1993 DODGE TRUCK automatic transmission

•
LUBRICATION AND MAINTENANCE
0 - 9 FLUID CAPACITIES

COOLING SYSTEM
QUARTS
LITERS

POWER STEERING PINTS

LITERS

3.9L ENGINE 15.1 14.3
ALL
2.7
1.28

5.2L ENGINE
(2WD)
17.0 16.1

REAR
AXLE
PINTS
LITERS

5.2L ENGINE
(4WD)
16.5 15.6

CHRYSLER
BVa
Inch
(210
mm) 4.4
2.08
5.9L ENGINE
(2WD)
15.5 14.7

CHRYSLER
9Va
Inch
(235
mm) 4.5
2.13
5.9L ENGINE
(4WD)
15.0 14.2
DANA
60 6.0
2.84
5.9L DIESEL ENGINE (MAN.TRANS.) 15.5 14.7
DANA
70 7.0

3.31
5.9L DIESEL ENGINE
(AUTO,
TRANS)
16.5 15.6
FRONT AXLE
PINTS

LITERS

ENGINE
CRANKCASE
QUARTS
LITERS

DANA
44
FBJ 5.6
2.65
3.9L,
5.2L & 5.9
ENGINES 4.0* 3.8*
DANA
60 F
6.5
3.07
5.9L DIESEL ENGINES 12.0*
11.4**

TRANSMISSION-AUTOMATIC

QUARTS
LITERS

FUEL TANK GALLON

LITERS
A
727 (5.9L
ENGINE) 8.4
7.9

STANDARD
3.9L & 5.2L ENGINES 22.0 83.0

A
998 (3.9L
ENGINE) 8.6
8.1
OPTIONAL 3.9L & 5.2L ENGINES 30.0 113.0

A
999 (5.2L
ENGINE) 8.6
8.1
5.9L ENGINE
{G
OR
D)
30.0 113.0

A
518 (5.2L & 5.9L
ENGINES) 10.2
9.6
AD 100
&
AW 100 34.0 128.0

TRANSMISSION-MANUAL
QUARTS
LITERS

TRANSFER
CASE
PINTS
LITERS

NV
4500
4.0
3.8

NP-205
4.5 2.13

GETRAG
360 (5
Speed)
3.5
3.3

NP-241
6.0
2.84
* Add
0.5 qt. or 0.45
liter
when
the oil filter
is
changed

*
*
Add
1 qt. or 0.9
liter
with
oil filter
change STARTING ASSISTANCE (JUMP STARTING)
WARNING:
DO NOT
ATTEMPT
TO
PUSH
OR
TOW
A
VEHICLE
TO
START
THE
ENGINE. UNBURNED FUEL COULD ENTER CATALYTIC CONVERTER
AND IGNITE AFTER
THE
ENGINE
IS
STARTED.
THIS COULD CAUSE
THE
CONVERTER
TO
OVER­ HEAT AND RUPTURE.

BOOSTER BATTERY

WARNING:
TO
PREVENT PERSONAL INJURY
OR,
DO
NOT
ALLOW BATTERY ACID
TO
CONTACT

EYES,
SKIN
OR
CLOTHING.
DO NOT
LEAN OVER
A

BATTERY WHEN CONNECTING JUMPER
CABLES.

DO
NOT
ALLOW
THE
POSITIVE
AND
NEGATIVE

CABLE
CLAMPS
TO
CONTACT EACH OTHER.
KEEP
OPEN FLAMES
AND
SPARKS
AWAY FROM
THE BATTERY ELECTROLYTE VENT HOLES.
AL­
WAYS
WEAR
EYE
PROTECTION WHEN INVOLVED

WITH
VEHICLE BATTERIES.

If it becomes necessary to use a booster battery and
jumper cables to start an engine, use the following procedure.
J9200-86

(1) Engage the parking brake. Shift the automatic
transmission to PARK (if a manual transmission, shift to NEUTRAL).
(2) Turn off all lights, and all other electrical

loads.

