1993 DODGE TRUCK air condition

GROUP TAB LOCATOR

Introduction

0
Lubrication
and
Maintenance
2
Front Suspension
and
Axle

3
Rear Suspension
and
Axles

5
Brakes

6
Clutch
7
Cooling System

8
Electrical

9
Engines
11
Exhaust System
and
Intake
Manifold

13
Frame
and Bumpers

14
Fuel
System

16
Propeller Shafts

19
Steering

21
Transmission
and
Transfer Case

22
Wheels and Tires

23
Body Components

24
Heating
and Air
Conditioning

25
Emission Control Systems Component and System Index
Service Manual Comment Forms (Rear
of
Manual)

0 - 2
LUBRICATION
AND
MAINTENANCE

• Commercial service
When a vehicle is continuously subjected to severe
driving conditions, lubricate:
• Body components
• All the driveline coupling joints
• Steering linkage More often than normal driving conditions

DUSTY
AREAS
With this type of severe driving condition, special
care should be given to the:
• Engine air cleaner filter
• PCV filter
• Crankcase ventilation system
• Brake booster control valve air filter. Verify that the filters and the associated compo­
nents are clean. Also verify that they are functioning
effectively. This will minimize the amount of abra­ sive particles that enter the engine.

OFF-ROAD
(4WD)
OPERATION
After off-road (4WD) operation, inspect the under­
side of the vehicle. Inspect the:
• Tires
• Body structure
• Steering components
• Suspension components • Exhaust system
• Threaded fasteners

HARSH
SURFACE ENVIRONMENTS
After extended operation in harsh environments,
the brake drums, brake linings, and rear wheel bear­ ings should be inspected and cleaned. This will pre­
vent wear and erratic brake action.

ROUTINE MAINTENANCE
The following routine maintenance is recommended
on a monthly basis: TIRES—Inspect the tires for unusual wear/damage.
Determine if the inflation pressure is adequate for
the vehicle load. BATTERY—Inspect and clean the terminals.
Tighten the terminals if necessary. FLUIDS—Determine if the component fluid levels
are acceptable. Add fluid, if necessary. LIGHTS/ELECTRICAL—Test all the electrical sys­
tems in the vehicle for proper operation. It is also recommended that the engine oil and the
washer fluid level be determined at each fuel fill-up.

VEHICLE
NOISE CONTROL
Vehicles with a GVWR of 4 535 kg (10,000 lbs), or
more, are required to comply with Federal Exterior Noise Regulations (Fig. 2).
VEHICLE
NOISE
EMISSION
CONTROL INFORMATION

DATE
OF
VEHICLE
MANUFACTURE

THIS
VEHICLE CONFORMS
TO
U.S. EPA REGULATIONS FOR NOISE EMISSION

APPLICABLE
TO
MEDIUM
AND HEAVY
DUTY
TRUCKS. THE
FOLLOWING
ACTS OR THE CAUSING THEREOF BY ANY PERSON ARE PROHIBITED BY THE NOISE CONTROL ACT
OF 1972. (A) THE
REMOVAL
OR

RENDERING
INOPERATIVE, OTHER
THAN
FOR
PURPOSES
OF
MAINTENANCE,
REPAIR.
OR REPLACEMENT, OF ANY NOISE CONTROL DEVICE OR ELEMENT OF
DESIGN
(LISTED
IN
THE
OWNERS
MANUAL)
INCORPORATED
INTO
THIS
VEHICLE
IN COMPLIANCE
WITH
THE NOISE CONTROL
ACT:
(B) THE
USE
OF
THIS
VEHICLE
AFTER SUCH DEVICE
OR
ELEMENT
OF
DESIGN HAS BEEN REMOVED
OR
RENDERED
INOPERATIVE.

PU626D

Fig.
2 Vehicle
Noise
Emission
Control Information
Label

UNAUTHORIZED
DEFEAT
OF
NOISE
CONTROL COMPONENTS
Federal law prohibits removal, altering or other­
wise defeating any noise control component. This in­
cludes before or after the vehicle is in use. Federal
law also prohibits the use of a vehicle after a noise
control component is defeated.

REQUIRED MAINTENANCE/SERVICE
FOR
NOISE
CONTROL

The following maintenance is required after each
6-month or 9 600 km (6,000 miles) interval. This will
ensure that the vehicle noise control components are
operating properly.

EXHAUST SYSTEM
Inspect exhaust system for exhaust leaks and dam­
aged components. The exhaust hangers, clamps and
U-bolts should be attached and in good condition.
Burned or ruptured mufflers, damaged exhaust pipes should be replaced. Refer to Group 11—Exhaust Sys­
tem/Intake Manifold for service information.

