DO NOT
BLEED
AIR
FROM
THE
FUEL

SYSTEM
OF A
HOT ENGINE.
DO
NOT ALLOW FUEL
TO SPRAY ONTO THE EXHAUST MANIFOLD WHEN
BLEEDING
AIR
FROM THE FUEL SYSTEM.

To determine which fuel injector is malfunctioning,
run the engine and loosen the high pressure fuel line nut at the injector. Listen for a change in engine
speed (Fig. 14). Tighten the line nut. If engine speed

drops,
the injector was operating normally. If engine
speed remains the same, the injector is malfunction­
ing. Test all injectors in the same manner one at a

time.

Fig. 14
Inspecting
Injector Operation
Once an injector has been found to be malfunction­
ing, remove it from the engine and replace it. Refer
to Diesel Engine Service Procedures for injector re­ moval and installation.

FUEL
SUPPLY
RESTRICTIONS

CAUTION:
Do not
operate
the
engine
if the
fuel
sup­ ply
line
has
a
restriction
of
more
than
12.7
kPa
(3.75
in
Hg).
Refer
to
Lift
Pump
Test.

Fuel supply line restrictions can cause starting
problems and prevent the engine from revving up.
The starting problems include; engine miss under load, low power and blue or white fog like exhaust.
Test all fuel supply lines for restrictions or blockage.
Flush or replace as necessary. Bleed the fuel system
of air once a fuel supply line has been replaced.

FUEL/WATER
SEPARATOR
FILTER
A blocked or clogged fuel/water separator filter can
cause starting problems and prevent the engine from
revving up. It can also cause engine miss under load,
low power and blue or white fog like exhaust. The maximum allowable fuel pressure drop across
the fuel/water filter separator is 21 kPa (3 psi).

CAV

WIRE

COLOR DESCRIPTION
CAV
WIRE

COLOR DESCRIPTION

1 WT/BK
WATER-IN-FUEL SENSOR 37 OVERDRIVE LAMP SIGNAL
2 TN/BK
COOLANT SENSOR (AUTOMATIC TRANSMISSION ONLY) 38
3 RD BATTERY
39
4
BK/LB*

SENSOR RETURN 40
5 BK/WT
SIGNAL GROUND 41
6 VT/WT*
5 VOLT SUPPLY 42
7 TN/YL 8 VOLT INPUT 43 GR/LB TACHOMETER
8 44
9 DB
IGNITION SENSE 45 LG DATA LINK RECIEVE
10 RD/WT*
OVERDRIVE OVERRIDE 46
11 BK/TN POWER GROUND
47 WT/OR* VEHICLE SENSOR
12 BK/TN
POWER GROUND 48 BR/RD* SPEED CONTROL COAST/SET SWITCH
13 49 YL/RD* SPEED CONTROL ON/OFF SWITCH
14 50 WT/LG* SPEED CONTROL RESUME/ACCEL SWITCH
15 OR/BK* HEATER
#2
RELAY 51 DB/YL ASD RELAY
16 YL/BK HEATER #1 RELAY 52
17 53 LG/RD* SPEED CONTROL VENT SOLENOID
18 54 BK/PK* WATER-IN-FUEL LAMP
19 55 OR/LG* OVERDRIVE SOLENOID
20 DG GENERATOR FIELD 56 DG/WT WAIT-TO-START LAMP
21 BK/RD
CHARGE (INTAKE) AIR TEMPERATURE SENSOR 57 DG/OR ASD SENSE
22
OR/DB*

THROTTLE POSITION SENSOR 58
23 59
24 GY/BK
REFERENCE PICKUP 60
25 PK
DATA LINK TRANSMIT WIRE COLOR CODES LB
LIGHT BLUE VT VIOLET
26 BK BLACK LG LIGHT GREEN WT
WHITE
27 BR
A/C CLUTCH REQUEST BR BROWN OR ORANGE
YL YELLOW
28 LG/RD THERMO SWITCH DB DARK BLUE PK PINK *
WITH TRACER
29 WT/PK* BRAKE SWITCH DG DARK GREEN
RD RED
30 BR/YL*
PARK/NEUTRAL SWITCH GY GRAY TN TAN
31 ruin
32 BK/PK*
MALFUNCTION INDICATOR LAMP
n

33 TN/RD*
SPEED CONTROL VACUUM SOLENOID CONNECTOR

J//000OOOOOOO
1 1

HI
173456789
10 J/^"*\

Hi
oooooooooo (1 Oj]
VlX
21
22
23
24
25
26
27
28
29
30
\V~V//
oooooooooo
\
II
12 13
14 15
16 17 18
19 20
\
34 DB/OR
WIDE OPEN THROTTLE (A/C) TERMINAL
J//000OOOOOOO
1 1

HI
173456789
10 J/^"*\

Hi
oooooooooo (1 Oj]
VlX
21
22
23
24
25
26
27
28
29
30
\V~V//
oooooooooo)}

31
32 33 34 35 36 37 38 39 40
1JU

35 SHOWN \\\
41 42 43 44 45 46 47 48 49
SO
1
^m^^
|

oooooooooo
1
1
oooooooooo
J//

36
Li

J9314-185

PCM
CONNECTOR CAVITY DESCRIPTION

14-104
FUEL
SYSTEM

• DIESEL FUEL INJECTION SYSTEM DIAGNOSIS-CONTINUED

SYMPTOM
CAUSE
ACTION

Either poor performance,

black
smoke
or low
power
Injection
pump
to engine timing
Fuel injection pump malfunction or
not adjustable
Check
injection
pump
to
engine
timing

