engine DODGE TRUCK 1993 Service Owner's Manual

0-10
LUBRICATION
AND
MAINTENANCE

•

O.K.TO

JUMP
START BATTERY
CONDITION
INDICATOR DO NOT

JUMP
START J9100-26 DARKENED
INDICATOR
WITH
GREEN
DOT
•
LETTERS
Uk-
FLUID
Lt- E:L .

DARKENED
INDICATOR
NO
GREEN
DOT •
BATTERY CHARGE
10'//
• Ft UID
L
EVEl
OK
LIGHT
OR
BRIGHT
INDICATOR

•
RAT-cci,
C
H
A
P
C;
F
R^'^Owh

AM.w-GE
FlAf StIll BE
r-
•
!
F-
r tjr r
?
STA
F
•
r
O U n
C
AI:

Fig.
5
Battery
Condition indicator
(4) Attach a red jumper cable connector clamp to
the positive (4-) terminal on the booster battery. At­
tach the other red cable connector clamp to the pos­ itive (+) terminal on the discharged battery (Fig. 6).

CAUTION:
Do not
allow
the
positive (
+
)
and
nega­

tive
(-)
cable clamps
to
contact each other.
Do not
lean over
the
battery when connecting
the
cable

clamps.

WARNING:
DO NOT
CONNECT
A
JUMPER CABLE CONNECTOR CLAMP
TO THE
NEGATIVE POST
OF

THE DISCHARGED BATTERY.

(5) Connect a black jumper cable connector clamp
to the negative (-) terminal on the booster battery. Connect the other black jumper cable connector
clamp to a good ground source on the engine that is
to be started (Fig. 7).
Verify the engine ground (negative) contact
surface area is free of grease. Make sure there is
a good connection to bare metal. The engine
ground (negative) connection must provide good
electrical continuity.
(6) Start the engine.

WARNING:
THE
USE
OF ANY
JUMPER CABLE
DIS­
CONNECTION PROCEDURE OTHER THAN
THAT
DESCRIBED
BELOW COULD RESULT
IN:
• PERSONAL INJURY CAUSED BY BATTERY
ACID SQUIRTING FROM THE BATTERY VENTS
• PERSONAL INJURY AND/OR PROPERTY DAM­
AGE CAUSED BY BATTERY EXPLOSION
• DAMAGE TO THE BOOSTER VEHICLE OR THE
DISABLED VEHICLE CHARGING SYSTEM. (7) After the engine is started, the jumper cables
must be disconnected in the following order:
• Black (negative) cable connector clamp from the
engine ground contact • Black (negative) cable connector clamp from the
negative terminal (-) on the booster battery
• Red (positive) cable connector clamps from the pos­ itive
(
+ ) terminals on both batteries

BATTERY NEGATIVE
CABLE
TERMINAL POSITIVE
JUMPER
CABLE
BATTERY

J9000-37

Fig.
6 Positive
Jumper
Cable
Connection
ENGINE BATTERY
•GROUND NEGATIVE NEGATIVE
CABLE
-JUMPER
CABLE

BATTERY
J9000-38

Fig.
7
Both
Jumper
Cables
Connected
On
Disabled
Vehicle PORTABLE STARTING UNIT
There are many types of portable starting units
available for starting engines. Follow the manufac­
turer's instructions.

VEHICLE
LIFTING RECOMMENDATIONS
Refer to the Owner's Manual for emergency vehicle
lifting procedures.
FLOOR JACK When properly positioned, a floor jack can be used
to lift a vehicle (Fig. 8). Support the vehicle in the
raised position with jack stands at the front and rear ends of the frame rails.

CAUTION:
Do not
attempt
to lift a
vehicle with
a

floor jack positioned under:

LUBRICATION
AND
MAINTENANCE
0-11

J
DRIVE-ON
HOIST

I
FRAME
CONTACT
HOIST
TWIN
POST
CHASSIS
HOIST

FLOOR
JACK
RROOD30
Fig.
8 Correct Vehicle Lifting
Locations
An axle tube
A body side sill
A steering linkage component
A drive shaft
The engine or transmission oil pan
The fuel tank
• A front suspension arm Use the correct frame rail lifting locations only
(Fig. 8).
HOIST A vehicle can be lifted with:
• A single-post, frame-contact hoist
• A twin-post, chassis hoist
• A ramp-type, drive-on hoist
When a frame-contact type hoist is used, verify
that the lifting pads are positioned properly (Fig. 8).

