1993 DODGE TRUCK cooling

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

8B
- 6
BATTERY/STARTER/GENERATOR
SERVICE

•
GENERATOR SERVICE
CONTENTS
page

GENERATOR
REPLACEMENT-
DIESEL
ENGINE
8

GENERAL
INFORMATION
6

GENERAL
INFORMATION This section will cover generator removal
and in­

stallation.
The
generator
is not
serviceable. Informa­
tion covering on-vehicle testing
can be
found
in
Group
8A -
Battery/Starting/Charging/System Diag­
nostics. The standard equipment generator
on the D and W

bodies
is the 75 amp
generator.
The
Ramcharger
is
equipped with
the 90 amp
generator. When
a
vehicle
is equipped with
a
heavy duty package
or
diesel
en­

gine,
a 120 amp
generator
is
used.

GENERATOR
REPLACEMENT
-3.9L/5.2L/5.9L-LDC

GAS
ENGINE
Drive belts
on
these engines
are
equipped with
a

spring loaded automatic belt tensioner
(Fig. 1).
This
belt tensioner
is
used
on all
belt configurations.
For
more information, refer
to
Group
7 -
Cooling, Belt
Removal/Installation.

REMOVAL
(1) Disconnect negative cable from battery.
(2) Attach
a
socket/wrench
to
pulley mounting bolt
of automatic tensioner
(Fig. 1).

(3) Rotate tensioner assembly clockwise
(as
viewed
from front) until tension
has
been relieved from belt. (4) Remove belt from idler pulley first.
(5) Remove belt from vehicle.

(6)
Remove lower generator mounting bolt
and nut

(Fig.
2).

(7) Remove upper generator mounting bolt
and re­

move generator.
(8) Remove
B+
terminal
nut, 2
field terminal

nuts,
ground,
and
harness hold down nuts
(Fig. 3).

Remove wire connectors.

INSTALLATION
(1) Install harness
to
generator. Tighten nuts
as

follows:
• Ground terminal,
B+
terminal
and
Wire Harness Hold Down
7-10 N*m
(60-90
in.
lbs.).
• Field terminals
2.5-3 N-m
(20-30
in.
lbs.). (2) Install generator. Tighten both bolts
to 41 N»m

(30
ft.
lbs.).
page

GENERATOR
REPLACEMENT—3.9L/5.2L/
5.9L-LDC
GAS
ENGINE
6

GENERATOR
REPLACEMENT—5.9L
HDC-GAS
ENGINE
7
Fig.
1 Automatic Belt Tensioner—Belt
Removal/

Installation

Fig.
2
Generator
Mounting
Bolts

•

Fig.
3
Remove
or install
Wire
Connector
Assembly
CAUTION:
When
installing
serpentine
accessory

drive
belt,
the
belt
MUST
be
routed
correctly.
If not,
the engine may overheat due to the
water
pump ro­

tating
in the wrong
direction.
Refer to Group 7 -
Cooling
System
for
correct
engine
belt
routing.
The

correct
belt
with
the
correct
length
must be
used

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

(5)
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.
(6) Check belt indexing marks. Refer to Group 7 -
Cooling, Automatic Belt Tensioner.
(7) Connect negative cable to battery.

GENERATOR
REPLACEMENT—5.9L
HDC-GAS

ENGINE
Drive belts on these engines are equipped with a
spring loaded automatic belt tensioner (Fig. 4). This
belt tensioner is used on all belt configurations. For more information, refer to Group 7 - Cooling, Belt
Removal/Installation.

REMOVAL
(1) Disconnect negative cable from battery.
(2) Attach a socket/wrench to pulley mounting bolt
of automatic tensioner (Fig. 4). The threads on this
bolt are left hand.
BATTERY/STARTER/GENERATOR
SERVICE
8B - 7

Fig.
4 Automatic Belt Tensioner—5.9L
HDC-Gas
Engine
(3) Rotate tensioner assembly counterclockwise (as
viewed from front) until tension has been relieved
from belt.
(4) Remove belt from idler pulley first.
(5) Remove belt from vehicle.
(6) Remove lower generator mounting bolt and nut
(Fig. 5).

Fig.
5 Generator
Mounting
Bolts

(7) Remove upper generator mounting bolt and re­
move generator.
(8) Remove B+ terminal nut, 2 field terminal

nuts,
ground, and harness hold down nuts (Fig. 6).
Remove wire connectors.

8B
- 8
BATTERY/STARTER/GENERATOR
SERVICE

•

Fig.
6
Remove
or Install
Wire
Connector
Assembly
INSTALLATION

(1) Install harness to generator. Tighten nuts as
follows:
• Ground terminal, B+ terminal and Wire Harness
Hold Down 7-10 Nun (60-90 in. lbs.).
• Field terminals 2.5-3 Nun (20-30 in. lbs.).
(2) Install generator. Tighten both bolts to 41 Nun
(30 ft. lbs.).

CAUTION:
When
installing
the
serpentine
accessory

drive
belt,
the
belt
MUST
be
routed
correctly.
If not,

the
engine
may
overheat
due to the
water
pump
ro­

tating
in the
wrong
direction.
Refer
to
Group
7 -
Cooling
System
for
correct
engine
belt
routing.
The

correct
belt
with
the
correct
length
must
be
used

(3) Position drive belt over all pulleys except wa­
ter pump pulley.
(4) Attach a 3/8 inch rachet to tensioner.
(5) 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.
(6) Connect negative cable to battery.
GENERATOR
REPLACEMENT—DIESEL
ENGINE

(1) Remove negative cable from battery.
(2) Remove generator drive belt. See Group 7 -
Cooling System, for instructions. (3) Remove B+ terminal nut, 2 field terminal

nuts,
ground, and harness hold down nuts (Fig. 6).
Remove wire connectors. (4) Remove upper mounting bolt and nut (Fig. 7). (5) Remove lower mounting bolt.
(6) Remove generator from the vehicle.
(7) To install generator, first tighten lower mount­
ing bolt to 43 Nun (32 ft. lbs.). Tighten upper bolt to
24 Nun (18 ft. lbs.).
Fig.
7
Remove
or Install Generator
Mounting
Bolts