1993 DODGE TRUCK Service Repair Manual

7 - 42 COOLING SYSTEM
• SERPENTINE DRIVE BELT DIAGNOSIS-DIESEL ENGINE

Condition

Possible
Cause
Correction

RIB
CHUNKING (1) Foreign objects imbedded in
(1) Remove foreign objects from

(ONE
OR
MORE
RIBS
(1)
pulley grooves.
pulley
grooves.
Replace
belt.

HAS
SEPARATED
pulley grooves.
Replace
belt.

FROM
BELT BODY) (2) Installation damage.
(2) Replace
belt.

RIB
OR
BELT
WEAR
(1) Pulley(s) misaligned.
(1)

Align
pulley(s).
(2) Abrasive environment.
(2)
Clean pulley(s). Replace
(2)

belt
if necessary.
(3)
Rusted
pulley(s).
(3) Clean rust from pulley(s).
(4)
Sharp
or jagged pulley groove tips.
(4)
Replace pulley.
(5) Rubber
deteriorated.

(5)
Replace
belt.

LONGITUDINAL
(1) Belt has mistracked from
(1)
Replace
belt.

BELT
CRACKING
(1)
pulley groove. Replace
belt.

(CRACKS
BETWEEN

TWO
RIBS)
pulley groove.
Replace
belt.

(CRACKS
BETWEEN

TWO
RIBS)
(2) Pulley groove tip has worn away
(2) Replace
belt.

(2)
rubber to tensile member.

BELT
SLIPS
(1) Belt slipping because of
0) Replace tensioner.
(1)
insufficient tension.
(2) Incorrect
belt.

(2)
Replace
belt.

(3) Belt or pulley subjected to
(3)
Replace
belt
and clean pulleys.

substance
(belt
dressing,
oil,

ethylene
glycol)
that
has reciuced friction.
(4) Driven component bearing
failure.

(4)
Replace
faulty
component bearing.
(5) Belt glazed and hardened from
(5)
Replace
belt.

(5)

heat
and excessive slippage.

"GROOVE
JUMPING" (1) Belt tension
either
too
(1) Replace tensioner.

(BELT
DOES
NOT 5 (1)

high
or too low. Replace tensioner.

MAINTAIN
CORRECT
high
or too low.

POSITION
ON PULLEY) (2) Incorrect
belt.

(2) Replace
belt.

(3) Pulley(s) not
within
design
(3)
Replace pulley(s).
tolerance.
(4) Foreign object(s) in grooves.
(4)
Remove foreign objects
from grooves.
(5) Pulley misalignment.
(5)
Check and Replace.
(6) Belt cordline is broken.
(6)
Replace
belt.

BELT
BROKEN
0)
Excessive
tension.
0) Replace
belt
and

(NOTE:
IDENTIFY 0)
tensioner.

AND
CORRECT
PROBLEM
BEFORE
(2) Incorrect
belt.

(2) Replace
belt.

NEW
BELT
IS (2)
Replace
belt.

INSTALLED)
(3) Tensile members damaged during
(3) Replace
belt.

(3)

belt
installation.
(4) Severe misalignment.
(4)
Check and replace.
(5) Bracket, pulley, or bearing
(5)
Replace
defective
component
(5)

failure.
ana
belt.

NOISE
0) Belt slippage.
(1) Replace
belt
or
belt
tensioner.

(OBJECTIONAL
0)
Belt slippage.
Replace
belt
or
belt
tensioner.

SQUEAL,
SQUEAK,
(2) Bearing noise.
(2) Locate and
repair.

OR
RUMBLE
IS (2)
Bearing noise.

HEARD
OR FELT (3) Belt misalignment.
(3) Replace
belt.

WHILE
DRIVE
BELT (3)
Belt misalignment.
Replace
belt.

IS
IN OPERATION) (4) Belt-to-pulley mismatch.
(4) Install correct
belt.