WARNING:
WHEN
A
SERVICE
PROCEDURE
RE­
QUIRES
THE
REMOVAL
OF
THE
REAR
AXLE,
FUEL

TANK,
OR
SPARE
TIRE,
EITHER:

• PLACE ADDITIONAL WEIGHT ON THE REAR
END OF THE VEHICLE
« ATTACH THE VEHICLE TO THE HOIST
« PLACE JACK STANDS UNDER THE VEHICLE
FOR SUPPORT TO PREVENT TIPPING WHEN
THE CENTER OF BALANCE CHANGES
4WD VEHICLES A standard hoist can be used to lift a 4WD vehicle.
The hoist should be inspected for adequate clearance. The lift arms, pads or ramps should be adjusted to
ensure that there is adequate clearance (Fig. 9).
ADJUSTMENT
PAD

ii 7
MAINTAIN
CLEARANCE
HOIST
ARM

RK44

Fig.
9 Lifting 4WD Vehicle
With
Single-Post
Hoist—
Typical
When a twin-post hoist is used, a 4 x 4 x 12-inch
wood spacer also could be required. Place the wood spacer under the front axle (opposite the differential
housing). This will maintain balance and level lift­ ing.

CAUTION:
The
block
that
is
used must
be
secured in
a
safe manner. This
will
ensure
that
it
will
not un­

balance
the
vehicle.
VEHICLE
TOWING
RECOMMENDATIONS
When it is necessary to tow a Ram Truck, the rec­
ommended method is either:
• the sling-type, rear-end raised towing method; or
• the wheel-lift towing method with a tow dolly lo­
cated under the front wheels. A vehicle with flat-bed hauling equipment can also
be used to transport a disabled vehicle.

SLING-TYPE
FLAT
BED
RR0OD29
Fig.
10 Tow Vehicles
With
Approved
Equipment

0 - 14
LUBRICATION
AND
MAINTENANCE

•
ENGINE
MAINTENANCE

INDEX

page
Air
Injection
Systems/Air Pump
. 17

Air-Conditioner
Compressor
21
Battery
19

Cooling System
15

Crankcase
Ventilation
System
17
Diesel Engine
Air Filter
Canister
17

Drive Belts
20
Engine
Air
Cleaner
Filter
Element
16

Engine Break-In
14

Engine
Oil 14

Engine
Oil
Change
and Filter
Replacement
15

Exhaust Gas
Recirculation
(EGR) System
...... 19
page
Exhaust
Manifold
Heat
Control
Valve
. 17
Exhaust System
, 21

Fuel System
18

Hoses
and
Fittings
16
Ignition
Cables,
Distributor
Cap and
Rotor
...... 19

Ignition
Timing
. 19

Oxygen
(02)
Sensor
19
Rubber/Plastic Components
20

Spark Plugs
. 19

Throttle
Control
Linkage
18

Vacuum Operated, Emission
Control
Components
19

ENGINE BREAK-IN
After first starting a new engine, allow it to idle
for 15 seconds before shifting into a drive gear. Also:
• Drive the vehicle at varying speeds less than 88
km/h (55 mph) for the first 480 km (300 miles).
• Avoid fast acceleration and sudden stops.
• Do not drive at full-throttle for extended periods of
time
• Do not drive at constant speeds
• Do not idle the engine excessively A special break-in engine oil is not required. The
original engine oil installed is a high quality lubri­
cant. New engines tend to consume more fuel and oil un­
til after the break-in period has ended.

ENGINE
OIL SPECIFICATIONS

API SERWICE
GRADE
Use an engine oil that conforms to API Service
Grade S5 SG/CD or SG/CE. MOPAR®provides engine
oils that conform to all of these service grades.

SULFATED ASH—DIESEL ENGINES
Oils that contain an excessive amount of sulfated
ash can cause deposits to develop on Diesel engine
valves. These deposits can result in valve wear.

