engine DODGE TRUCK 1993 Service Manual PDF

•

CLUTCH
6 - 13

APPLY
LIGHT
COAT
OF

HI-TEMP
GREASE
TO
THESE

SURFACES
BEFORE
INSTALLATION
J9106-15

Fig.
7 Input Shaft Lubrication
Points
(Typical)

ENGINE BLOCK
CLUTCH
DISC AND COVER

J9006-32

Fig.
8
Clutch
Housing
Installation—Gas
Engine
(4)
Verify that clutch housing alignment dowels
are in good condition and properly seated. (5) Transfer slave cylinder, release fork and boot,
fork pivot stud and wire/hose brackets to new hous­ ing.

CLUTCH HOUSING INSTALLATION
(1) Lubricate release fork and pivot contact sur­
faces with Mopar High Temperature wheel bearing grease before installation.
Fig.
9
Clutch
Housing/Transmission

Installation—Diesel
Engine
(2) Align and install clutch housing on transmis­
sion. Tighten housing bolts closest to alignment dow­
els first and to torque values indicated (Figs. 8 and

9).
(3) Install transmission-to-engine strut after in­
stalling clutch housing. Tighten bolt attaching strut
to clutch housing first and engine bolt last.
(4) Install transmission and transfer case if
equipped. Refer to procedure in Group 21.

RELEASE
BEARING REPLACEMENT
(1) Remove transmission.
(2) On models with gas engine and new style re­
lease fork, remove clutch housing for access to re­
lease fork, pivot stud and release bearing retainer springs. (3) Disconnect release bearing from release fork
and remove bearing (Fig. 10). (4) Inspect bearing slide surface on transmission
front bearing retainer. Replace retainer if slide sur­ face is scored, worn or cracked. (5) Inspect release lever and pivot stud. Be sure
stud is secure and in good condition. Be sure lever is
not distorted or worn. Replace release lever retainer spring if bent or damaged. (6) Lubricate crankshaft pilot bearing, input shaft
splines, bearing retainer slide surface, lever pivot
ball stud and release lever pivot surface with Mopar
high temperature bearing grease. (7) Install release lever and release bearing. Be
sure lever and bearing are properly secured. (8) Install clutch housing, if removed.

en
PEDAL
SUPPORT
CYLINDER FLUID

RESERVOIR

PEDAL SHIFT
CLUTCH FLUID LINE (DIESEL ENGINE)
CLUTCH FLUID LINE (GAS ENGINE)

SLAVE

CYLINDER O
I—
e HI
O
x CLUTCH
HOUSING
WITH

GAS

ENGINE CLUTCH
HOUSING
SLAVE

CYLINDER
WITH

DIESEL

ENGINE SHIELD
J9206-1

Fig. 14
Clutch
Linkage
And
Pedal
Components

•

CLUTCH
6-17
CLUTCH PEDAL INSTALLATION

(1) Lubricate pedal shaft, pedal shaft bore and all
bushings with Mopar Multi Mileage grease. (2) Insert pedal pin into cylinder push rod. Then
position clutch pedal in support. (3) Slide pedal shaft through clutch pedal bore and
bushings. (4) Install bolt that retains pedal shaft in support.
(5) Secure push rod to pedal pin with wave washer,
flat washer and retaining ring.

FLYWHEEL SERVICE
Inspect the flywheel whenever the clutch disc,
cover and housing are removed for service. Check
condition of the flywheel face, hub, ring gear teeth,
and flywheel bolts. Minor scratches, burrs, or glazing on the flywheel
face can be scuff sanded with 180 grit emery cloth. However, the flywheel should be replaced if the disc
contact surface is severely scored, heat checked,
cracked, or obviously worn. Cleanup of minor flywheel scoring should be per­
formed with surface grinding equipment. Remove
only enough material to reduce scoring (approximate­
ly 0.001 - 0.003 in.). Heavy stock removal is not rec­
ommended. Replace the flywheel if scoring is severe
and deeper than 0.076 mm (0.003 in.). Excessive
stock removal can result in flywheel cracking or
warpage after installation; it can also weaken the flywheel and interfere with proper clutch release. Check flywheel runout if misalignment is sus­
pected. Runout should not exceed 0.08 mm (0.003
in.).
Measure runout at the outer edge of the fly­
wheel face with a dial indicator. Mount the dial in­
dicator on a stud installed in place of one of the
flywheel attaching bolts. Clean the crankshaft flange before mounting the
flywheel. Dirt and grease on the flange surface may cock the flywheel causing excessive runout. Check condition of the flywheel hub and attaching

