1993 DODGE TRUCK wheel

25
- 12
EMISSION
CONTROL
SYSTEMS
EGR
DIAGNOSIS
CHART

NOTE: ALL TESTS MUST BE MADE
WITH
FULLY
WARM ENGINE RUNNING CONTINUOUSLY FOR
AT
LEAST TWO MINUTES
WARNING: BE SURE
TO
APPLY PARKING BRAKE AND/OR BLOCK WHEELS BEFORE PERFORMING IDLE CHECK
OR
ADJUSTMENT,
OR ANY
ENGINE RUNNING TESTS
OR
ADJUSTMENTS.

Condition
Possible Cause
Correction

EGR
VALVE STEM

DOES
NOT MOVE
ON

SYSTEM
TEST.
(a) Cracked, leaking, disconnected or
plugged hoses.

EGR
VALVE STEM

DOES
NOT MOVE
ON

SYSTEM
TEST.

OPERATES
NORMALLY
ON EXTERNAL

VACUUM
SOURCE.
ENGINE
WILL
NOT

IDLE.
DIES OUT
ON

RETURN
TO
IDLE
OR

IDLE
IS
VERY ROUGH
OR SLOW.
(a) Defective control system—Plugged passages.
(b) Defective control system—solenoid or solenoid control circuit,
(a) High EGR valve leakage in closed
position.
(b) EGR tube to intake manifold leak.
(c) Solenoid or control signal to solenoid failure. (a)
(b)
(a)
(b)
(a) Verify correct hose connections and leak
check and confirm that alt hoses are open.
If defective hoses are found, replace hose
harness.
Disconnect hose harness from EGR vacuum
transducer and connect auxiliary vacuum supply. Raise engine rpm to 2000 rpm and hold. Apply 10" Hg vacuum while checking
valve movement. If no valve movement oc­
curs,
replace valve/transducer assy. If valve
opens (approx. 3mm or 1/8" travel), hold
supply vacuum to check for diaphragm
leakage. Valve should remain open 30
seconds or longer. If leakage occurs, replace
valve/transducer assy. If valve is satisfac­
tory, check control system. Remove throttle body and inspect port (slot
type) in throttle bore and associated passage in throttle body. Use suitable sol­
vent to remove deposits and check for flow
with light air pressure. Normal operation
should be restored to EGR system. Refer to Group 14. General Diagnosis "On
Board Diagnostics" to check solenoid.
If removal of vacuum hose from EGR valve
does not correct rough idle,
(a
1)
Turn
engine off. Remove the air cleaner ex­ posing the inlet to the throttle body.
(a2) Disconnect the backpressure hose from the EGR valve.
(a3) Using a nozzle with a rubber grommet con­ nection, direct compressed air (50 to 60 psi)
down through the steel backpressure tube on
the EGR valve while opening and closing the
throttle blade.
(a4) If the sound from the compressed air changes distinctly in step a3, the poppet is leaking
and air is entering the intake manifold. Replace the EGR valve.
Remove tube and visually inspect tube seal
on gasket. Tube end should be uniformally
indented on gasket with no signs of leak. If
signs of exhaust gas leakage are present, replace gaskets and tighten flange nuts to
23 N-m (200 in. lbs.). If an intake plenum
leak persists, replace EGR tube and gaskets,
following installation instructions.
Verify correct hose connections and leak
check and confirm that all hoses are open. If defective hoses are found, replace nose
harness.
(cl) Refer to Group 14, General Diagnosis "On Board Diagnostics" to check solenoid. (b)
(c)
NOTE:
DO
NOT
ATTEMPT
TO CLEAN BACK-PRESSURE EGR VALVE, REPLACE
ENTIRE VALVE/TRANSDUCER ASSEMBLY
IF
NECESSARY.

9225-26

25
- 14
EMISSION
CONTROL
SYSTEMS

HEATER

RELAYS
J9114-240

Fig.
6 Air
intake
Heaters—Diesel
Engine

low. When the ignition key is turned to the ON po­
sition, the solenoids will make a clicking noise. This
indicates they are energized. Refer to Group 14, Fuel
System for air intake heater relay operation.
WHEEL

WELL
J9114-67

Fig.
7 Air Intake Heater
Relays—Diesel
Engine

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).

COMPONENT AND SYSTEM INDEX

Name
Group-page

AUDIO
SYSTEMS
8F-1
SERVICE
PROCEDURES 8F-7
TEST PROCEDURES 8F-2
BATTERY/STARTER/GENERATOR SERVICE 8B-1 BATTERY SERVICE PROCEDURES 8B-1
GENERATOR SERVICE 8B-6
SPECIFICATIONS 8B-9
STARTER SERVICE PROCEDURES 8B-4
BODY COMPONENTS 23-1 CAB/BODY INTERIOR COMPONENTS
23-35

DOORS
23-21
EXTERIOR COMPONENTS 23-1
FIXED GLASS
23-29
PAINT
CODE CHART
23-54

REFINISHING PROCEDURES
23-54

BRAKES
5-1 BENDIX DISC BRAKE 5-37 BRAKE ADJUSTMENTS-BRAKE BLEEDING 5-7
BRAKE DIAGNOSIS 5-3

CHRYSLER
DISC BRAKE 5-27 DRUM BRAKES—ELEVEN INCH 5-46
DRUM BRAKES-TWELVE INCH 5-50
GENERAL INFORMATION 5-1 MASTER CYLINDER—COMBINATION VALVE-BRAKE
LINES 5-10
PARKING BRAKES 5-56
POWER BRAKE BOOSTER-BRAKE PEDAL 5-20 POWER BRAKE VACUUM PUMP-DIESEL ENGINE. . 5-22