SAE
WISC0SITY
An SAE viscosity grade is used to specify the vis­
cosity of engine oil. SAE 30 specifies a single viscos­
ity engine oil.
Engine oils also have multiple viscosities. 10W-30

<
5W-30

1
1 1

F
-20 0 10 20 32 60 80 100

C
-29 -18 -12 -7 0 16 27 38
ANTICIPATED
TEMPERATURE RANGE BEFORE
NEXT
OIL
CHANGE
J9000-39

Fig.
1 Temperature/Engine Oil Viscosity—Gasoline
Engines

-12°C
-18°C 10°F
0°F- 15W-40

-23°c(^-10eF

I
10W-30
WITH
WITHOUT
BLOCK HEATER
BLOCK
SYNTHETIC
OIL

HEATER
10W-30 5W-30

J9100-29

Fig.
2 Temperature/Engine Oil Viscosity—Diesel
Engines

ENERGY
G0NSERWING
OIL
An Energy Conserving type oil is recommended for
gasoline engines. They are designated as either EN­
ERGY CONSERVING or ENERGY CONSERVING

II.
OIL
LEVEL
INDICATOR (DIPSTICK)

GASOLINE ENGINES
The engine oil indicator is located at the right
front of the engine.

•

LUBRICATION
AND
MAINTENANCE
0 - 15
DIESEL
ENGINES

The Diesel engine oil level indicator is located at
the left center of the engine, above the
fuel
injection

pump (Fig. 3).

Fig.
3
Diesel
Engine
Oil
Dipstick

ACCEPTABLE
OIL
LEVEL
To maintain proper lubrication of an engine, the
engine oil must be maintained at an acceptable level.
For gasoline engines, the acceptable levels are indi­ cated between the ADD and
FULL
marks on oil
dip­
stick. For Diesel engines, the acceptable levels are
indicated between the L (low) and H
(high) marks
on
oil dipstick. The oil level should be checked periodically. The
vehicle should be on a level surface. Wait for
five
minutes after stopping the engine. For gasoline en­
gines,
add oil only when the level indicated on the
dipstick is at or below the ADD mark. For Diesel en­
gines,
add oil only when the level indicated on the
dipstick is between the L and H marks.
Never oper­
ate a Diesel
engine when
the oil
level
is below
the L mark. The distance between the L and H
marks represents 1.9L (2 Qts) engine oil.

CAUTION:
Do not
overfill
an
engine crankcase
with

oil. This
will
cause
oil
aeration
and
result
in a de­

crease
in the
engine
oil
pressure.
ENGINE
OIL
CHANGE AND FILTER REPLACEMENT

WARNING: PROTECTIVE CLOTHING
AND
GLOVES SHOULD
BE
WORN. EXPOSED SKIN SHOULD
BE

WASHED
WITH
SOAP
AND
WATER
TO
REMOVE
USED
ENGINE
OIL.
DO NOT
USE
GASOLINE, THIN­
NER,
OR
SOLVENTS
TO
REMOVE ENGINE
OIL

FROM
SKIN.
DO NOT
POLLUTE. DISPOSE
OF
USED
ENGINE
OIL
PROPERLY.
ENGINE
OIL
FILTER

All engines are equipped with a throw-away type
oil filter. The same type of filter is recommended
when the filter is changed.

OIL CHANGE
AND
FILTER
REPLACEMENT
Bring engine up to normal operating temperature.
A more complete drainage of oil will result.
(1) Remove the drain hole plug and drain the en­
gine oil from the crankcase.
(2) Install the drain hole plug with a replacement
gasket. For gasoline engines, the oil filter should be
replaced during every second engine oil change.
For Diesel engines, the oil filter should be re­
placed during every engine oil change.
(3) Rotate the oil filter counterclockwise to remove
it.
(4) Clean the engine cylinder block oil filter boss. (5) Apply a light coat of new engine oil to the rub­
ber seal on the oil filter.
(6) Install and hand tighten the oil filter 1/2 to 3/4
of a turn clockwise. (7) Add new engine oil at the fill hole location on
top of the engine cylinder head cover. Wipe off any spilled oil.
(8) Observe the oil level on the dipstick.

