1993 DODGE TRUCK clutch

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power steering fluid transmission rear entertainment oil dipstick seats height adjustment

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Page 539 of 1502

DODGE TRUCK 1993 Service Repair Manual
8W
- 64
WIRING DIAGRAMS
TO DAYTIME
RUNNING LIGHTS
MODULE C—A21
140R

SEE
SH 46) l4UK
TO
A/C

ELECTRONIC CYCLING
^A21 hob
SWITCH

(SEE
SH 70)
TO
MESSAGE

CENTER (DIESEL)
(SEE

Page 542 of 1502

DODGE TRUCK 1993 Service Repair Manual
WIRING DIAGRAMS 8W - 87
ENGINE COOLANT TEMPERATURE SWITCH TRANSMISSION
THERMO SWITCH

(LEFT

SIDE
REAR
OF ENGINE BLOCK)
-K4
18BK/LB

-K4
18BK/LB

-K4
18BK/LB

-K4
20BK/LB
K2
20TN

Page 599 of 1502

$DODGE TRUCK 1993 Service Repair Manual 8W - 124 WIRING DIAGRAMS • \j i i i i i i i i 1 I r 11 II i I i M ig VIEWED FROM WIRE END OF CONNECTOR ^ AUTO TRANSMISSION ONLY CAV IGNITION SYSTEM CIRCUITS SHEET K32 20WT/B$

8W
- 124
WIRING
DIAGRAMS

•
\j i i i i i i i i 1 I r 11 II i I i M ig
VIEWED
FROM WIRE

END
OF
CONNECTOR

^
AUTO TRANSMISSION ONLY
CAV

IGNITION SYSTEM CIRCUITS
SHEET

K32 20WT/BK WATER
IN
FUEL
SENSOR
25
2 K2 20TN/BK ENGINE COOLANT TEMP
SENSOR
25

3
AH ioRD DIRECT BATTERY FEED 22

4
K4 18BK/LB

SENSOR
RETURN 26
5
Zll
16BK/WT
SIGNAL
GROUND 23

e
!<6
20VT/WT
5
VOLT
SUPPLY 26

"7 /
K44 10TN/YL

8 VOLT
INPUT 25
8
—

9 JA21
HOB

IGNITION
FEED
21

10
76
20
OR/WT

TRANSMISSION
OD
CONTROL 14
11
Z12
18BK/TN
POWER
GROUND 23

12 Z12
18BK/TN

POWER
GROUND 23

13 —
—
14
——«
___ —
J.5
S22 180R/BK

HEATER
Ul
RELAY 21
16
S21
18YL/BK

HEATER
#1
RELAY 21

17 —
-- —
18 —
19 —
20
K20
18DG

GENERATOR
FIELD DRIVER 20
21 IK21 18BK/RD
TRANSMISSION
OD
LOCKOUT SOLENO
0
25
22
K22 180R/DB
THROTTLE POSITION (SENSOR) 26
23
—
—
24
K24 18GY/BK