REAR
WHEEL ANTILOCK
(RWAL)
BRAKES 5-59
SPECIFICATIONS 5-65
CHIME/BUZZER WARNING
SYSTEMS
8U-1
CLUTCH 6-1 CLUTCH DIAGNOSIS 6-2 CLUTCH SERVICE 6-11
COOLING SYSTEM 7-1
DIAGNOSIS 7-4
ENGINE ACCESSORY DRIVE BELTS 7-40
ENGINE BLOCK HEATERS 7-48

SERVICE
PROCEDURES 7-15 SPECIFICATIONS 7-49
ELECTRICAL 8A-1 BATTERY TEST PROCEDURES 8A-2
ENGINE STARTER MOTOR TEST PROCEDURES.... 8A-9
GENERAL INFORMATION 8A-1
GENERATOR TEST PROCEDURES ON VEHICLE . . . 8A-13
GROUP INDEX 8A-1
SPECIFICATIONS 8A-18
BATTERY/STARTING/CHARGING
SYSTEMS
DIAGNOSTICS 8A-1

EMISSION
CONTROL
SYSTEMS.
25-1 AIR INJECTION SYSTEM—5.9L HDC-GAS ENGINE . 25-15 COMPONENT REMOVAL/INSTALLATION 25-17 EVAPORATIVE EMISSION CONTROLS 25-6
EXHAUST EMISSION CONTROLS 25-10
GENERAL INFORMATION 25-1
ENGINES 9-1 3.9L ENGINE SERVICE PROCEDURES 9-17 5.2L ENGINE SERVICE PROCEDURES 9-47
5.9L (DIESEL) ENGINE SERVICE PROCEDURES . . . 9-107
Name
Group-page

5.9L ENGINE SERVICE PROCEDURES 9-77 ENGINE DIAGNOSIS 9-5
STANDARD SERVICE PROCEDURES 9-1
EXHAUST SYSTEM AND INTAKE MANIFOLD 11-1
EXHAUST SYSTEM DIAGNOSIS 11-3
GENERAL INFORMATION 11-1

SERVICE
PROCEDURES (DIESEL ENGINES) 11-17

SERVICE
PROCEDURES (GASOLINE ENGINES) 11-4
SPECIFICATIONS 11-27
FRAME AND BUMPERS 13-1 ATTACHED COMPONENTS 13-30
BUMPERS
13-1
FRAME 13-20
SNOW PLOW 13-3
FRONT SUSPENSION AND AXLE 2-1 FRONT SUSPENSION—2WD VEHICLES 2-7
FRONT SUSPENSION—4WD VEHICLES 2-14 FRONT WHEEL ALIGNMENT 2-3
GENERAL INFORMATION 2-1 MODEL 44 FRONT AXLE 2-17
MODEL 60 FRONT AXLE 2-49
TORQUE SPECIFICATIONS 2-75
FUEL SYSTEM 14-1 ACCELERATOR PEDAL AND THROTTLE CABLE . . . 14-25
DIESEL
FUEL INJECTION—COMPONENT DESCRIPTION/SYSTEM OPERATION 14-76

DIESEL
FUEL INJECTION-GENERAL DIAGNOSIS. . 14-88

DIESEL
FUEL INJECTION-SERVICE
PROCEDURES
14-106

FUEL DELIVERY SYSTEM-EXCEPT DIESEL 14-3
FUEL DELIVERY-DIESEL ENGINE 14-15 FUEL TANKS 14-20
GENERAL INFORMATION 14-1 MULTI-PORT FUEL INJECTION (MPI)-COMPONENT DESCRIPTION/SYSTEM OPERATION-EXCEPT
DIESEL
14-29
MULTI-PORT FUEL INJECTION
(MPlj-COMPONENT
REMOVAL/INSTALLATION-EXCEPT DIESEL .... 14-64
MULTI-PORT FUEL INJECTION (MPI)—GENERAL DIAGNOSIS-EXCEPT DIESEL 14-43

SERVICE
ADJUSTMENTS-DIESEL
14-122
SPECIFICATIONS
14-123

HEATING AND AIR CONDITIONING 24-1 CLIMATE CONTROL SYSTEM
24-29

COMPRESSOR
SERVICE
(SD-709)
24-21 DIAGNOSTIC PROCEDURES 24-3
GENERAL INFORMATION 24-1 REFRIGERANT SYSTEM SERVICE PROCEDURES . . 24-17
TORQUE SPECIFICATIONS
24-39

HORNS 8G-1
SERVICE
PROCEDURES 8G-3
TEST PROCEDURES 8G-1

IGNITION
SYSTEMS
8D-1 COMPONENT IDENTIFICATION/SYSTEM OPERATION. 8D-1
COMPONENT REMOVAL/INSTALLATION 8D-18 DIAGNOSTICS/SERVICE PROCEDURES 8D-7
IGNITION
SWITCH
8D-25

SPECIFICATIONS
8D-28

INSTRUMENT PANEL AND GAUGES 8E-1

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