Replace
fuel
injection pump
White or blue fog-like exhaust in full-load range Improper
fuel

Drain
fuel
tank,
flush
system,
fill
with proper
fuel,
change
filter

Empty
fuel
tank or
fuel
tank vent blocked
Fill
tank, bleed
system,
check tank vent

Air
in
fuel
system
Bleed
fuel
system

Clogged
fuel
filter
Replace
fuel
filter

Restricted
or blocked
fuel
injection lines
Remove
restriction or replace lines

Restricted
or blocked
fuel
supply lines
Remove
restriction or replace lines

Wax
buildup in
fuel
filter
(cold weather

only)
Replace
fuel
filter,
use
recommended
i
diesel fuel.
Inspect
fuel
heater electrical connector for
damage.

Incorrect injection pump to engine timing
Adjust
injection pump timing
Injection pump overflow fitting switched
with inlet fitting Install fittings in
proper
positions

Fuel injection pump malfunction or
not adjustable
Replace
fuel
injection pump
Incorrect lale speed
Low
idle misadjusted
Adjust
idle
stop
screw
Fuel injection pump malfunction or
not adjustable
Replace
fuel
injection pump

Engine
does
not rev up Improper
fuel
Drain
fuel
tank,
flush
system,
fill
with proper
fuel,
change
filter

Empty
fuel
tank or
fuel
tank
vent blocked
Fill
tank, bleed
system,
check
tank vent J9114-26

23 - 54
BODY COMPONENTS

•
REFINISHING PROCEDURES

SERVICE
INFORMATION
Exterior vehicle body colors are identified on the
Body Code plate. The plate is attached to the top, right side of the cowl below the cowl grille. The color
code location is described in the manual introduction. OEM paint colors are generally available from all
of the major paint suppliers. They are supplied in the
form of either mixing formulas or factory packaged (pre-mixed) paint. The exterior colors and corresponding Ram Truck,
Chassis Cab and Ramcharger paint codes are listed
in the following chart.

BASE
COAT/CLEAR COAT FINISH
On most vehicles a two part paint application (base
coat/clear coat) is used. Color paint that is applied to
primer is called base coat. The clear coat protects
base coat from ultraviolet light. It also provides a du­
rable high gloss finish.

WET SANDING, BUFFING
AND
POLISHING
Minor acid etching, orange peel or smudging in
clear coat can be reduced with light wet sanding,
hand buffing and polishing. If the finish has been wet sanded in the past, it cannot be repeated. Wet sanding operation should be performed by a trained
automotive painter.

CAUTION:
Do not remove clear
coat
finish,
if

equipped.
Base
coat
paint
must
retain
clear
coat
to
shine.
ble.
For best results, use Mopar®Scratch Filler/
Primer, Touch-up Paints and Clear Top Coat. Refer
to Introduction group of this manual for Body Code
Plate information.

TOUCH-UP
PROCEDURE \l)
Scrape loose paint and corrosion from inside
scratch or chip.
(2) Clean affected area with Mopar®Tar/Road Oil
Remover and allow to dry.
(3) Fill the inside of the scratch or chip with a coat
of filler/primer. Do not overlap primer onto good sur­
face finish. The applicator should be wet enough to
puddle/fill the defect without running. Do not stroke
brush applicator on body surface. Allow the filler/ primer to dry hard.
(4) Cover the filler/primer with color touch-up
paint. Do not overlap color touch-up onto the original color coat. Butt the new color to the original color if
possible. Do not stroke applicator brush on body sur­

face.
Allow touch-up paint to dry hard.
(5) On vehicles without clear coat, the touch-up
color can be lightly (600 grit) wet sanded and pol­
ished with rubbing compound.
(6) On vehicles with clear coat, apply clear top coat
to touch-up paint with the same technique as de­ scribed in step 4. Allow clear top coat to dry hard. If
desired, step 5 can be performed on clear top coat.

PAINTED SURFACE TOUCH-UP
When a painted metal surface has been scratched
or chipped, it should be touched-up as soon as possi-

PAINT CODE CHART

GENERAL
INFORMATION
The following paint code chart lists the paint color
name on the left side and the paint code on the right

side.
The paint colors listed are available at your lo­
cal paint supplier. Clear Coat (CO colors are desig­
nated after the color title.

EXTERIOR COLORS
Colorado Red-CC HE4
Dk. Copper Pearl-CC LVB Lt. Champagne Met.-CC KV4
Dk. Forest Green-CC GG7
Dk. Spectrum Blue Met.-CC JB6
Banzai Blue Met.-CC KC3
Black -CC DX8 Dk. Silver Met.-CC KS7
Silver Star Met.-CC KAC
Bright White-CC GW7
Bright Turquoise Met.-CC KQ2
Medium Turquoise Met.-CC MQF
Light Turquoise-CC MQG
Parade Blue Met.-CC... MC6
Dark Arctic Gray-CC MS9
Light Arctic Gray-CC MSC

INTERIOR COLORS
Charcoal S8
Crimson Red M6
Spice/Dk. Spice TT