1993 DODGE TRUCK engine oil

•

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.

•

EMISSION
CONTROL
SYSTEMS
25 - 9 (4) Turn engine off and remove PCV valve from
cylinder head (valve) cover. The valve should rattle
when shaken (Fig. 11).
Fig. 11
Shake
PCV Valve-Typical
Replace the PCV valve and retest the system if it
does not operate as described in the preceding tests.
Do not attempt to clean the old PCV valve.
(5) If the paper is not held against the opening in
cylinder head (valve) cover after new valve is in­ stalled, the PCV valve hose may be restricted and
must be replaced. The passage in the intake manifold
must also be checked and cleaned. To clean the intake manifold fitting, turn a 1/4
inch drill (by hand) through the fitting to dislodge
any solid particles. Blow out the fitting with shop air. If necessary, use a smaller drill to avoid remov­
ing any metal from the fitting.
CRANKCASE
BREATHER/FILTER-GAS POWERED

ENGINES
The crankcase breather/filter (Fig. 12) is located on
the cylinder head (valve) cover. It must be kept clean and lubricated. At the recommended interval, remove
the filter and wash it thoroughly in kerosene or sim­ ilar solvent. Lubricate or wet the filter by inverting
it and filling with SAE 30 engine oil. Filter must
then be thoroughly drained. More frequent service
may be necessary for vehicles operated extensively on short run, stop and go or extended engine idle ser­

vice.
The filter must be replaced at correct intervals. Re­
fer to Lubrication and Maintenance, Group 0 in this service manual. 8925-28
Fig. 12 Crankcase Breather/Filter—Gas Powered
Engines

25 - 16
EMISSION
CONTROL
SYSTEMS

•

DOWNSTREAM
dciicc
HOSE
RELIEF
HOLES
J9325-37

Fig.
2 Air Injection
Pump
Operation cessive noise is fault of air injection system, discon­
nect drive belt and operate engine.
CAUTION:
Do not lubricate air injection pump. Wipe
all oil off of pump
housing.
Oil in the pump
will
cause
rapid deterioration and failure.

CAUTION:
Completely cover the air pump before

cleaning
the engine or underhood compartment. Refer to the Component Removal/Installation section
of this group for air pump replacement procedures.

CHECK
VALVE—AIR
INJECTION
TUBE
A check valve (Fig. 1) is located on each of the air
injection downstream tubes. The check valve has a one-way diaphragm which pre­
vents hot exhaust gases from backing up into the hose and pump. The check valve will protect the system if
the air injection pump belt fails, an air hose ruptures or exhaust system pressure becomes abnormally high.

TESTING
CHECK
VALVE
The check valves are not repairable. To determine
condition of valve, remove the rubber air tube from
the inlet side of each check valve. Start the engine. If
exhaust gas is escaping through the inlet side of
valve, it must be replaced.
Refer to the Component Removal/Installation section
of this group for check valve replacement procedures.

AIR
PUMP
DIAGNOSIS

Condition
Possible
Cause
Correction

EXCESSIVE
BELT
NOISE
(a)
Loose
belt
or defective auto,
belt
tensioner. (a) Refer to
Group
7,
Cooling.

(b) Seized pump. (b) Replace pump.

EXCESSIVE
PUMP
NOISE.

CHIRPING
(a) Insufficient break-in.
(a) Recheck for
noise
after
1600 km.

(1,000
miles) of operation.

EXCESSIVE
PUMP
NOISE CHIRPING,
RUMBUNG, OR KNOCKING (a) Leak in
hose.

(a) Locate
source
of leak
using
soap

solution
and correct.
(b)
Loose
hose.
(b)
Reassemble
and replace or tighten

hose
clamp.
(c)
Hose
touching other engine parts. (c) Adjust
hose
position.

(d) Relief valve inoperative. (d) Replace
relief
valve.
(e) Check valve inoperative. (e) Replace check valve.
(f)
Pump
mounting fasteners
loose.
(f) Tighten mounting
screws
as specified.

(g)
Pump
failure.
(g)
Replace pump.
NO AIR SUPPLY (ACCELERATE ENGINE TO 1500 RPM AND OBSERVE AIR
FLOW
FROM

HOSES.
IF THE
FLOW
INCREASES
AS
THE

RPM'S
INCREASE, THE
PUMP
IS
FUNCTION­
ING NORMALLY. IF NOT, CHECK POSSIBLE

CAUSE.
(a)
Loose
drive belt.
(b)
Leaks
in
supply
hose.

(c) Leak at fitting(s). (a) Refer to
Group
7,
Cooling.

(b) Locate leak and repair or replace as required.
(c) Tighten or replace
clamps.

(d) Check valve inoperative. (d) Replace check valve.
J9325-38

•

EMISSION
CONTROL SYSTEMS
25 - 19
EGR
VALVE

REMOVAL

The EGR valve and the electric EGR transducer
(EET) are serviced as one unit.
(1) Disconnect vacuum hose to EGR valve/trans­
ducer assembly. Note position of hoses on EGR valve
and transducer for easier installation.
(2) Remove EGR mounting bolts (Fig. 5).

Fig.
5 EGR
Valve
Mounting
Bolts

(3) Remove EGR valve and gasket. Discard old
gasket. Clean intake manifold mating surface and
check for cracks.

INSTALLATION
(1) Place new EGR gasket on intake manifold. (2) Install EGR valve. Tighten mounting bolts to
23 N*m (200 in. lbs.) torque. (3) Connect vacuum hose to valve/transducer as­
sembly.

EGR
TUBE-GAS POWERED ENGINES

REMOVAL
(1) Remove air filter housing.
(2) Remove the spark plug cable loom and plug ca­
bles from valve cover mounting stud at rear of right
valve cover. Position spark plug cables to top of valve cover.
(3) Disconnect two vacuum hoses at exhaust gas
recirculation (EGR) valve. (4) Remove 2 EGR valve mounting bolts (Fig. 5)
and remove EGR valve. Discard old gasket.
(5) Disconnect electrical connector at engine oil
pressure sending unit.
(6) To prevent damage to oil pressure sending unit,
a special tool, such as number C-4597 must be used
(Fig. 6). Remove sending unit from engine.
(7) Loosen EGR tube mounting nut at intake man­
ifold (Fig. 7).
Fig.
6 Oil
Pressure
Sending
Unit—Removal/Installation

Fig.
7 EGR Tube—Typical
(8) Remove EGR tube mounting bolts at exhaust
manifold (Fig. 7) and remove EGR tube.

INSTALLATION
(1) Clean the EGR tube and exhaust manifold (at
EGR tube mounting point) of any old gasket mate­

rial.
(2)
Install a new gasket to exhaust manifold end of
EGR tube. (3) Install EGR tube to both manifolds. Tighten
mounting nut at intake manifold. Tighten two
mounting bolts at exhaust manifold to 23 N»m (204 in. lbs.) torque.
(4) Coat the threads of the oil pressure sending
unit with thread sealant. Do not allow any of the
thread sealant to get into the sending unit opening
or the opening at the engine. Install sending unit to