J9107-74

•

*IF VEHICLE IS NOT EQUIPPED
WITH
POWER

STEERING,
THIS
WILL
BE
AN
IDLER PULLEY.
J9307-26
Fig.
2 Beit
Routing
- 3.9U5.2L/5.9L
LDC-Gas
Engine

AUTOMATIC TENSIONER

J9307-55
Fig.
3 Beit Routing—5.9L HDC-Gas Engine—With
A/C

(2)
Rotate tensioner assembly clockwise (as viewed
from front) until tension has been relieved from belt.
(3) Remove belt from idler pulley first.

(4)
Remove belt from vehicle.

INSTALLATION

CAUTION:
When
installing
serpentine accessory

drive
belt, belt
must
be
routed
correctly.
If not, en­
gine
may
overheat
due to
water
pump
rotating in
COOLING
SYSTEM
7 - 43

AUTOMATIC TENSIONER

J9307-56

Fig.
4 Belt Routing—5.9L
HDC-Gas
Engine—Without A/C

'POWER STEERING PUMP IS
NOT
BELT DRIVEN
Fig.
5 Belt Routing-5.9L Diesel-With A/C
wrong
direction. Refer
to
(Fig.
2) for
correct engine
belt routing.
The
correct belt with correct length

must
be
used.

(1) Position drive belt over all pulleys except idler
pulley. This pulley is located between generator and
A/C compressor.
(2) Attach a socket/wrench to pulley mounting bolt
of automatic tensioner (Fig. 7).

7 - 44
COOLING
SYSTEM

•

Fig.
6 Belt Routing-5.9L Diesel-Without A/C
Fig.
7 Belt Tensioner-3.9L/5.2U5.9L
LDC-Gas
Engine
(3)
Rotate socket/wrench clockwise. Place belt over
idler pulley. Let tensioner rotate back into place. Re­
move wrench. Be sure belt is properly seated on all
pulleys.

(4)
Check belt indexing marks. Refer to the pro­
ceeding Automatic Belt Tensioner for more belt in­
formation. 5.9L
HDC-GAS
ENGINE

REMOVAL
Drive belts are equipped with a spring loaded au­
tomatic belt tensioner (Fig. 8). This belt tensioner
will be used on all belt configurations, such as with or without power steering or air conditioning. For
more information, refer to Automatic Belt Tensioner,
proceeding in this group.

Fig.
8 Belt Tensioner—5.9L
HDC-Gas Engine

(1) Attach a socket/wrench to pulley mounting bolt
of automatic tensioner (Fig. 8). (The threads on this
bolt are left hand).
(2) Relax the tension from the belt by rotating the
tensioner counterclockwise (as viewed from front) (Fig. 8). When all belt tension has been relaxed, re­
move belt from tensioner pulley first and other pul­ leys last.

INSTALLATION

CAUTION:
When installing serpentine
accessory

drive belt, belt must
be
routed correctly.
If not, en­
gine
may
overheat
due to
water pump rotating
in

wrong
direction. Refer
to
(Figs.
3 or 4) for
correct
engine
belt routing.
The
correct belt with correct length must
t^e
used.

CAUTION:
if the
pulley
is to be
removed from
the

tensioner,
its
mounting bolt
has left
hand threads.

(1) Position drive belt over all pulleys except ten­
sioner pulley. (2) Attach a socket/wrench to pulley mounting bolt
of automatic tensioner (Fig. 8).

•

COOLING
SYSTEM
7 - 45 (3) Rotate socket/wrench counterclockwise. Install
belt over tensioner pulley. Let tensioner rotate back into place. Remove wrench. Be sure belt is properly
seated on all pulleys.

5«9L
DIESEL ENGINE

REMOVAL
Drive belts on diesel engines are equipped with a
spring loaded automatic belt tensioner (Fig. 9). Fig­
ure 9 displays the tensioner for vehicles without air conditioning.
This belt tensioner will be used on all belt config­
urations, such as with or without air conditioning.
For more information, refer to Automatic Belt Ten­ sioner, proceeding in this group.
Fig.
9 Belt Tensioner—5.9L
Diesel
Engine—Typical
(1) A 3/8 inch square hole is provided in the auto­
matic belt tensioner (Fig. 9). Attach a 3/8 inch drive-
long handle ratchet to this hole.
(2) Rotate ratchet and tensioner assembly counter­
clockwise (as viewed from front) until tension has
been relieved from belt.
(3) Remove belt from water pump pulley first.
(4) Remove belt from vehicle.