bolts.
Replace the flywheel if the hub exhibits cracks in the area of the attaching bolt holes. Install new attaching bolts whenever the flywheel
is replaced and use Mopar Lock N' Seal, or Loctite
242 on replacement bolt threads.
Recommended flywheel bolt torques are:
• 75 N»m (55 ft. lbs.) for gas engine flywheels
• 137 N*m (101 ft. lbs.) for diesel flywheels Inspect the teeth on the starter ring gear. If the
teeth are worn or damaged, the flywheel should
be replaced as an assembly. This is the recom­ mended and preferred method of repair.
In cases where a new flywheel is not readily avail­

able,
a replacement ring gear can be installed. How­
ever, the following precautions must be observed to
avoid damaging the flywheel and replacement gear.
(a) Mark position of the old gear for alignment
reference on the flywheel. Use a scriber for this
purpose.
(b) Wear protective goggles or approved safety
glasses. Also wear heat resistent gloves when han­
dling a heated ring gear. (c) Remove the old gear by cutting most of the
way through it (at one point) with an abrasive cut­ off wheel. Then complete removal with a cold chisel
or punch. (d) The ring gear is a shrink fit on the flywheel.
This means the gear must be expanded by heating in order to install it. The method of heating and expanding the gear is extremely important. Ev­
ery surface of the gear must be heated at the same
time to produce uniform expansion. An oven or
similar enclosed heating device must be used. Tem­
perature required for uniform expansion is 325-350° F.

CAUTION:
Never
use an
oxy/acetylene torch
to re­
move
the old
gear,
or to
heat
and
expand
a new

gear.
The
high temperature
of the
torch flame
will

cause
localized heating
and
damage
the
flywheel.
In

addition,
using
the
torch
to
heat
a
replacement gear

will
cause uneven heating
and
expansion.
The
torch
flame
will
also
anneal
the
gear
teeth
resulting
in
rapid wear
and
damage
after
installation.

(e) The heated gear must be installed evenly to
avoid misalignment or distortion. A shop press and
suitable press plates should be used to install the
gear if at all possible.
(f) Be sure to wear eye and hand protection.
Heat resistent gloves and safety goggles are needed
for personal safety. Also use metal tongs, vise
grips,
or similar tools to position the gear as neces­sary for installation.
(g) Allow the flywheel and ring gear to cool
down before installation. Set the assembly on a
workbench and let it cool in normal shop air.

CAUTION:
Do not
use water,
or
compressed
air to

cool
the
flywheel.
The
rapid cooling produced
by

water
or
compressed
air can
distort,
or
crack
the
gear
and
flywheel.

COOLING SYSTEM

CONTENTS page

DIAGNOSIS
... 4

ENGINE
ACCESSORY
DRIVE BELTS
40

ENGINE
BLOCK HEATERS
48

GENERAL
INFORMATION
Throughout this group, references are made to partic­
ular vehicle models by alphabetical designation or by
the particular vehicle nameplate. A chart showing a
breakdown of alphabetical designations is included in
the Introduction section at the beginning of this man­
ual.
5.9L gas powered engines will be' referred to as ei­
ther: LDC (Light Duty Cycle) or HDC (Heavy Duty
Cycle).

