1993 DODGE TRUCK 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.

•
HEATING AND AIR CONDITIONING 24 - 39 LOU¥ER ASSEMBLIES
REMOVAL
(1) Remove faceplate.
(2) Set faceplate with trim surface down, insert a
small screwdriver tip into the outlet housing pivot

hole.

(3)
While forcing down louver assembly pivot pin,
pull louver assembly out of rear of faceplate (Fig. 9).
INSTALLATION

(1) Position louver assembly, bottom pivot first,
into the faceplate outlet housing. The bottom pivot
pin is a smaller diameter than the top pivot pin.
(2) While deflecting the upper louver assembly
pivot pin, carefully swing the assembly into housing, so the felt pads are not damaged. Ensure top and bot­
tom pivot pins are properly engaged. (3) Install faceplate.
TORQUE
SPECIFICATIONS

DESCRIPTION
fORQUE
DESCRIPTION

Compressor (SD-709) Cylinder Head Bolts 32 N-m (24 ft. lbs.)
Magnetic Clutch Hex Nut... 37 N-m (27 ft. lbs.)
Mounting Bolts 27 N-m (20 ft. lbs.)
Oil Filter Plug
10
N-m (7 ft. lbs.)
Service Valve-to-Compressor Fitting* ........ 47 N-m (35 ft. lbs.)
TORQUE

H-Valve Control Head Torx Drive Bolts
11
N-m
(100
in. lbs.)
H-Valve Plumbing Sealing Plate Bolt 23 N-m (200 in. lbs.)
Refrigerant Cans-to-Manifold Gauge Set Nuts 9.5 N-m (7
ft.
lbs.)
•Wet Torque - Lubricate the service valve
coupling
threads and
O-rings
with
compressor
oil.
J9324-100

•

EMISSION
CONTROL
SYSTEMS
25
- 1
CONTENTS

page page

AIR INJECTION
SYSTEM-o
9L
HDC-GAS EVAPORATIVE EMISSION CONTROLS
6
ENGINE
15
EXHAUST EMISSION CONTROLS
10

COMPONENT
REMOVAL/INSTALLATION
17
GENERAL INFORMATION
1

GENERAL
INFORMATION

Throughout this group, references are made
to
par­
ticular 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
manual.
The 5.9L (V-8) gas powered engine will
be
referred
to
in
this group
as
either the: LDC (Light Duty Cy­ cle)
or
HDC (Heavy Duty Cycle) engine.
The
HDC
engine can
be
easily identified
by
the
use
of
an en­

gine mounted
air
injection pump. The 3.9L/5.2L/5.9L
LDC engine will not use
an
air
injection pump.
Maintenance requirements for LDC and HDC emis­
sion systems differ because
of
different load
and
op­
erating conditions. This section will cover emission control systems
for

the 3.9L (V-6), 5.2L (V-8), 5.9L LDC (V-8), 5.9L HDC (V-8) and 5.9L (in-line six cylinder) diesel engines.

SERVICE
REMINDER INDICATOR
(SRI)
LIGHT
The instrument panel mounted SRI light was for­
merly referred
to as the
emission maintenance
re­
minder (EMR) light.
It is
used with 5.9L HDC-gas
powered engines only.
It is
not
used with diesel
en­
gines.

The SRI system
is
incorporated into the powertrain
control module (PCM)
(the
PCM
was
formerly
re­

ferred
to as the
engine controller
or
SBEC).
The

PCM records
the
vehicles mileage and stores
it
into
memory every
8
miles. At that time, the PCM checks
for the 60,000 and 82,500 mileage trip points. When
the current mileage matches one
of
the above men­
tioned trip points,
the
SRI light
is
activated.
The following parts are
to
be replaced
at
either the
indicated mileage
or
when the SRI light remains
on

when the key
is in
the ON position. After performing
the required maintenance,
the
SRI light must
be
re­ set
to
turn the light
off.

96,000
km
(60,000 miles):
• Replace EGR Valve
• Clean EGR passage • Replace PCV Valve
132,000
km
(82,500 miles):
• Replace Oxygen Sensor
Refer
to
Group
0,
Lubrication and Maintenance
for

all required maintenance schedules.
Failure
to
perform
the
required maintenance
and

only reset the SRI light may be
a
violation of federal
law. Only after performing
the
required mainte­
nance, should the SRI light
be
reset.

RESETTING
SRI
LIGHT
(1) Connect
the
DRB
II
scan tool
to
the
data link
connector (Fig.
1)
in
the engine compartment.
TORQUE CONVERTER
CLUTCH RELAY
A/C
CLUTCH RELAY
.
STARTER RELAY

AUTO
SHUTDOWN RELAY FUEL PUMP RELAY DATA LINK
CONNECTOR POWERTRAIN
CONTROL
MODULE
J9314-164

Fig.
1
Data
Link
Connector
(2) Refer
to
DRB
II
scan tool operation
in
the ap­

propriate Powertrain Diagnostic Procedures manual. (3) Reset SRI light.