CAUTION:
Do not
overfill
the
engine crankcase
with

oil.
(9)
Start the engine. Observe the oil pressure
gauge or warning lamp (as applicable). If the oil
pressure does not increase, stop the engine immedi­ ately. Check oil level.

COOLING SYSTEM

WARNING:
USE
EXTREME CAUTION WHEN
THE
ENGINE
IS
OPERATING.
DO NOT PUT
YOUR
HANDS NEAR
THE
DRIVE BELT(S), PULLEYS
OR
FAN BLADE.
DO NOT
STAND
IN A
DIRECT LINE
WITH
THE FAN
BLADE.

INSPECTION SCHEDULE
Determine the coolant level. Inspect the cooling
system hoses/clamps after each service interval has
elapsed.

COOLANT LEVEL
It is recommended that the engine coolant level be
inspected at least once a month during periods of hot
weather.
With the engine at normal operating temperature,
check the coolant level in the coolant reserve tank.
The coolant level must be at least above the ADD mark. Add coolant to the coolant reserve tank only.

0-18
LUBRICATION
AND
MAINTENANCE

•
COOLANT FREEZE PROTECTION

Cooling systems contain a 50/50 mixture of anti­
freeze (ethylene glycol) and distilled water. This is
the recommended coolant mixture.
It is recommended that the degree of coolant pro­
tection be tested every 12 months. If the coolant is
contaminated or rusty, the cooling system should be
drained, flushed. Refill with a 50/50 mixture of fresh
coolant. Refer to Group 7—Cooling Systems for addi­
tional information.

SYSTEM
INSPECTION

WARNING:
IF THE
ENGINE
HAS
BEEN RECENTLY
OPERATED,
DO NOT
REMOVE
THE
RADIATOR

CAP.
THIS WILL AVOID
YOU
BEING SCALDED

WITH
HOT, PRESSURIZED COOLANT.

(1) Test the radiator cap for proper sealing and op­
eration. Use caution when removing the radiator cap
to avoid contact with hot coolant. Place a heavy rag
or towel over the cap and turn to the first stop. Do
not press down. Pause to allow the pressure to re­
lease through the overflow tube. Then press down
and turn counterclockwise to remove the cap.
(2) Inspect the coolant overflow tubing and the
connections at the coolant reserve tank and at the
radiator.
(3) Inspect the entire cooling system for leaks. A
black-light detector can be used as an aid in detect­ ing the source of coolant leaks.
(4) Inspect the radiator and air conditioner con­
denser fins for debris, etc. (5) If necessary, refer to Group 7—Cooling Systems
for additional information and service procedures.

RADIATOR CAP
The radiator cap must be completely tightened to
provide proper pressure. Inspect and test radiator cap
when cooling system service is performed.

MAIN,
FLUSH
AND
FILL

WARNING: ANTI-FREEZE (ETHYLENE GLYCOL)
IS
POISONOUS.
KEEP
OUT OF THE
REACH
OF
CHIL­

DREN.

Drain, flush, and fill the cooling system at the in­
terval specified in maintenance schedule. For proper service instructions see Group 7, Cooling System.

HOSES AND
FITTINGS
It is recommended that rubber hoses be periodi­
cally inspected. Inspect all hose fittings for looseness and corrosion.
ENGINE
AIR
CLEANER
FILTER
ELEMENT

MAINTENANCE
SCHEDULE
With normal driving conditions, the engine air
cleaner filter element should be replaced:
• Light-Duty Cycle-after each 48 000 km (30,000
miles) interval has elapsed
• Heavy-Duty Cycle-after
each
38 000 km (24,000
miles) interval has elapsed
When the vehicle is operated in dusty areas, the
filter element should be replaced more often.
For Diesel engines, the air filter canister should be
cleaned at the same time the filter is replaced.

SERVICE/REPLACEMENT
(1) Remove the air cleaner cover.
(2) Remove the air cleaner filter (Fig. 4).