AIR
FILTER
HOUSING/CANISTER
Inspect the air filter assembly for proper fit. Verify
the cover is securely attached to the housing/canis­
ter. Inspect all the air filter housing hoses for con­ nections. The gasket between the air filter housing and throttle body must be in good condition. The air
filter element should be clean and serviced according
to the maintenance schedule.

FUEL
REQUIREMENTS
GASOLINE
ENGINES
All engines require the use of unleaded gasoline to
reduce the effects of lead to the environment. Also unleaded fuel is necessary to prevent damage to the
catalytic converter/02 sensor. The fuel must have a
minimum octane rating of 87 based on the (R + M)/2
calculation method.

GASOLINE ENGINE MAINTENANCE SCHEDULE

LIGHT
DUTY
CYCLE

SCHEDULED
MAINTENANCE
FOR
EMISSIONS
CONTROL
-
PROPER
VEHICLE
PERFORMANCE

Inspection and service is also necessary any
rime
a
malfunction
is observed or suspected.

X
= Scheduled maintenance for all vehicles.

O
= Scheduled maintenance for all vehicles, Recommended for proper
vehicle
performance.
Where both
time
and mileage Miles (Thousand) are
shown,
follow the
interval

which
occurs
first. Kilometers (Thousand) 7'A
15
22'A
30
37'A
45
52'A

60
67'A
75
82'A

90 97'/2 105 112'A
120
Where both
time
and mileage Miles (Thousand)
are
shown,
follow the
interval

which
occurs
first. Kilometers (Thousand) 12 24
36 48
60 72 84 96 108 120
132 144 156 168 180 192

Coolant
Condition,
Coolant
Hoses/Clomps
X X X X X X

O O O O O
O O O
o
O

Exhaust
System—Check
X
X X X X

X
O O O

o
O
O O
o o o

Oil—Change
(6 months)
X X X X X X

O O O

o o

O O
o o
o
Oil Filter—Change (2nd Oil Change)
X
X X
o o
O
o
o

Spark
Plug—Replace
X

0
o o

Air
Filter—Replace
X

o

O
o

Coolant—Flush/Replace
(36 months) &
24
months/48 000 km
(30,000
miles)
thereafter
O

X
X

PCV
Valve—Replace if
Necessary
O'
O' O'

Battery—Replace
O

This maintenance is recommended by Chrysler Corporation to the owner, but is not
required
to
maintain
the
warranty.

0 - 6
LUBRICATION
AND
MAINTENANCE
GASOLINE ENGINE MAINTENANCE SCHEDULE

HEAVY
DUTY
CYCLE

Inspection and service is also necessary anytime
a
malfunction is observed or suspected.
When both
time
and mileage
are
Miles (Thousand)

shewn,
follow
the
interval

which occurs first. Kilometers (Thousand) 6
12 18 24
30 36 42 48 54
60 66 72

78
82V2
84 90
96
102 108
When both
time
and mileage
are
Miles (Thousand)

shewn,
follow
the
interval

which occurs first. Kilometers (Thousand) 9.6 19 29
38 48 58 67 77
85 96 106 116
125 132
135
145
154 164
174

Coolant
Condition, Coolant
Hoses/Clamps
X
X X X
X X X X
X X X X
X X X
X X X

Exhaust
System
—
Check
X X X X X X X X X X X
X X X X X
X X

Oil
—
Change
(6
Months)
X X X X X X X
X X

X
X
X

X X X

X X
X

Oil
Filter
—
Change (2nd
Oil
Change)
X X X X
X X
X X
X

Drive Belt Tension
—
Inspect
&
Adjust
X' X
X1

X X' X

Drive Belts (V-Type)
—
Replace
X

Air
Filter/Air
Pump
Air
Filter
—
Replace
X X X
X

Crankcase
Inlet
Air
Filter
(6 &
8
Cyl.
Eng.
Only)
—
Clean
X X
X X

Spark
Plug
—
Replace
X X X

Fuel
Filter
—
Replace as necessary

Coolant
—
Flush/Replace
(36
months)
& 24
months/48
000 km

(30,000
miles)
thereafter
X
EGR
Valve
&
Tube
—
Replace X2

EGR
Tube
—
Clean Passengers
X2
PCV
Valve
—
Replace X2

Vacuum
Emission
Components
—
Replace
X

Ignition Timing
—
Adjust
to
Specs,
as necessary X
Ignition Cables, Distributor Cap
&
Rotor
—
Replace
X

Manifold Heat Control Valve
—
Lubricate
X

Battery
—
Replace X

Oxygen
Sensor
—
Replace
X2

1 For California vehicles, this maintenance is recommended
by
Chrysler Motors
to the
owner but, is not
required
to
maintain the
warranty
on the
air
pump drive
belt.