REFERENCE
PICKUP 25

25 021
20PK DATA LINK TRANSMIT 23

26 —
—
—
27
J
C20
18BR

A/C
COMPRESSOR
CLUTCH INPUT 26

28 T25
20LG/RD
TRANSMISSION
THERMO SWITCH
25

29 V40
18WT/PK

BRAKE
SENSE 37

30 rTTF
18BR/YL
"
PARK/NEUTRAL
POSITION SWITCH
21

31 — —

32 G3 20BK/PK MALFUNCTION INDICATOR LAMP
22

33
V36 20TN/RD
VEHICLE
SPEED
CONTROL VACUUM 37

34
CI3 20DB/0R
W.O.T.
CUTOUT
RELAY 26

35 —
—.
36 —
— —
37
T61 20BK/0R
TRANSMISSION
OD
LAMP SIGNAL
14

38 — —
—
39 —
— —

40
—

41
—
42 —
—

43 G21 20GY/LB

TACHOMETER
PROVISIONS 22
44
— —
45 D20
20LG DATA LINK RECEIVE 23

46 —
—
47
G7 20WT/OR
VEHICLE
SPEED
SENSOR
PICKUP
25

48
V31 20BR/RD
VEHICLE
SPEED
CONTROL-SET 37
49 V32 20YL/RD
VEHICLE
SPEED
CONTROL-ON/OFF 37

50
V33
20WT/LG

VEHICLE
SPEED
CONTROL-RESUME 37

5i K51
20DB/YL
AUTOMATIC SHUT-DOWN RELAY
22
52
—
— —
53
V35
20LG/RD

VEHICLE
SPEED
CONTROL-VENT 37
54 K31 20BK/PK
WATER-IN-FUEL LAMP 23

5r:
T60 200R/LG

TRANSMISSION
OD
SOLENOID 14
56 E5 20DG/WT WAIT-TO-START LAMP
23

57
A142
16DG/0R

A.S.D.-BATTERY
SENSE
22

50 —
— —
53 —
— —

60
— .—
AD
83
POWERTRAIN CONTROL MODULE
II

(PCM
II)
CONNECTOR
(5.9L
DIESEL ENGINE)
J938w-n

Page 602 of 1502

DODGE TRUCK 1993 Service Repair Manual
•

WIRING
DIAGRAMS
8W - 127
CAVITY
INSTRUMENT PANEL CIRCUITS

1

10
11
12

13
14

15

16
17
18
19
20
21
22

23

24
25

26
27
28 29
30 31
31
32

33

34

35

36
37

•

WIRING
DIAGRAMS
8W - 127
CAVITY
INSTRUMENT PANEL CIRCUITS

1

10
11
12

13
14

15

16
17
18
19
20
21
22

23

24
25

26
27
28 29
30 31
31
32

33

34

35

36
37
38
39
40
41
42

43

44

45
46
47
48
49
50
A3
12RD/WT

C7 12BK/TN
A61 16DG/BK
L4
16VT/WT

L3
16RD/0R

V30 20DB/RD
V31 20BR/RD
V33
20WT/LG

V32 20YL/RD
V32 20YL/RD G86
20DG/WT

G34 16RD/GY
L20
20LG/WT

G21 20GY/LB
G20
18VT/YL

G6
20GY

G60 20GY/YL G85
20TN/0R

L61
18LG

L61
18LG

L60
18TN

L60
18TN
A15
16PK

T61 20BK/OR
LI
18VT/BK

L7 18BK/YL
F20
18WT

V10 20BR
A41
14YL

S21 14YL/BK
X2
18DG/R0

Ml
18PK

Gil
20WT/BK
V5
18DG

V6
18DB
C2 18DB/YL
G3 20BK/PK
Gl 20DG/GY
V40
18WT/PK
G24 22GY/PK
G7
20WT/0R
T6
200R/WT

V3 18BR/WT
V4 18RD/YL
A21
14DB

A21
14DB

A4 12BK/RD
Al
12RD

A2 12PK/BK BATTERY FEED

A/C
AND
HEATER BLOWER MOTOR
FUEL PUMP FEED
(GAS
ONLY)
HEADLAMP-LOW BEAM
HEADLAMP-HIGH BEAM VEHICLE
SPEED
CONTROL
VEHICLE
SPEED
CONTROL VEHICLE
SPEED
CONTROL
VEHICLE
SPEED
CONTROL

WAIT
TO
START LAMP (DIESEL ONLY)
HIGH BEAM INDICATOR LAMP
HIGH BEAM FEED (D.R.L. MODULE)
TACHOMETER (DIESEL)
ECT SEND/UNIT
OR
SWITCH
ENGINE
OIL
PRESSURE
LAMP
ENGINE
OIL
PRESSURE
GAUGE-SEND
UNIT

WATER
IN
FUEL LAMP (DIESEL)
LEFT FRONT TURN SIGNAL LAMP
RIGHT FRONT TURN SIGNAL LAMP
HAZARD FLASHER
TRANSMISSION
OVERDRIVE INDICATOR LAMP

BACK-UP
LAMPS

PARKING
LAMPS

BACK-UP
LAMP FEED
WINDSHIELD WASHER MOTOR
IGNITION START
IGNITION START (DIESEL)

HORNS

UNDERHOOD LAMP
ELECTRIC VACUUM
SENSOR
(DIESEL) WINDSHIELD WIPER SWITCH
WINDSHIELD WIPER SWITCH
A/C
COMPRESSOR CLUTCH
MALFUNCTION INDICATOR
4 WHEEL DRIVE SWITCH