VEHICLE
EMISSION CONTROL INFORMATION
(VECI)
LABEL
All vehicles equipped with
a
gasoline powered
en­

gine have
a
VECI label. The 3.9L/5.2L/5.9L LDC-gas powered engine will
have
a
label that combines both emission control
in­

formation and vacuum hose routing.
EMISSION CONTROL
SYSTEMS

25
- 2
EMISSION
CONTROL
SYSTEMS

• This label is located in the engine compartment
(Fig. 2) and contains the following:
• Engine family and displacement
• Evaporative family
• Emission control system schematic
• Certification application
• Engine timing specifications (if adjustable)
• Idle speeds (if adjustable)
• Spark plug and gap The 5.9L HDC-gas powered engine will have two

labels.
One of the labels is located in the engine com­
partment (Fig. 2) and will contain vacuum hose rout­ ing only. The other is attached to the engine air
filter housing and will contain the following:
• Engine family and displacement
• Evaporative family
• Certification application
• Engine timing specifications (if adjustable)
• Idle speeds (if adjustable)
• Spark plug and gap There are unique labels for vehicles built for sale
in the state of California, the country of Canada and
for both Light Duty Cycle (LDC) and Heavy Duty Cycle (HDC) engines. Canadian labels are written in
both the English and French languages. These labels
Fig.
2
VECI
Label
Location
are permanently attached and cannot be removed
without defacing information and destroying it. The following VECI label illustrations are used
as examples only. If there are any differences be­
tween these illustrations and the VECI label, those shown on vehicle label should be used.
FEDERAL VEHICLE EMISSION CONTROL INFORMATION LABEL-TYPICAL
IMPORTANT VEHICLE INFORMATION
THIS VEHICLE CONFORMS
TO U.S. EPA
REGULATIONS APPLICABLE
TO
1993
MODEL YEAR
NEW
LIGHT-DUTY
TRUCKS
WITH
A
CURB

WEIGHT
GREATER
THAN
3.450
POUNDS
AT ALL
ALTITUDES.

C/5

>]
* BASIC IGNITION TIMING AND IDLE FUEL/AIR MIXTURE HAVE BEEN
PRESET
AT THE
FACTORY.
SEE THE
SERVICE MANUAL FOR PROPER
PROCEDURES AND OTHER ADDITIONAL INFORMATION.
o ADJUSTMENTS MADE
BY
OTHER THAN APPROVED SERVICE MANUAL PROCEDURES
MAY
VIOLATE FEDERAL AND
STATE
LAWS.
CAUTION: APPLY PARKING
BRAKE
WHEN SERVICING VEHICLE. 5.2
LITER

PCR5.9T5FEY4
PTAPG
SPARK
PLUGS

.035 in. GAP
RC12YC
NO ADJUSTMENTS NEEDED TEE
CONNECTOR
W/ORIFICE ROLLOVER VALVE
W/ORIFICE
PCV VALVE-
TO CLIMATE CONTROL,
VEHICLE SPEED CONTROL, 4X4 AXLE
(WHEN EQUIPPED)
INTAKE MANIFOLD
"
ORIFICE EVAP PURGE
SOLENOID FILTER
M THROTTLE M M BODY M
M fO~0| M TO
AIR

—J
CLEANER
-CRANKCASE
BREATHER J9325-22

EMISSION
CONTROL SYSTEMS
25 - :

CALIFORNIA VEHICLE EMISSION CONTROL INFORMATION LABEL-TYPICAL

or,

o_ UJ
u_

U
^
>
CO

CQ

o
IMPORTANT
VEHICLE
INFORAAATION

THIS VEHICLE CONFORMS
TO
U.S.
EPA AND STATE
OF
CALIFORNIA REGULATIONS APPLICABLE
TO 1993
MODEL YEAR NEW
LIGHT-DUTY

TRUCKS
AND
MEDIUM-DUTY VEHICLES PROVIDED
THAT
THIS VEHICLE
IS
ONLY INTRODUCED
INTO
COMMERCE FOR
SALE
IN THE

STATE
OF
CALIFORNIA.
*
BASIC
IGNITION TIMING
AND
IDLE FUEL/AIR
MIXTURE HAVE BEEN
PRESET
AT THE
FACTORY.
SEE THE
SERVICE MANUAL
FOR
PROPER
PROCEDURES
AND
OTHER
ADDITIONAL
INFORMATION.

o
ADJUSTMENTS MADE
BY
OTHER
THAN
APPROVED
SERVICE MANUAL PROCEDURES
MAY
VIOLATE
FEDERAL
AND
STATE
LAWS.