CAUTION:
Do not tap the filter or immerse the filter medium in liquid to remove trapped debris.
(3) Clean filter by blowing the trapped debris from
the filter with compressed air (Fig. 5). Direct the air in the opposite direction of normal intake air flow.
Keep the air nozzle at least two inches away from
the filter.
(4) If the filter has become partially saturated with

oil,
replace the filter. Inspect the crankcase ventilat­
ing system for proper operation.
(5) Wash the air cleaner cover and body with
cleaning solvent. Wipe it dry.
(6) Install the air cleaner filter element. Attach
the cover to the body (Fig. 4).
Fig,
4
Engine
Air Oeaner—
Typical

•

Fig.
5
Cleaning
Filter
Element—Typical

DIESEL
ENGINE
AIR
FILTER CANISTER MAINTENANCE SCHEDULE

The Diesel engine air filter should be cleaned after
each interval specified in the Diesel engine mainte­
nance schedule.
When the vehicle is operated in dusty areas, the
canister should be cleaned more frequently.

EXHAUST
MANIFOLD HEAT CONTROL VALVE
MAINTENANCE SCHEDULE
The exhaust manifold heat valve should be ser­
viced after the interval specified in the maintenance schedule has elapsed.
SERVICE The exhaust manifold heat valve is located at the
left manifold (Fig. 6). Test the valve for non-re­ stricted movement.
Fig.
6 Manifold Heat Control
Valve
LUBRICATION
AND
MAINTENANCE
0 - 17

Fig.
7 Positive
Crankcase
Ventilation

System—Typical

SYSTEM OPERATION
Each PCV system is comprised of an air inlet filter,
a flow-control (PCV) valve, and the associated hoses.
The air inlet filter is located at the cylinder head cover (Fig. 7).
WARNING:
USE
EXTREME CAUTION WHEN
THE

ENGINE
IS
OPERATING.
DO NOT PUT
YOUR
HANDS NEAR
THE
DRIVE BELT(S), PULLEYS
OR

FAN BLADE.
DO NOT
STAND
IN A
DIRECT LINE

WITH
THE FAN
BLADE.

(1) With the engine idling, accelerate momen­
tarily. The valve shaft counterweight should move CLOCKWISE.
(2) If no movement is observed, either the shaft is
binding or the thermostat spring is weak or broken. (3) If the thermostat spring is weak or broken, re­
place the spring.
(4) Verify the manifold is COOL. Apply
MOPAR®Rust Penetrant (or an equivalent product)
to each end of the valve shaft at the bearings (Fig.
6).

(5) Allow the solvent to penetrate for a few min­

utes.
Then, rotate the valve shaft back and forth un­
til it turns without restriction.

AIR INJECTION SYSTEMS/AIR PUMP
Air injection system/air pump valves and switches
should be periodically tested for proper operation. In­
spect the check valve tubing for corrosion. Replace it
if excessive corrosion exists.

CRANKCASE
VENTILATION
SYSTEM
All gasoline engines are equipped with a positive
crankcase ventilation (PCV) system. The PCV sys­
tem prevents emission of residual engine oil vapor
from the crankcase (Fig. 7).

0-18
LUBRICATION
AND
MAINTENANCE

• MAINTENANCE SCHEDULE
A crankcase ventilation system must be clean to
provide good operation and durability. Periodic main­
tenance is necessary. Replace the PCV valve. Re­
move residual combustion deposits from the hoses and throttle body/intake manifold passages.
The PCV valve should be replaced and the system
should be serviced at the interval specified in main­
tenance schedule. If a vehicle is routinely used for short trips, the crankcase ventilation system could
possibly require more maintenance.
CRANKCASE AIR INLET FILTER
MAINTENANCE SCHEDULE Replace or clean, the air inlet filter at the interval
specified in maintenance schedule.
More frequent PCV system maintenance could be
required for:
• Vehicles routinely used for short trips
• Vehicles routinely involved in stop and go traffic
operation
• Vehicles routinely involved in extended periods of
engine idle
MAINTENANCE Clean and lubricate the crankcase air inlet filter
according to the following procedure. (1) Disconnect the fresh air hose from the port on
the crankcase air inlet filter housing (Fig. 8).
(2) Remove the air filter housing from the cylinder
head cover (Fig. 8). Clean the filter in kerosene or a similar solvent.
(3) Lubricate the filter by inverting the housing
and filling it with SAE 30 viscosity engine oil.
(4) Insert the air filter housing nipple in the cylin­
der head cover grommet. Connect the fresh air hose
to the upper port (Fig. 8).
J9000-52

Fig.
8
Crankcase
Air Inlet
Filter
THROTTLE CONTROL LINKAGE

Transmission linkage pivot pin areas (Fig. 9),
should be serviced. The areas lubricated every second
oil change with a multi-purpose lubricant (NLGI GC-
LB).