BRAKE
SENSOR

SRI
LAMP
(GAS
ENGINE ONLY)
VEHICLE
SPEED
SENSOR
(2
WIRES)
TRANSMISSION
OVERDRIVE SWITCH
WINDSHIELD WIPER
LOW
SPEED

WINDSHIELD WIPER HIGH
SPEED

IGNITION-RUN
I
START
BATTERY FEED IGNITION SWITCH
(Bl)

IGNITION SWITCH
(B3)
SHEET
NO

4,6.30,47
66,67,68 78
43,45,47
36,38
23

43,46
46,47
22
27,28
23

43.45,56
43,45.56

3,5,56
12,14 7.79
43,45,47
7.9
53.55 8,9
30
29
34
54,55 67,69 19,22

13

32,34,36,38
19

19,25
12,14
54.55
10,23.77,78
3.5.39

4,6.10
4.6.10
TERMINAL
END

OF DISCONNECT
ff
p
45 46
47
48 49
50
35 36 37
38 39
40 41
42
43 44
29 30 31
© 32
33 34
23 24
25
© 26
27 28
17 18
19 ©
20 21 22
7 8 9
10 11
12 13
14 15 16
1
^
1.
2
3
4 5 &

J *j

LARGE
INDEX
INSTRUMENT PANEL
J938W-11

50-WAY BULKHEAD
DISCONNECT
AD
86

Page 605 of 1502

DODGE TRUCK 1993 Service Repair Manual
8W - 130
WIRING
DIAGRAMS

•

1 2 3

A 4

5 6

7
8

/

9
10

11
/

12 13
14

15 16

/

17
18
19
20

21

u
22
23
24

25 26

u

27
28 29

30
31
u

32

Page 617 of 1502

DODGE TRUCK 1993 Service Repair Manual
9
- 12
ENGINES

•
CONDITION

POSSIBLE
CAUSES
CORRECTION

EXCESSIVE
EXHAUST

SMOKE
(Cont'd)
More
than
one
sealing washer
under an injector.
Check
and remove
extra
washer.

9
- 12
ENGINES

•
CONDITION

POSSIBLE
CAUSES
CORRECTION

EXCESSIVE
EXHAUST

SMOKE
(Cont'd)
More
than
one
sealing washer
under an injector.
Check
and remove
extra
washer.
Improperly operating injectors.
Check
and replace inoperative injectors.
Improperly operating or over-
fueled injection pump.
Replace
injection pump.

Piston
rings
not sealing
(blue smoke). Perform blow-by check. Correct as required.

ENGINE
WILL
NOT

SHUT-OFF
Fuel shutoff valve inoperative.

Engine
running on fumes drawn into the air intake.
Stop
the engine mechanically
with
lever on the
fuel
pump.

Check/replace
sealing washer, piston and
spring.

Check
the air intake ducts for the source of the fumes.
WARNING:
In
ease
of engine runaway due to flammable
fumes

from gasoline spills or turbocharger oil leaks
being
sucked
into the
engine,
shut off engine ignition switch first then use a CO* or dry
chemical type
fire
extinguisher
and direct the
spray
under
the
front
bumper to
remove
oxygen
supply. The engine air
intake
is on the

passenger
side
behind the bumper. The
fire
extinguisher
must
bo
directed at this location for emergency shutdown conditions.

COOLANT
TEMPERA

TURE
ABOVE
NORMAL
Low
coolant level.
(a) Check coolant level. Add coolant, if necessary.
(b) Locate and correct the source of the coolant leak. Refer to
troubleshooting
logic for coolant
loss.

Incorrect/improperly operating

pressure
cap.
Replace
cap
with
the correct rating for the
system.

High
lube oil level.
Check/drain
oil to correct level.

Loose
drive belt on water

pump/fan.
Check/replace
belt or belt tensioner.
Inadequate air flow to the radiator. Check/repair radiator core, fan shroud and fan clutch as
required.

Radiator
fins
plugged.
Blow
debris from fins.

Collapsed
radiator
hose.
Replace
the
hose.

Improperly operating tempera

ture
sensor/gauge.
Verify
that
the
gauge
and temperature
sensor
are accurate.

Replace
gauge/sensor,
if bad.
Improperly operating, incorrect

or
no thermostat.
Check
and replace the thermostat.

Air
in the cooling
system.
(a) Make sure the
fill
rate
is not being exceeded and the correct
vented thermostat is installed.
(b) Check for loose hose
clamps.
Tighten if
loose.