INSTALLATION

CAUTION:
When installing serpentine
accessory

drive belt, belt must
be
routed correctly.
If not, en­

gine
may
overheat
due to
water pump rotating
in

wrong
direction. Refer
to
(Figs.
5 or 6) for
correct

engine
belt routing.
The
correct belt with correct
length
must
be
used.

(1) Position drive belt over all pulleys except wa­
ter pump pulley. (2) Attach a 3/8 inch ratchet to tensioner.
(3) Rotate ratchet and belt tensioner counterclock­

wise.
Place belt over water pump pulley. Let ten­ sioner rotate back into place. Remove ratchet. Be
sure belt is properly seated on all pulleys.

AUTOMATIC
BELT
TENSIONER
Drive belts on all engines are equipped with a
spring loaded automatic belt tensioner (Figs. 10, 11
or 12). This belt tensioner will be used with all belt configurations, such as with or without power steer­
ing or air conditioning.

Caution:
Do not
attempt
to
check belt tension with

a
belt tension
gauge
on
vehicles equipped with
an

automatic
belt tensioner. Fig.
10 Belt Tensioner—3.9U5.2U5.9L
LDC-Gas
Engine
On 3.9L/5.2L and 5.9L LDC-gas engines, the ten­
sioner is equipped with an indexing arrow (Fig. 13)
on back of tensioner and an indexing mark on ten­
sioner housing. If a new belt is being installed, arrow
must be within approximately 3 mm (1/8 in.) of in­ dexing mark (Point B—Fig. 13). Belt is considered
new if it has been used 15 minutes or less. If this
specification cannot be met, check for:
• The wrong belt being installed (incorrect length/
width)
• Worn bearings on an engine accessory (A/C com­
pressor, power steering pump, water pump, idler pul­ ley or generator)
• A pulley on an engine accessory being loose
• Misalignment of an engine accessory
• Belt incorrectly routed. Refer to (Figs. 2, 3 or 4) On 3.9L/5.2L and 5.9L LDC-gas engines, a used
belt should be replaced if tensioner indexing arrow
has moved beyond point A (Fig. 13).

7
- 4S
COOLING
SYSTEM

•
PULLEY BOLT IDLER
iUlLTPULLEY-
TENSIONER
MOUNTING
BOLT TENSIONER
ASSEMBLY
TENSIONER \
rULLC,\
, / ^ J9307-64 ,

Fig.
11 Beit Tensioner—5.9L
HDC-Gas
Engine

MOUNT.
BOLT
3/8
SQUARE HOLE
ACCESSORY

DRIVE
BELT AUTOMATIC
BELT

TENSIONER
J9307-59

Fig.
12 Belt Tensioner—5.9L
Diesel
Engine—Typical

3MLm.2Lm.9L
LDG°GA8
ENGINES

REMOVAL
(1) Remove accessory drive belt. Refer to Belt Re­
moval/Installation in this group. (2) Disconnect wiring and secondary cable from ig­
nition coil.
(3) Remove ignition coil from coil mounting
bracket (two bolts). Do not remove coil mounting
bracket from cylinder head. (4) Remove tensioner assembly from mounting
bracket (one nut) (Fig. 13).

WARNING: BECAUSE
OF
HIGH
SPRING
PRES­
SURE,
DO
NOT ATTEMPT
TO
DISASSEMBLE
AUTO­
MATIC
TENSIONER.
UNIT
IS
SERVICED
AS AN

ASSEMBLY
(EXCEPT
FOR
PULLEY).
TENSIONER
MOUNTING NUT
INDEXING ARROW
INDEXING MARK

J9207-17

Fig.
13 indexing Marks-3.9L/5.2L/5.9L
LDC-Gas
Engine
(5) Remove pulley bolt. Remove pulley from ten­
sioner.