CAUTION:
APPLY
PARKING BRAKE
WHEN
SERVICING
VEHICLE.
5.2
LITER

PCR360T5FHB2
PTAPG
SPARK
PLUGS

.035
in.
GAP RC12YC NO ADJUSTMENTS NEEDED

RHC/CO/NOx
STDS.
.50/9.0/1.0
TEE
CONNECTOR

W/ORIFICE
TO

ATMOSPHERE
ROLLOVER
VALVE

W/ORIFICE

/

PCV
VALVE-

TO
CLIMATE
CONTROL,

VEHICLE SPEED
CONTROL,
4X4
AXLE

(WHEN
EQUIPPED)

INTAKE
MANIFOLD"
ORIFICE
—
M

r-
M
EVAP
PURGE

SOLENOID
FILTER
THROTTLE
BODY
FUEL
TANK PRESSURE
RELIEF/

ROLLOVER
VALVE
W/ORIFICE

FUEL

PRESSURE

REGULATOR
1

r—O
O^-CRANKCASE
TO
AIR

CLEANER
APPLICABLE
TO
35

GALLON
FUEL
TANK
ONLY
J9325-23

CANADA VEHICLE EMISSION CONTROL INFORMATION LABEL-ATYPICAL
VEHICLE
EMISSION
CONTROL
INFORAAATION

THIS
VEHICLE
WAS
BUILT
FOR
SALE
IN
CANADA
AND WAS
DESIGNED
TO
MEET
THE
EMISSION
REQUIREMENTS
OF THE
CANADA
MOTOR
VEHICLE
ACT.
IT
WAS NOT
DESIGNED
TO
COMPLY
WITH
THE

REQUIREMENTS
OF
OTHER
COUNTRIES.

'
BASIC
IGNITION TIMING
AND
FUEL
INJECTION
MIXTURE HAVE BEEN
PRESET
AT
THE
FACTORY.
ADJUSTMENTS
SHOULD
NOT
BE
MADE
DURING
ROUTINE
SERVICE.

CAUTION:
APPLY
PARKING BRAKE
WHEN
SERVICING
VEHICLE.
5.2
LITRES

SPARK
PLUGS
0.9
mm GAP
RC12YC

RENSEIGNEMENTS RELATIFS
AU
SYSTEME
ANTIPOLLUTION

LE
PRESENT
VEHICULE
A
ETE
FABRIQUE'
POUR ETRE
VENDU
AU
CANADA
ET
IL
A
ETE
CONCU
DE

MANIERE
A
SE
CON
FORMER
AUX
NORMES
ANTIPOLLUTION
DE LA LOI SUR LA
SECURITE
DES
VEHICULES
AUTOMOBILES
DU
CANADA.
IL
N'EST
PAS
DESTINE'
A SE
CON
FORMER
AUX
NORMES
D'AUTRES
PAYS.

*
LE
CALAGE
DE
L'ALLUMAGE
INITIAL
ET LE
MELANGE
D'INJECTION
D'ESSENCE
ONT
ETC:
PREREGLE'S
A
L'USINE.
N'EFFECTUEZ
AUCUN
REGLAGE
LORS
DE
TRAVAUX
D'ENTRETIEN
REGULIERS.

AVERTISSEMENT:
SERREZ
LE
FREIN
DE
STATIONNEMENT
POUR
FAIRE
L'ENTRETIEN
OU
LA
RE'PARATION
DU
VEHICULE.
5.2
LITRES

,
BOUGIES

ECARTEMENT
0.9 mm
RC12YC

ROLLOVER VALVE W/ORIFICE CLAPET DE DECHARGE AVEC AJUTAGE EVAP PURGE SOLENOID

E'LECTROVALVE
DE
_
FUEL TANK PURGE
DU
FILTRE RESERVOIR
D'ESSENCE
-

A CHARBON ACTIF /
TO CLIMATE CONTROL,
VEHICLE SPEED CONTROL.
4X4 AXLE (WHEN EQUIPPED)
VERS LA COWMAN DE
DE

TEMPERATURE. LE REGULATEUR DE VITESSE, LESSIEU
4X4 (LORSQU'AINSI EQUIPE')
INTAKE MANIFOLD ORIFICE AJUTAGE DE LA TUBULURE D'ADMISSION FUEL TANK PRESSURE RELIEF/
I

ROLLOVER VALVE W/ORIFICE
CLAPET DE DECHARGE
DU
RESERVOIR D'ESSENCE AVEC AJUTAGE FUEL PRESSURE REGULATOR
REGULATEUR DE PRESSION DE CARBURANT CHECK VALVE W/ORIFICE
SOUPAPE
A
DOUBLE EFFET
-
AVEC AJUTAGE AAAP SENSOR
"

CAPTEUR DE PRESSION
ABSOLUE DE LA TUBULURE THROTTLE BODY
CORPS DE PAPILLON APPLICABLE
TO
35

GALLON FUEL TANK ONLY
UNIQUEMENT APPLICABLE
AU

RESERVOIR D'ESSENCE DE
132
L