COOLING
SYSTEM
The cooling system regulates engine operating tem­
perature. It allows the engine to reach normal oper-
page

SERVICE
PROCEDURES
15

SPECIFICATIONS
; 49
ating temperature as quickly as possible. It also
maintains normal operating temperature and pre­
vents overheating.
The cooling system also provides a means of heat­
ing the passenger compartment and cooling the auto­
matic transmission fluid (if equipped). The cooling system is pressurized and uses a centrifugal water
pump to circulate coolant throughout the system.
An optional factory installed maximum duty cool­
ing package is available on most models. This pack­ age will provide additional cooling capacity for
vehicles used under extreme conditions such as
trailer towing in high ambient temperatures.
NOTE: HEATER
COOLANT FLOW
CIRCUIT
IS
ALWAYS

OPEN
EXCEPT
WHEN
IN MAX. A/C
OR
OFF
MODES
HEATER
INTAKE MANIFOLD
COOLANT FLOW "METERED" FROM REAR
TO

FRONT
AND
BELOW EXHAUST
HEAT
CROSSOVER
SHUT
OFF
VALVE

A/C
ONLY COOLANT FLOW
-
PUMP
TO

CYLINDER BLOCK,
UP
THROUGH CYLINDER HEADS
TO
INTAKE MANIFOLD WATER
BOX TO
RADIATOR-TO PUMP

•BYPASS
THERMOSTAT CLOSED-HIGH FLOW
THERMOSTAT OPEN
- LOW
FLOW
J9207-18

Fig.
1
Cooling
System
Routing—3.9U5.2L Engine—Typical

7 - 2
COOLING
SYSTEM

•

NOTE: HEATER
COOLANT FLOW
CIRCUIT
IS
ALWAYS

OPEN
EXCEPT
WHEN
IN MAX. A/C
OR
OFF
MODES
HEATER
INTAKE MANIFOLD
COOLANT FLOW "METERED" FROM REAR
TO

FRONT
AND
BELOW EXHAUST HEAT
CROSSOVER
SHUT
OFF
VALVE

A/C
ONLY COOLANT FLOW
-
PUMP
TO

CYLINDER
BLOCK,
UP
THROUGH
CYLINDER
HEADS
TO
INTAKE MANIFOLD WATER BOX
TO
RADIATOR
—
TO PUMP

•BYPASS
THERMOSTAT CLOSED-HIGH FLOW
THERMOSTAT OPEN
-
LOW FLOW

CYLINDER
HEAD
RR07B52

Fig.
2
Cooling
System
Routing—5.9L (V-8 Gas)—Typical All vehicles are equipped with either a 3.9L (V-6),
a 5.2L (V-8), a 5.9L (LDC-gas V-8), a 5.9L (HDC-gas
V-8) or a 5.9L (in-line 6 cylinder diesel) engine.
As coolant temperature reaches approximately

220°F,
the engine idle speed is increased by the pow-
ertrain control module (PCM) to provide increased
cooling system performance. The PCM was formerly
referred to as the engine controller or SBEC.

COOLING
SYSTEM
COMPONENTS—EXCEPT

DIESEL
ENGINE
The cooling system consists of:
• A down-flow radiator
• Thermal viscous fan drive
• Fan shroud
• Radiator pressure cap
• Thermostat
• Coolant reserve/overflow system
• Transmission oil cooler (automatic transmission)
• Coolant
• Water pump (to circulate coolant)
• Hoses and hose clamps Coolant flow circuits for 3.9L (V-6) and 5.2L (V-8)
engines with water cooled intake manifolds are
shown in figure 1. Coolant flow circuits for 5.9L (V-8 Gas) engines
with water cooled intake manifolds are shown in fig­ ure 2.
COOLING
SYSTEM
COMPONENTS-DIESEL

ENGINE
Coolant flow circuits for 5.9L (diesel) engines with
water cooled intake manifolds are shown in figure 3. The cooling system (Fig. 3) consists of: a cross-flow
radiator, engine driven cooling fan, thermal viscous
fan drive, fan shroud, radiator pressure cap, thermo­ stat, coolant reserve/overflow system, transmission
oil cooler (if equipped with an automatic transmis­
sion),
coolant, water pump, hoses and hose clamps.

SYSTEM
COOLANT ROUTING-DIESEL ENGINE
Coolant is drawn from radiator into the water
pump. Water pump output is directed to the engine oil cooler cavity of the cylinder block (Fig. 4). From the oil cooler cavity, the coolant circulates
around each cylinder. It then crosses to the lift pump
side of engine where it flows up into cylinder head
through openings in top of cylinder block (Fig. 4). Coolant flows past the valve bridges (Fig. 5), to ex­
haust manifold side of engine, to thermostat. As cool­ ant flows toward the thermostat, it provides cooling
for the injector nozzle.
When thermostat is closed (engine is below operating
temperature), coolant flows through bypass passage to
water pump inlet (Fig. 6). Once operating temperature is reached, the thermostat opens and blocks the bypass
passage. Coolant then flows to the radiator inlet.