INSTALLATION
(1) Install pulley and pulley bolt to tensioner.
Tighten bolt to 61 Nnn (45 ft. lbs.).
(2) Install tensioner assembly to mounting bracket.
An indexing tab is located on back of tensioner.
Align this tab to slot in mounting bracket. Tighten nut to 67 Nnn (50 ft. lbs.) torque.
(3) Connect all wiring to ignition coil. (4) Install coil to coil bracket. If nuts and bolts are
used to secure coil to coil bracket, tighten to 11 Nnn (100 in. lbs.) torque. If coil mounting bracket has
been tapped for coil mounting bolts, tighten bolts to 5 Nnn (50 in. lbs.) torque.

CAUTION:
To
prevent damage
to
coil case, coil mounting bolts must
be
torqued.

(5) Install drive belt. Refer to Belt Removal/Instal­
lation in this group. (6) Check belt indexing marks (Fig. 13).

•

COOLING
SYSTEM
7 - 47 5.9L HDC'GAS ENGINE

REMOVAL

(1) Remove accessory drive belt. Refer to Belt Re­
moval/Installation in this group. (2) Remove tensioner mounting bolt (Fig. 11) and
remove tensioner.

CAUTION:
If the
pulley
is to be
removed
from
the

tensioner,
its
mounting
bolt has
left
hand
threads.

WARNING:
BECAUSE
OF
HIGH SPRING
PRES­
SURE,
DO
NOT ATTEMPT TO
DISASSEMBLE
AUTO­ MATIC TENSIONER. UNIT
IS
SERVICED
AS AN

ASSEMBLY
(EXCEPT FOR PULLEY).
INSTALLATION
(1) Install pulley and pulley bolt to tensioner (ob­
serve the previous CAUTION). Tighten bolt to 88
N*m (65 ft. lbs.) torque.
(2) Install tensioner assembly to mounting bracket.
A dowel pin is located on back of tensioner (Fig. 14).
Align this to dowel hole (Fig. 15) in tensioner mount­
ing bracket. Tighten bolt to 41 N-m (30 ft. lbs.)
torque.
(3) Install drive belt. Refer to Belt Removal/Instal­
lation in this group.
5.9L DIESEL ENGINE

REMOVAL
(1) Remove accessory drive belt. Refer to Belt Re­
moval/Installation in this group. (2) Remove tensioner mounting bolt (Fig. 12) and
remove tensioner.

WARNING:
BECAUSE
OF
HIGH SPRING
PRES­
SURE,
DO
NOT ATTEMPT
TO
DISASSEMBLE
AUTO­ MATIC TENSIONER. UNIT
IS
SERVICED
AS AN

ASSEMBLY
(EXCEPT FOR PULLEY).
BELT
TENSIONER

DOWEL
PIN
J9307-63

Fig.
14 Tensioner
Dowel
Pin—5.9L
HDC-Gas
Engine
Fig.
15 Tensioner
Mounting
Bracket
Dowel

Hole—5.9L
HDC-Gas
Engine

INSTALLATION
(1) Install pulley to tensioner.
(2) Install tensioner assembly to mounting bracket.
A dowel is located on back of tensioner. Align this
dowel to hole in tensioner mounting bracket. Tighten
bolt to 41 N*m (30 ft. lbs.) torque.
(3) Install drive belt. Refer to Belt Removal/Instal­
lation in this group.

7
- 48
COOLING
SYSTEM

•
ENGINE BLOCK HEATERS

GENERAL
INFORMATION
DESCRIPTION AND OPERATION An optional engine block heater
is
available with
for
all
models. The heater
is
equipped with
a
power
cord that
is
located behind the grille. The cord
is at­

tached
to an
engine compartment component with
tie-straps.
The
heater warms
the
engine providing easier engine starting
and
faster warm-up
in low

temperatures. The heater
is
mounted
in a
core hole of the engine cylinder block (in place of
a
freeze plug)
with
the
heating element immersed
in
engine cool­ ant.
The
power cord
is
located behind
the
radiator
grille. Connect the power cord
to a
grounded 110-120
volt AC electrical outlet with
a
grounded, three wire
extension cord.

WARNING:
DO NOT
OPERATE ENGINE
UNLESS
BLOCK
HEATER
CORD
HAS
BEEN
DISCONNECTED
FROM POWER
SOURCE
AND
SECURED
IN
PLACE.