(c) If aeration continued, check for a
compression
leak through the head gasket.
Inoperative water pump.
Check
and replace the water pump.
incorrect injection pump timing. Verify pump timing marks are aligned. Check/time the injector

pump
(refer
to Group 7,
Cooling
System).
J9209-56
SERVICE DIAGNOSIS (DIESEL ENGINE) - PERFORMANCE (CONT.)

Page 625 of 1502

DODGE TRUCK 1993 Service Repair Manual
TRANSFER

CASE

INSULATOR

MOUNTING PLATE

NUT(B
RAIL

ASSEMBLY
SPACER

UPPER

INSULATOR

NUT®
LOWER

INSULATOR

J9109-242
Fig.
9 Rear
Engine
Support—4WD
with
Manual

Trans

TRANSFER

CASE

INSULATOR

MOUNTING PLATE

NUT(B
RAIL

ASSEMBLY
SPACER

UPPER

INSULATOR

NUT®
LOWER

INSULATOR

J9109-242
Fig.
9 Rear
Engine
Support—4WD
with
Manual

Transmission
(8) If necessary, remove the transmission support
spacer (automatic transmission) from the extension
assembly (Fig. 8).
(9) If necessary, remove the engine rear support
plate (automatic transmission) from the transfer case (Fig. 8).

INSTALLATION-4WD
(1) If removed, position the engine rear support
plate (automatic transmission) to the transfer case (Fig. 8). Install the bolts and tighten to 41 N-m (30
ft. lbs.) torque.
(2) If removed, position the transmission support
spacer (automatic transmission) to the extension as
sembly (Fig. 8). Install the bolts and tighten to 68 N-m (50 ft. lbs.) torque.
(3) Install insulator mounting plate, mounting

bolts,
spacers, washers and upper/lower insulators to
the rail assembly (Figs. 8 and 9). Tighten the mount
ing nuts to 204 N*m (150 ft. lbs.) torque.
(4) AUTOMATIC TRANSMISSION-Align the
engine rear support plate and the transmission sup
port spacer to the insulator mounting plate (Fig. 8). Lower the engine and transmission onto the insula
tor mounting plate and install the bolts. Tighten the transmission support spacer nuts to 204 N-m (150 ft. lbs.) torque. Tighten the engine rear support plate
bolts to 41 N-m (30 ft. lbs.) torque.
(5) MANUAL TRANSMISSION—Align the
transfer case to the insulator mounting plate and lower the engine and transmission. Install the bolts and tighten the nuts (Fig. 9 - nut A) to 204 N-m (150 ft. lbs.) torque. Install the bolts and tighten the nuts
(Fig. 9 - nut B) to 41 N-m (30 ft. lbs.) torque. (6) Install the skid plate.
(7) Lower the vehicle.

ENGINE
ASSEMBLY

REMOVAL (1) Scribe hood hinge outlines on hood. Remove the
hood.
(2) Remove the battery. (3) Drain cooling system (refer to Group 7, Cooling
System for the proper procedure).
(4) Remove the air cleaner. (5) Disconnect the radiator and heater hoses. Re
move radiator (refer to Group 7, Cooling System).
(6) Set fan shroud aside. (7) Remove the vacuum lines. (8) Remove the distributor cap and wiring.
(9) Disconnect the accelerator linkage.
(10) Remove MPI throttle body. (11) Disconnect the fuel lines. (12) Disconnect the starter wires.
(13) Disconnect the oil pressure wire. (14) Discharge the air conditioning system, if
equipped (refer to Group 24, Heating and Air Condi
tioning for service procedures). (15) Disconnect the air conditioning hoses.
(16) Disconnect the power steering hoses, if
equipped. (17) Remove starter motor (refer to Group 8B, Bat
tery/Starter/Generator Service). (18) Remove the generator (refer to Group 8B, Bat
tery/Starter/Generator Service).
(19) Raise and support the vehicle on a hoist.
(20) Disconnect exhaust pipe at manifold.
(21) AUTOMATIC TRANSMISSION: (a) Support transmission. This will assure that
the torque converter will remain in proper position in the transmission housing. (b) Remove bell housing bolts and inspection
plate.
(c) Attach a C-clamp on front bottom of trans
mission torque converter housing to prevent torque
converter from falling out.
(d) Remove torque converter drive plate bolts
from torque converter drive plate. Mark converter and drive plate to aid in assembly.
(22) MANUAL TRANSMISSION: (a) Support transmission.
(b) Disconnect clutch release mechanism and re
move transmission to clutch housing bolts.