• COOLING
SYSTEM
7 - 3
Fig. 3 Diesel Engine Cooling System-Typical

1.
Coolant
Flow from Cylinder
Block

2.
Coolant
to Thermostat
Housing

Fig. 4
Cylinder
Block
Coolant
Routing-Diesel Engine Fig 6 coolant Flow at Thermostat-Diesel Engine

DIAGNOSIS

PRELIMINARY
CHECKS

ENGINE COOLING SYSTEM OVERHEATING Establish what driving conditions caused the com­
plaint. Abnormal loads on the cooling system such as
the following may be the cause:

1.
PROLONGED IDLE, VERY HIGH AMBI­
ENT TEMPERATURE, SLIGHT TAIL WIND AT
IDLE, SLOW TRAFFIC, TRAFFIC JAMS, HIGH SPEED OR STEEP GRADES.
Driving techniques that avoid overheating are:
• Idle with A/C off when temperature gauge is at
end of normal range. * Increasing engine speed for more air flow is recom­
mended.

2.
TRAILER TOWING: Consult Trailer Towing section of owners manual.
Do not exceed limits.

3.
AIR CONDITIONING; ADD-ON OR AFTER
MARKET: A maximum cooling package should have been or­
dered with vehicle if add-on or after market A/C is
SYMPTOM AND ACTION

SYMPTOM
installed. If not, maximum cooling system compo­
nents should be installed for model involved per
manufacturer's specifications.

4.
RECENT SERVICE OR ACCIDENT RE­
PAIR:
Determine if any recent service has been performed
on vehicle that may effect cooling system. This may

be:

• Engine adjustments (incorrect timing)
• Slipping engine accessory drive belt(s) • Brakes (possibly dragging)
• Changed parts. Incorrect water pump or pump ro­
tating in wrong direction due to belt not correctly
routed
• Reconditioned radiator or cooling system refilling (possibly under filled or air trapped in system).
If investigation reveals none of the above as a
cause for an engine overheating complaint, refer to
the following Symptom and Action chart:
PRELIMINARY FIRST) ACTION
Blinking Engine Temperature
Warning Light or High Gauge indication - Without Coolant Loss
Normal during temporary operation
with
heavy load, towing
a
trailer,
high
outdoor temperatures, and/or on
a
steep
Loss
grade.

Coolant Loss
Hot Vehicle (Not Engine) Heat Damage,
Hot Carpet, Seat,
Hot
Catalytic
Converter,
Smoke, Burnt Odor
Hot Engine Crackling Noise Hot Smell
Severe Local Hot Spots
Coolant Color
Coolant Reserve Bottle Level Changes
Coolant Not Returning To Radiator
Improper refilling procedures
can
result
in
trapped air
in
the
system.
Subsequent
operation
of the
pressure cap and coolant reserve system
will
deaereate
the

cooling
system.
A low
coolant
level
will
then result
in the
Coolant Reserve
Tank. Add coolant.
If
condition persists,
refer
to
System
Diagnosis.

Check
heat shielding, exhaust
system,
engine emission controls, ignition
timing, engine misfiring.

A
moderate amount
of
sound from heating
metal
can
be
expected
with
any

vehicle. However,
a
crackling sound from
trie
thermostat
housing,
a hot
smell and/or severe local
hot
spots on
an
engine can indicate blocked coolant

passages,
bad castina, core sand deposits and subsequent blockage,
cracked cylinder block
or
head,
or
blown cylinder head gasket. Usually
accompanied
with
coolant
loss.

Coolant
color is
not
necessarily
an
indication
of
adequate
temperature
or

corrosion
protection.
Level changes
are to be
expected as coolant volume fluctuates
with
engine
temperature.
If the
level
in the
bottle
is
between
the
Maximum and Minimum
marks
at
normal engine operating temperature,
the
level
should
return
to

within
that
range
after
operation
at
elevated temperatures.