PIVOT
AREAS
Fig.
9
Transmission
Linkage
Pivot Areas

FUEL
SYSTEM

INSPECTION The fuel system filler cap, nozzle, tubes, hoses, and
connections should be inspected periodically.
FUEL FILTER The fuel filter requires service only when a fuel
contamination problem is suspected. For proper diag­
nosis and service procedures refer to Group 14, Fuel
System.
GASOLINE ENGINE FUEL REQUIREMENTS All gasoline engines require fuel that has a mini­
mum octane rating of 87 determined by the (R +
M)/2 calculation method.
The use of a brand of unleaded gasoline that con­
tains additives is recommended. Gasoline with addi­
tives will improve fuel economy and reduce emissions.

ALCOHOL/GASOLINE
BLENDS
Many brands of blended unleaded gasoline am now
available. Unleaded gasoline is blended with oxygenated-type
fuels to produce a clean air gasoline in many areas.
The use of this type of blended fuel is recommended.
ETH ANOL—Unleaded gasoline and ethanol
blended fuels are a mixture of 10 percent ethanol and 90 percent unleaded gasoline. This is an accept­
able blend of fuel.
MTBE— MTBE blended fuels are a mixture of un­
leaded gasoline and up to 15 percent MTBE (Methyl
Tertiary Butyl Ether). Unleaded gasoline blended
with MTBE is acceptable.

•

LUBRICATION
AND
MAINTENANCE
0 - 19 ETBE— This fuel is a mixture of unleaded gasoline
and up to 17 percent ETBE (Ethyl Tertiary Butyl

Ether).
Unleaded gasoline blended with ETBE is ac­ ceptable.
METHANOL—Do not use unleaded gasoline
blended with methanol. The use of this type of alco­ hol can result in engine performance and damage to
critical components. Engine problems that result
from the use of methanol possibly will not be covered by the new vehicle warranty.
Certain brands of unleaded gasoline contain a per­
centage of unidentified alcohol. These types of un­
leaded gasoline are not recommended.

ADDITIVES MIXED
WITH
GASOLINE
Use of fuel system cleaning additives should be
avoided. Many of these solutions could contain highly
active solvents. This type of solvent can be harmful
to the gasket and diaphragm material within the fuel system.

DIESEL
ENGINE FUEL REQUIREMENTS
All Diesel engines normally can use number 2D
Diesel fuel for most year-round operations. A fuel
conforming to ASTM Specification D-975 is recom­
mended. For extreme cold-weather operation (below
-18°C/0°F), or for prolonged cold-climate operation ei­
ther:
• Use No. ID fuel, or
• Add an equal quantity of kerosene to No. 2D fuel (a 50/50 mixture).
Both methods provide protection against fuel gel­
ling and waxing.
Diesel fuel seldom is without water contamination.
To help prevent fuel system malfunctions, drain all accumulated water from the separators periodically.

VACUUM OPERATED,
EMISSION
CONTROL
COMPONENTS

MAINTENANCE SCHEDULE
The following emission controls should be replaced
at the interval specified in the maintenance sched­

ule:

• Bi-level purge check valves
• Delay valves
• Heated air temperature sensor (HATS)
• Air cleaner vacuum motors

EXHAUST
GAS RECIRCULATION (EGR)
SYSTEM

MAINTENANCE SCHEDULE
Replace the EGR valve and tube, and clean the
passages at the interval specified in maintenance schedule. If necessary, refer to Group 25—Emission
Control Systems for additional information.
OXYGEN
(02)
SENSOR

MAINTENANCE SCHEDULE
Replace the 02 sensor at the interval specified in
maintenance schedule.