CAUTION:
DO NOT
lift
the engine by the intake
manifold.

(23) Install an engine lifting fixture.
(24) Remove engine front mount bolts.

Page 626 of 1502

DODGE TRUCK 1993 Service Repair Manual
•
3.9L
ENGINE
9 - 21 (25) Lower the vehicle.
(26) On automatic transmission vehicles, discon
nect the engine from the torque converter drive
plate. On manual transmission vehicles, move engi

•
3.9L
ENGINE
9 - 21 (25) Lower the vehicle.
(26) On automatic transmission vehicles, discon
nect the engine from the torque converter drive
plate. On manual transmission vehicles, move engine forward until drive pinion shaft clears the clutch

disc.
Remove engine from engine compartment. (27) Install engine assembly on engine repair
stand.
INSTALLATION (1) Remove engine from the repair stand and posi
tion in the engine compartment.
(2) Install engine support fixture.
(3) Raise and support the vehicle on a hoist.

(4)
AUTOMATIC TRANSMISSION: (a) Position the torque converter and drive plate.
Install torque converter drive plate bolts. Tighten
the bolts to 31 Nnn (270 in. lbs.) torque.
(b) Install the engine front mounts.
(c) Install bell housing bolts. Tighten the bolts to
41 N-m (30 ft. lbs.) torque.
(d) Remove C-clamp.
(e) Install the inspection plate.
(5) MANUAL TRANSMISSION: (a) Position the drive pinion shaft to the clutch

disc.
(b) Connect the clutch release mechanism and
install the transmission to clutch bolts. Tighten the
bolts to 68 N-m (50 ft. lbs.) torque.
(c) Install the engine front mounts.
(6) Remove transmission support.
(7) Install exhaust pipe to manifold.
(8) Lower the vehicle.
(9) Remove engine lifting fixture.
(10) Install the generator (refer to Group 8B, Bat
tery/Starter/Generator Service). (11) Install starter motor (refer to Group 8B, Bat
tery/Starter/Generator Service). (12) Connect power steering hoses, if equipped.
(13) Connect air conditioning hoses.
(14) Evacuate and charge the air conditioning sys
tem, if equipped (refer to Group 24, Heater and Air Conditioning for service procedures). (15) Using a new gasket, install MPI throttle body.
Tighten the throttle body bolts to 23 N-m (200 in. lbs.) torque. (16) Connect the accelerator linkage.
(17) Connect the starter wires. (18) Connect the oil pressure wire.
(19) Install the distributor cap and wiring.
(20) Connect the vacuum lines.
(21) Connect the fuel lines.
(22) Install the radiator (refer to Group 7, Cooling
System). Connect the radiator hoses and heater

hoses.

(23) Install fan shroud in position. (24) Fill cooling system (refer to Group 7, Cooling
System for the proper procedures). (25) Install the air cleaner.
(26) Install the battery.
(27) Warm engine and adjust.
(28) Install hood and line up with the scribe
marks. (29) Road test vehicle.

CYLINDER
HEAD COVER
A steel backed silicon gasket is used with the cyl
inder head cover (Fig. 1). This gasket can be used again.

CYLINDER HEAD COVER GASKET

J9209-104

Fig.
1 Cylinder Head
Cover
Gasket

REMOVAL (1) Disconnect the negative cable from the battery.
(2) Disconnect closed ventilation system and evap
oration control system from cylinder head cover. (3) Remove cylinder head cover and gasket. The
gasket may be used again.
CLEANING Clean cylinder head cover gasket surface. Clean head rail, if necessary.
INSPECTION Inspect cover for distortion and straighten, if nec
essary. Check the gasket for use in "head cover installation.
If damaged, use a new gasket.
INSTALLATION (1) The cylinder head cover gasket can be used
again. Install the gasket onto the head rail.
(2) Position the cylinder head cover onto the gas
ket. Tighten the bolts to 11 N-m (95 in. lbs.) torque. (3) Install closed crankcase ventilation system and
evaporation control system.
(4) Connect the negative cable to the battery.

ROCKER
ARMS

REMOVAL (1) Disconnect spark plug wires by pulling on the
boot straight out in line with plug.
(2) Remove cylinder head cover and gasket.

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