THE POWER
CORD
MUST BE
SECURED
IN ITS RE­
TAINING
CLIPS
AND ROUTED AWAY FROM
EX­
HAUST MANIFOLDS AND MOVING
PARTS.

REMOVAL
(1) Disconnect negative battery cable from battery.
(2) Drain coolant from radiator and cylinder block.
(3) Remove pow^r cord from heater (Fig.
1 or 2).

(4)
Loosen bolt
at
center
of
block heater. Remove
block heater.
INSTALLATION (1) Thoroughly clean cylinder block core hole
and

block heater seat. (2) Insert block heater (with element loop pointing

down).

(3) With heater fully seated, tighten center bolt se­
curely.

(4)
Fill cooling system with recommended coolant.
Refer
to
Refilling Cooling System section
in
this
group.
Fig.
1
Engine
Block
Heater—Except
Diesel

Fig.
2
Engine
Block
Heater—Diesel
Engine

SPECIFICATIONS

GENERAL
INFORMATION

The following specifications are published from the
latest information available at the time of publica­
tion. If anything differs between the specifica­
tions found on the Vehicle Emission Control
Information (VECI) label and the following spec­
ifications, use specifications on VECI label. The
VECI label is located in the engine compartment.
DRIVE
BELT
TENSION

All engines are equipped with a spring loaded au­
tomatic belt tensioner. Do not attempt to check belt
tension with a belt tension gauge on vehicles
equipped with an automatic belt tensioner. Refer to
Automatic Belt Tensioner in this group.

CAPACITIES

ENGINE
MODEL
DRIVE
CAPACITY

ENGINE
MODEL
DRIVE

QUARTS
LITERS

3.9L D150,
D250
2WD
15.1 14.0
5.2L D150, D250,
D350
2WD
17.0 16.0
5.2L
RAMCHARGER
4WD
16.5 15.7
5.2L W150, W250,
W350
4WD
17.0 16.0
5.9L D150, D250,
D350
AND
RAMCHARGER
2WD
15.5 14.7
5.9L
RAMCHARGER
4WD
15.0 14.0
5.9L W150, W250,
W350
4WD
15.5 14.7

DIESEL
ALL
MANUAL

16.0 15.1

DIESEL
ALL
AUTOMATIC

17.0 16.1

J9207-41

TORQUE

DISCMPflON
TORQUE

TORQUi
Automatic Belt Tensioner Pulley
Bolt-3.9l/2.5L/5.9LLDC

Gas
Engine
61
N-m (45
ft.
lbs.)

Automatic Belt Tensioner Pulley
Bolt
-
5.9L
HDC
Gas
Engine
88
N-m
(65
ft.
lbs.)

Automatic Belt Tensioner-to- Mounting Bracket
-
3.9L/5.2L/ 5.9L IDC
Gas
Engine
67
N-m
(50
ft.
lbs.)

Automatic Belt Tensioner-to- Mounting Bracket
-
5.9L

HDC
Gas
Engine
41
N-m
(30
ft.
lbs.)

Fan
Shroud
Mounting Nuts
11
N-m
(95
in. lbs.)

Hose
Clamps
4
N-m
(34
in. lbs.)

Idler
Pulley Mounting
Bolt
-
All
Gas
Engines
61
N-m
(45
ft.
lbs.)
Radiator Mounting
Bobs
11
N-m
(95
in. lbs.)
Radiator
Top
Mounting Brackets- Diesel Engine...... 23 N-m
(17
in. lbs.)

Thermal
Viscous
Fan-to-Hub- Diesel Engine
57
N-m
(42
ft.
lbs.)

Thermostat
Housing
Bolts
-
All Except Diesel 23 N-m (200 in. lbs.)
Thermostat
Housing
Bolts
-
Diesel Engine
24
N-m
(18
ft.
lbs.)

Water
Pump
Mounting
Bolts
-
All
Gas
Engines
40
N-m
(30
ft.
lbs.)

Water
Pump
Pulley
Bolts
-
All
Gas
Engines
27 N-m (20
ft.
lbs.)

Water
Pump
Mounting
Bolts
-
Diesel Engine
24
N-m(18ft.
lbs.) J9307-60