2 Requires
Emission
Maintenance Reminder Light.
If
so equipped, these parts
are to be
replaced
at the
indicated mileage,
or
when the
emissions
maintenance reminded light remains on continuously
with
the key in the
"on" position, whichever occurs first.
J9100-20

DIESEL
ENGINE
MAINTENANCE
SCHEDULE
HEAVY
DUTY
CYCLE
Inspection
and
service
is
also
necessary
any
time
a
malfunction
is
observed
or
suspected.

Iff both
time
and distance Miles (Thousand)
are listed, use the
interval

that
ends
first. Kilometers (Thousand) 6
12
18 24
30 36 42

4S
54
60 66
72 78
84 90 96
102 108
Iff both
time
and distance Miles (Thousand)
are listed, use the
interval

that
ends
first. Kilometers (Thousand) 9,6 19
29
38 48 58 67

77

85 96 106
116 125 135 145 154
164 174

Coolant
Condition, Coolant
Hoses/Clamps
(12 months)

Coolant
Flush/Replace (36 months) & 24 months/
48 000 km
(30,000
miles)
thereafter
O

Oil—Change
(6 months)
X X X
X X X
X X X X X
X X X X X X
X

Oil Filter—Replace (Every Oil Change)
X X X
X X X
X X
X X X
X
X X X X
X X

Drive Belts—Replace
As
Necessary
X X
X X X X

Air Filter—Replace
X X
X X

Air Filter—Clean (California Only) e

®

• •
Air
Filter
Canister—Clean
o o o
o

Fuel Filter—Service When Necessary

Injection
Pump
Timing & Engine Idle Speed—

Check
& Adjust
©

• 9 • • •
Underhood Rubber/Plastic Components—Inspect/Replace • • • • •

X
— All vehicles
O
— All
vehicles
except
California.
Recommended
for
California.
•
— California only.
Recommended
for all vehicles.

0 - 14
LUBRICATION
AND
MAINTENANCE

•
ENGINE
MAINTENANCE

INDEX

page
Air
Injection
Systems/Air Pump
. 17

Air-Conditioner
Compressor
21
Battery
19

Cooling System
15

Crankcase
Ventilation
System
17
Diesel Engine
Air Filter
Canister
17

Drive Belts
20
Engine
Air
Cleaner
Filter
Element
16

Engine Break-In
14

Engine
Oil 14

Engine
Oil
Change
and Filter
Replacement
15

Exhaust Gas
Recirculation
(EGR) System
...... 19
page
Exhaust
Manifold
Heat
Control
Valve
. 17
Exhaust System
, 21

Fuel System
18

Hoses
and
Fittings
16
Ignition
Cables,
Distributor
Cap and
Rotor
...... 19

Ignition
Timing
. 19

Oxygen
(02)
Sensor
19
Rubber/Plastic Components
20

Spark Plugs
. 19

Throttle
Control
Linkage
18

Vacuum Operated, Emission
Control
Components
19

ENGINE BREAK-IN
After first starting a new engine, allow it to idle
for 15 seconds before shifting into a drive gear. Also:
• Drive the vehicle at varying speeds less than 88
km/h (55 mph) for the first 480 km (300 miles).
• Avoid fast acceleration and sudden stops.
• Do not drive at full-throttle for extended periods of
time
• Do not drive at constant speeds
• Do not idle the engine excessively A special break-in engine oil is not required. The
original engine oil installed is a high quality lubri­
cant. New engines tend to consume more fuel and oil un­
til after the break-in period has ended.

ENGINE
OIL SPECIFICATIONS

API SERWICE
GRADE
Use an engine oil that conforms to API Service
Grade S5 SG/CD or SG/CE. MOPAR®provides engine
oils that conform to all of these service grades.

SULFATED ASH—DIESEL ENGINES
Oils that contain an excessive amount of sulfated
ash can cause deposits to develop on Diesel engine
valves. These deposits can result in valve wear.