Coolant
will
not
return
to the
radiator
if the
radiator cap vent valve does
not

function,
if
an
air
leak destroys vacuum,
or if the
overflow
passage
is
blocked
or
restricted. Inspect
all
portions
of the
overflow
passage,
pressure

cap,
filler
neck nipple, hose, and
passages
within
the
bottle
for
vacuum leak
only. Coolant
return
failure
will
be
evident
by a low
level
in the
radiator.
Reserve
bottle
level
should increase during heat-up.

J9207-31

•
COOLING
SYSTEM
7 - 6 COOLING SYSTEM DIAGNOSIS (EXCEPT DIESEL)

CONDITION
AND
CHICK

OPTIONAL
M°¥
GAUGE
READS
LOW
(!) Verify
gauge
reading. Is a low temperature indicated?
(2) Is code 17 recorded in On Board
Diagnostics
memory?
(3) Is the
gauge
reading in the cold
range?

(4) Low coolant level during cold ambient temperatures
(accompanied
with poor heater performance).
(5) Coolant level is correct.

GAUGE
HEADING
HIGH.
NO
PRESSURE
BLOW
OFF
FROM
RADIATOR
PRESSURE
CAP
OR
STEAM
FROM
COOLANT

RESERVE
TANK.

(1) Verify
gauge
reading. Is a high temperature reading indicated?
(2)
Gauge
reading at
"H"
without
signs
of boiling.
(3) Low coolant level in radiator and coolant reserve tank.
(4) Coolant level in radiator is low. But not low in coolant reserve tank.
(5) Test coolant
freeze
point.
(6) Ensure proper coolant flow.
DIAGNOSIS

30° TO 40°

GAUGE
TRAVEL
IS
NORMAL

Normal
Gauge
Travel
(1) Inspect temperature
gauge
sending
unit. Refer to Group 8, Electrical. Repair or replace sending unit as necessary.
(2) If code 17 is recorded, replace the thermostat. If not, the thermostat is not the
cause
of the low
gauge
reading.
(3) Inspect for
disconnected
sending
unit electrical connector or incorrect
sending
unit. Ensure that
gauge
sending
unit is installed

and
not an indicator light switch.
(4)
WARNING:
DO NOT
REMOVE
THE
RADIATOR
CAP
OF A
HOT,
PRESSURIZED
ENGINE.
SERIOUS
INJURY
CAN

RESULT
FROM
SCALDING
COOLANT.

Inspect
coolant level in the coolant reserve tank and radiator.

Inspect
system
for leaks.
(5) Inspect heater door
controls.
Refer to Group 24, Heating and
Air
Conditioning.

TO
TOP
AMBIENT

High
Gauge
Reading
— Hot Weather — Heavy Load
(1) Compare
gauge
reading to
High
Gauge
Reading Illustration
above.

(2) Inspect for grounded
gauge,
sending
unit or circuit. Refer to
Group
8, Electrical.
(3) a — Pill to full.
b
— Inspect for leaks in
system
and repair as
necessary,

c
—
Ensure
radiator pressure cap was shut tight. Verify
proper
operation of the radiator cap upper and lower
seals.

(4) a —
Fill
to full,
b
— Inspect for leaks in the
system
and repair as
necessary,

c
— Inspect for leaks in the coolant reserve tank to radiator
hose.

d
— Verify proper operation of the radiator cap upper and lower
seals.

(5) a — Adjust coolant solution to
50/50
mixture of anti-freeze and water. Refer to Coolant in this
group,

b
— If a reading is not recorded or below
—
50, the mixture is
too
rich. Clean
system
and
fill
with a
50/50
mixture of
anti-freeze and water. Refer to Coolant in this
group.

(6) a •— With the thermostat open and a slight amount of coolant
removed,
inspect for coolant flow through the radiator at
the
filler
neck opening,

b
— Determine reason for lack of coolant flow and repair as
necessary.
J9007-69

7 - 6
COOLING
SYSTEM

• COOLING SYSTEM DIAGNOSIS (EXCEPT DIESEL)—CONTINUED
Condition and Checks
Diagnosis

(7) Other possible
causes.
(7) a — If
symptom
occurs
during high speed operation inspect for

plugged
air
inlet
side of the radiator or condenser,

plugged
radiator core tubes, add on A/C package
without
proper radiator, engine not operating
within
specifications,

dragging
brakes,
trailer
towing or
hill
climbing, or an insect screen.
b — If
symptom
occurs
during high or low
speed
operation inspect for: thermostat being stuck
partially
open if ambient

temperature
is
below
70°F
and
the vehicle
has
high

mileage,
plugged
air
inlet
side of the radiator or
condenser, add on
A/C
with
incorrect radiator.

c
— If
symptom
occurs
during low
speed
operation only, inspect the radiator fan drive. Repair as necessary.