IGNITION
CABLES,
DISTRIBUTOR CAP AND

ROTOR

MAINTENANCE SCHEDULE
Replace the ignition cables, distributor cap, and ro­
tor at the interval specified in maintenance schedule.
Inspect the distributor for excessive wear and re­
place, as necessary. Refer to Group 8D—Ignition Sys­
tems for additional information.

IGNITION TIMING
MAINTENANCE SCHEDULE
Test and adjust, if necessary, the ignition timing at
the interval specified in maintenance schedule. Refer
to the specifications listed on the engine Emission Control Information label. Refer to Group 8D—Igni­
tion Systems and to Group 25—Emission Control Systems for additional service information.

SPARK
PLUGS MAINTENANCE SCHEDULE
Replace the spark plugs at the interval specified in
maintenance schedule. Refer to the Spark Plugs
chart below and to Group 8D—Ignition Systems for additional service information.

SPARK
PLUGS
ENGINE
SPARK

PLUG
SPARK

PLUG
GAP
TORQUE

3.9L
5.2L
5.9L
RN12YC

RN12YC

RN12YC
0.9 mm
(0.035
in.)
0.9 mm
(0.035
in.)
0.9 mm
(0.035
in.) 41 N*m (30 ft. lb.)
41 NVn (30 ft. lb.)
41 N*m (30 ft. lb.)

J9100-17

BATTERY

MAINTENANCE SCHEDULE
Replace battery at interval specified in mainte­
nance schedule.

0
- 21
LUBRICATION
AND
MAINTENANCE

• SERVICE INFORMATION
All vehicles are equipped with a maintenance-free
(MF) battery when shipped from the factory (Fig. 10).
A maintenance-free battery does not have removable
cell caps and does not require additional water. Each MF battery has a visual battery condition in­
dicator (Fig. 11). When an adequate battery charge

exists,
the indicator will have a GREEN dot. When
battery charging is necessary, the indicator will be dark. When the indicator is light brown colored or
yellow, the battery should be replaced.
INSPECTION

WARNING; WEAR SAFETY
GLASSES,
RUBBER
GLOVES
AND
PROTECTIVE CLOTHING WHEN SER­
VICING
A
BATTERY.
THE
BATTERY ELECTROLYTE CONTAINS SULFURIC ACID
AND
WILL CAUSE HARM
IF IT
CONTACTS SKIN, EYES
OR
CLOTHING.
IF SULFURIC ACID CONTACTS SKIN
OR
EYES,
GET

IMMEDIATE MEDICAL ATTENTION.
DO
NOT
SMOKE
IN
THE
VICINITY
OF A
BATTERY. KEEP OPEN
FLAMES
AND
SPARKS AWAY FROM BATTERY
FILLER CAPS BECAUSE EXPLOSIVE
GAS IS AL­

WAYS
PRESENT.

Battery maintenance should be completed before
the beginning of every winter season.
Use the following battery maintenance and inspec­
tion procedure. (1) Disconnect the battery negative cable and then
the positive cable.
(2) Clean the battery cables and terminal posts
with a wire brush and a battery terminal cleaner. (3) Remove the battery holddown strap. Clean the
battery tray with a solution of baking soda and wa­
ter. Rinse and dry the battery tray.
(4) Position the battery in the tray and install the
holddown strap. Do not over-tighten the nuts.
(5) Connect the battery positive cable and then the
negative cable to the battery.
(6) Apply a small amount of chassis lubricant (or
an equivalent protective coating) to the cable termi­

nals.

RUBBER/PLASTIC
COMPONENTS

INSPECTION Components should be inspected at the same time
as scheduled underhood maintenance is conducted.
Rubber/plastic components should be replaced imme­ diately if there is any evidence of wear. Inspect the exterior surface of rubber hoses and ny­
lon tubing for evidence of heat damage. The rubber
hose and nylon tubing located close to an exhaust
manifold should be given special attention. Verify
the nylon tubing located at these areas has not col­ lapsed.
INCREASED