SAE
WISC0SITY
An SAE viscosity grade is used to specify the vis­
cosity of engine oil. SAE 30 specifies a single viscos­
ity engine oil.
Engine oils also have multiple viscosities. 10W-30

<
5W-30

1
1 1

F
-20 0 10 20 32 60 80 100

C
-29 -18 -12 -7 0 16 27 38
ANTICIPATED
TEMPERATURE RANGE BEFORE
NEXT
OIL
CHANGE
J9000-39

Fig.
1 Temperature/Engine Oil Viscosity—Gasoline
Engines

-12°C
-18°C 10°F
0°F- 15W-40

-23°c(^-10eF

I
10W-30
WITH
WITHOUT
BLOCK HEATER
BLOCK
SYNTHETIC
OIL

HEATER
10W-30 5W-30

J9100-29

Fig.
2 Temperature/Engine Oil Viscosity—Diesel
Engines

ENERGY
G0NSERWING
OIL
An Energy Conserving type oil is recommended for
gasoline engines. They are designated as either EN­
ERGY CONSERVING or ENERGY CONSERVING

II.
OIL
LEVEL
INDICATOR (DIPSTICK)

GASOLINE ENGINES
The engine oil indicator is located at the right
front of the engine.

0-18
LUBRICATION
AND
MAINTENANCE

•
COOLANT FREEZE PROTECTION

Cooling systems contain a 50/50 mixture of anti­
freeze (ethylene glycol) and distilled water. This is
the recommended coolant mixture.
It is recommended that the degree of coolant pro­
tection be tested every 12 months. If the coolant is
contaminated or rusty, the cooling system should be
drained, flushed. Refill with a 50/50 mixture of fresh
coolant. Refer to Group 7—Cooling Systems for addi­
tional information.

SYSTEM
INSPECTION

WARNING:
IF THE
ENGINE
HAS
BEEN RECENTLY
OPERATED,
DO NOT
REMOVE
THE
RADIATOR

CAP.
THIS WILL AVOID
YOU
BEING SCALDED

WITH
HOT, PRESSURIZED COOLANT.

(1) Test the radiator cap for proper sealing and op­
eration. Use caution when removing the radiator cap
to avoid contact with hot coolant. Place a heavy rag
or towel over the cap and turn to the first stop. Do
not press down. Pause to allow the pressure to re­
lease through the overflow tube. Then press down
and turn counterclockwise to remove the cap.
(2) Inspect the coolant overflow tubing and the
connections at the coolant reserve tank and at the
radiator.
(3) Inspect the entire cooling system for leaks. A
black-light detector can be used as an aid in detect­ ing the source of coolant leaks.
(4) Inspect the radiator and air conditioner con­
denser fins for debris, etc. (5) If necessary, refer to Group 7—Cooling Systems
for additional information and service procedures.

RADIATOR CAP
The radiator cap must be completely tightened to
provide proper pressure. Inspect and test radiator cap
when cooling system service is performed.

MAIN,
FLUSH
AND
FILL

WARNING: ANTI-FREEZE (ETHYLENE GLYCOL)
IS
POISONOUS.
KEEP
OUT OF THE
REACH
OF
CHIL­

DREN.

Drain, flush, and fill the cooling system at the in­
terval specified in maintenance schedule. For proper service instructions see Group 7, Cooling System.

HOSES AND
FITTINGS
It is recommended that rubber hoses be periodi­
cally inspected. Inspect all hose fittings for looseness and corrosion.
ENGINE
AIR
CLEANER
FILTER
ELEMENT

MAINTENANCE
SCHEDULE
With normal driving conditions, the engine air
cleaner filter element should be replaced:
• Light-Duty Cycle-after each 48 000 km (30,000
miles) interval has elapsed
• Heavy-Duty Cycle-after
each
38 000 km (24,000
miles) interval has elapsed
When the vehicle is operated in dusty areas, the
filter element should be replaced more often.
For Diesel engines, the air filter canister should be
cleaned at the same time the filter is replaced.

SERVICE/REPLACEMENT
(1) Remove the air cleaner cover.
(2) Remove the air cleaner filter (Fig. 4).

CAUTION:
Do not tap the filter or immerse the filter medium in liquid to remove trapped debris.
(3) Clean filter by blowing the trapped debris from
the filter with compressed air (Fig. 5). Direct the air in the opposite direction of normal intake air flow.
Keep the air nozzle at least two inches away from
the filter.
(4) If the filter has become partially saturated with

oil,
replace the filter. Inspect the crankcase ventilat­
ing system for proper operation.
(5) Wash the air cleaner cover and body with
cleaning solvent. Wipe it dry.
(6) Install the air cleaner filter element. Attach
the cover to the body (Fig. 4).
Fig,
4
Engine
Air Oeaner—
Typical

•

LUBRICATION
AND
MAINTENANCE
0 - 21 ROUTINE INSPECTION
It is recommended that the drive belt(s) be rou­
tinely inspected for cracks, fraying and excessive
wear. Replace as necessary.