TEMPERATURE
GAUGE
READS
HOT.
PRESSURE
CAP
VENTS
RESULTING
IN
STEAM
AND
COOLANT
TRANSFER
TO

COOLANT
RESERVE
TANK.
(1) Coolant
level
low in radiator and coolant reserve tank. (1) a —
Fill
cooling
system
and vent trapped air.
b — Inspect for leaks. Repair as necessary.

c
—
Ensure
that
pressure cap
is
completely shut and
seals.

d
— If
level
is low in radiator but normal in the coolant reserve tank, check the
filler
cap to coolant reserve
bottle

connection and pressure cap seal.
(2) Test coolant
freeze
point. (2) Adjust coolant to
50/50
mix of
anti-freeze
and
water.
Refer to

Coolant
section in this group.
(3)
Ensure
coolant
is
flowing through system. (3) a — With the coolant
level
low and the thermostat open, check
for coolant flow through the radiator at the
filler
neck.
b — If a
metal
cracking
sound
is heard, inspect for core sand restricting coolant flow through the
water
jacket
and/or a

faulty
cylinder head casting.
(4) Thermostat stuck in the
closed
position
(prevalent
in cold ambient temperatures). (4) Replace thermostat if found to be stuck in
closed
position.
Refer
to the Thermostat Testing section in this group.
(5) Cylinder head gasket leak. (5) Inspect for leaking cylinder head gasket
with
a commercially
available Block Leak Tester.
J9007-57

•

COOLING
SYSTEM
7 - 7 COOLING SYSTEM DIAGNOSIS (EXCEPT DIESELJ-GONTINUED

CONDITION
AND
CHECKS
DIAGNOSIS

TEMPERATURE
GAUGE
IS
INCONSISTENT,
CYCLES
AND/OR
IS
ERRATIC.

(1) Is cycle normal.
MID

(a)
Normal Gauge Reaction to Thermostat Cycle.

MID

(b) Normal Gauge Reaction at Stop After Heavy Use.
(c) Hot Water Build-Up is Normal at
Stop
after
Heavy Use.
(2)
Is
coolant in radiator low (air
will
build up in the cooling
system
(2)
Fill
system,
vent trapped air and check for leaks,
and
cause
the thermostat to open
late).

(3)
Is
a cylinder head gasket leak allowing exhaust
gas
to
enter
(3) a — Test for leaking cylinder head
gasket
leak
with
a
cooling
system
(exhaust
gas
building up in the cooling
system
will
commercially available Block Leak Tester,

cause
the thermostat to open
late).

b
— Check for coolant in engine oil.

c
— Inspect for
white
steam from exhaust
system.

(4)
Water pump impeller loose on shaft.
Loose
accessory
drive belt. (4) Repair or replace as necessary.

(5)
Air leak
on
the
suction
side of the
water
pump (allows air to build (5) Find leak and repair,
up
in cooling
system
causing
thermostat to open
late).

WARNING
LIGHT
GLOWS
ALL
THE
TIME
(VEHICLE
NOT
EQUIPPED
WITH
GAUGE).

(1) Inspect
temperature
gauge
sending
unit. The warning light
sending
(1)
Ensure
that
a warning light
sending
unit
is
installed, unit
has
a screwdriver slot in the electrode (used for calibration).

Gauge
sending
units do not have a slot in the electrode.

NO
GAUGE
READING
INITIALLY
THEN
HOT
INDICATION

(VEHICLE
EQUIPPED
WITH
GAUGE).

(1)
Gauge
stationary
until
very hot, then
moves
immediately to "H"
(1)
Vehicle
is
equipped
with
sending
unit for light not
gauge.
J9007-70