ELECTROUTE CAPACITY
SEALED

VENT
CAPS TEST
INDICATOR ENVELOPE

SEPARATORS
BATTERY
HOLD DOWN
RK92

Fig. 10 Maintenance-Free (MF)
Battery

O.K. TO
JUMP START
BATTERY

CONDITION
INDICATOR
J9100-26
DARKENED
INDICATOR
WITH
GREEN
DOT
•
BATTERY CHARGE
OK '
•
FLUID LEVEL
OK

DARKENED
INDICATOR
NO
GREEN
DOT
•
BATTERY CHARGE
LOW
FLUID LEVEL
OK
LIGHT
OR
BRIGHT INDICATOR

•
BATTERY CHARGE UNKNOWN

•
FLUID uEv'EL
LOW
(CHARGE
MAY
STILL
BE
SUFFICIENT
TO
START YOUR
CAR)
Fig. 11
Battery
Condition Indicator
Inspect all the hose connections. Verify they are se­
cure and there is no fluid leakage.
ENGINE MOUNTS Inspect the rubber in the engine mounts for exces­
sive wear. Slight wear at the ends will not affect the
functioning of an engine mount. If excessive engine
movement is detected, the engine mount(s) should be
replaced.

DRIVE
BELTS

MAINTENANCE SCHEDULE Replace the drive belt(s) and adjust the drive ten­
sion at the interval specified in maintenance sched­

ule.
If necessary, refer to Group 7—Cooling Systems.

•

LUBRICATION
AND
MAINTENANCE
0 - 23 GEAR SHIFTER BOOTS
Inspect the shifter boots periodically for stone and
heat damage. Replace, if necessary.
SEVERE DRIVING CONDITIONS The interval between the transmission drain and
refill maintenance should be decreased to:
• NV4500 manual transmission—every 29 000 km (18,000 miles)
• Automatic transmission—every 19 000 km (12,000
miles)
A severe driving condition includes:
• Extended operation with heavy cargo loads
• Driving in deep mud or snow
• Off-road operation (4WD)
• Trailer towing
• Operation as a commercial vehicle
• Snow plowing
MANUAL TRANSMISSIONS

INSPECTION/LUBE
OIL
LEVEL
The transmission should be checked for leaks when
other service is necessary under the vehicle. To check
the lube oil level, remove the fill hole plug (Fig. 2 ). If the level is below the bottom of the fill hole, raise
the level to the bottom of the fill hole with:
• Castrol Syntorq for NV4500 transmissions
• SAE 5W-30 engine oil (API Service SG, SG/CD or
SG/CE) for Getrag 360 transmissions.

Fig.
2 NV4500 Manual
Transmission

DRAIN
AND
FILL
The NV4500 transmission fluid should be changed
according to the intervals listed in the Manual
Transmission—Drain & Refill Intervals chart below.

Also,
refer to the Fluid Capacities chart.
AUTOMATIC TRANSMISSIONS

FLUID
LEWEL
It is recommended that the fluid (ATF) level in au­
tomatic transmissions be checked while involved
with other underhood maintenance.
Vehicle operation with an incorrect ATF level
will greatly reduce the life of the transmission.
Fig.
3 Getrag 360 Manual
Transmission

MANUAL TRANSMISSION-DRAIN & REFILL INTERVALS
Normal

Service
Light
Duty
Cycle

60 000
km
37,500
miles

Heavy
Duty
Cycle

58 000
km
36,000
miles

Severe
Service
29 000
km
18,000
miles

J9000-43

The condition of the ATF also should be deter­
mined. If the ATF is dark in color and has a strong odor, the fluid should be changed. Also the filter should be replaced and the bands adjusted.
The following procedure must be used to check the
automatic transmission fluid (ATF) level.
(1) Position the vehicle on level ground.
(2) Operate the engine at idle speed.
(3) Apply the parking brake.
(4) Place the gear selector in N (neutral).
(5) Remove the dipstick from the tube. Wipe it
clean and determine if the ATF is hot or warm.
Hot ATF has a temperature of approximately
82°C (180°F). Warm ATF is when its temperature
is between 29-52°C (85-125°F). (6) Wipe the dipstick clean and completely insert it
into the tube. Remove the dipstick from the tube and
observe the ATF level.
(7) If the ATF is hot, the level should be in the
crosshatched area that is marked OK.
(8) If the ATF is warm, the level should be be­
tween the two dimples.