EXHAUST SYSTEM
An exhaust system must be properly aligned to
prevent stress, leakage, and vehicle body contact.
MAINTENANCE SCHEDULE Inspect the exhaust system at the interval specified
in maintenance schedule.
INSPECTION Inspect for cracked or loose joints, corrosion dam­

age,
and worn or broken hangers. Replace all compo­
nents that are damaged. Do not attempt repair. Also,
inspect for the following conditions and correct as
necessary:
• Exhaust system leaks, misalignment • Contact with body panels or the frame
• Catalytic converter bulging or excessive heat dam­
age

CAUTION:
A
catalytic converter
will
become
con­

taminated
if
leaded gasoline
is
burned
in the en­

gine.
If
this
occurs,
the
complete converter must
be
replaced.

AIR-CONDITIONER COMPRESSOR LUBRICANT
AND
REFRIGERANT
The lubricant level in the compressor should be
checked if there are indications that oil was lost.
Loss of lubricating oil usually accompanies a loss of
refrigerant. The presence of bubbles in sight glass in­ dicates that loss of refrigerant has occurred. For additional information involving the A/C sys­
tem, refer to Group 24—Heater And Air Condition­ ing.

•

LUBRICATION
AND
MAINTENANCE
0 - 31
Fig. 4 Master Cylinder Fluid Level
FLUID
SPECIFICATION

Power brake systems require MOP AR®Heavy-D uty
Brake Fluid, or an equivalent product identified with
FMVSS No. 116, DOT-3 and SAE J-1703 Standard designations. Use fresh brake fluid only when adding fluid to the
reservoir. Never use reclaimed fluid, fluid that does not conform to the DOT/SAE Standards, or fluid from a container that has been left open.

CAUTION:
Use of a
brake fluid that
has a
lower ini­

tial
boiling point then specified
by
FMVSS
No. 116
or
DOT 3
could result
in
sudden brake failure dur­
ing
hard, prolonged braking.

CAUTION:
Do not
allow petroleum base
fluids
to

contaminate
the
brake fluid. Seal damage
will
re­

sult.
BRAKE SYSTEM INSPECTION (1) Inspect the brake pads and linings for excessive
wear, cracks and broken rivets.
(2) Inspect brake pads and linings for contamina­
tion with brake fluid, axle lubricant and/or other flu­
ids.

(3) Replace the front brake pads and the rear
brake linings if they are worn to within 0.78 mm (1/32 in) of a rivet head.
(4) Operate the rear brake self-adjuster lever and
pivot. Test the operation of the self-adjuster screw for ease of movement. (5) Inspect the self-adjuster components for frayed
cables, loose or overheated springs, and a binding
condition.
(6) Inspect the caliper dust boots for damage/tears
and indications of brake fluid leakage. Inspect the
bushings and pins for corrosion, tears and a binding condition.
(7) Inspect the rear wheel cylinder dust boots for
fluid leaks. Inspect the pistons and cylinder bores for
proper appearance. (8) Inspect the brake differential warning valve
and housing for indications of leakage, kinked hoses and loose fittings.

BRAKE
FLUID
HOSES/TUBING
The rubber brake fluid hoses should be inspected
for:
• Correct length
• Severe surface cracking
• Swelling
• Pulling
• Scuffing
• Excessively worn areas If the hose fabric casing is exposed either by
cracks or abrasions in the rubber cover, the
hose should be replaced.
Faulty brake fluid hose installation can cause
twisting, and wheel/tire or chassis interference.
(1) Inspect all the hoses for kinks, a distorted con­
dition and fluid leakage. (2) Inspect the hose and tubing routing under the
vehicle. Verify that no hose/tubing is rubbing against any exhaust system or other underbody components.

PARKING
BRAKE
LUBRICATION
The pivot and sliding contact areas of the parking
brake ratio lever should be lubricated to maintain ease of operation (Fig. 5).
(1) Apply MOPAR®Spray White Lube or equiva­
lent to the sliding contact areas.
(2) Lubricate the control lever pivot areas with en­
gine oil.

PARKING
BRAKE
FUNCTIONAL
TEST
AND
INSPECTION
(1) Engage the parking brake pedal and then re­
lease it. (2) Test it for smooth operation and vehicle-hold­
ing capability.
(3) Inspect the parking brake cables for kinks,
fraying and a binding condition. (4) With the parking brake released, the rear
wheels should rotate without restriction. Adjust the
parking brake cable tension, if necessary.
(5) Repair any parking brake malfunctions.
BRAKE OPERATIONAL TEST (1) Drive the vehicle and test for proper brake ac­
tion.