(3)
Observe the battery condition indicator (Fig. 5).
If the battery condition indicator is light/bright col­
ored (or yellow), replace the battery. Do not attempt
to jump start an engine when the condition indi­
cator is light/bright colored (or yellow). If the
condition indicator is dark in the center (but without a green dot), proceed with connecting the jumper ca­

bles.

WARNING:
THE
ELECTROLYTE (ACID)
IN A
DIS­
CHARGED
BATTERY
CAN
FREEZE.
DO NOT AT­

TEMPT
TO
JUMP START
AN
ENGINE BEFORE DETERMINING
THE
CONDITION
OF THE
BATTERY
ELECTROLYTE.
THE
BATTERY COULD EXPLODE
AND CAUSE SEVERE PERSONAL INJURY.
CAUTION:
Do not
permit
the
metal
surfaces
on the

vehicles
to
contact.
This
could
establish
ground

(negative)
continuity
between
the
vehicle
bodies.

This
could
cause
the
on-board
computers
to be

damaged.
In
addition
it
could
reduce
the
amount
of

current
flow
through
the
starter
motor.

•

LUBRICATION
AND
MAINTENANCE
0 - 13 ground. Do not exceed speeds of 48 km/h (30 mph) or
a distance of 24 km (15 miles). The transmission
must be in neutral.
Front-end raised towing for a vehicle equipped
with an AUTOMATIC TRANSMISSION is not rec­ ommended.

CAUTION:lt
is not
recommended
to
flat
tow a
vehi­
cle.
LOCKED
VEHICLE
TOWING
When a locked vehicle must be towed, use a tow
dolly or flat bed hauler.
POSITION
CENTER
BAR
AND
WOOD
BEAM
BEHIND

BUMPER
AND
AHEAD
OF
STRUTS
TO
SUPPORT
CHAINS CLEAR
OF
SWAY
BAR RN966
Fig.
12 Front-End
Raised
Towing—Typical

•

LUBRICATION
AND
MAINTENANCE
0 - 23 GEAR SHIFTER BOOTS
Inspect the shifter boots periodically for stone and
heat damage. Replace, if necessary.
SEVERE DRIVING CONDITIONS The interval between the transmission drain and
refill maintenance should be decreased to:
• NV4500 manual transmission—every 29 000 km (18,000 miles)
• Automatic transmission—every 19 000 km (12,000
miles)
A severe driving condition includes:
• Extended operation with heavy cargo loads
• Driving in deep mud or snow
• Off-road operation (4WD)
• Trailer towing
• Operation as a commercial vehicle
• Snow plowing
MANUAL TRANSMISSIONS

INSPECTION/LUBE
OIL
LEVEL
The transmission should be checked for leaks when
other service is necessary under the vehicle. To check
the lube oil level, remove the fill hole plug (Fig. 2 ). If the level is below the bottom of the fill hole, raise
the level to the bottom of the fill hole with:
• Castrol Syntorq for NV4500 transmissions
• SAE 5W-30 engine oil (API Service SG, SG/CD or
SG/CE) for Getrag 360 transmissions.

Fig.
2 NV4500 Manual
Transmission

DRAIN
AND
FILL
The NV4500 transmission fluid should be changed
according to the intervals listed in the Manual
Transmission—Drain & Refill Intervals chart below.

Also,
refer to the Fluid Capacities chart.
AUTOMATIC TRANSMISSIONS

FLUID
LEWEL
It is recommended that the fluid (ATF) level in au­
tomatic transmissions be checked while involved
with other underhood maintenance.
Vehicle operation with an incorrect ATF level
will greatly reduce the life of the transmission.
Fig.
3 Getrag 360 Manual
Transmission

MANUAL TRANSMISSION-DRAIN & REFILL INTERVALS
Normal

Service
Light
Duty
Cycle

60 000
km
37,500
miles

Heavy
Duty
Cycle

58 000
km
36,000
miles

Severe
Service
29 000
km
18,000
miles

J9000-43

The condition of the ATF also should be deter­
mined. If the ATF is dark in color and has a strong odor, the fluid should be changed. Also the filter should be replaced and the bands adjusted.
The following procedure must be used to check the
automatic transmission fluid (ATF) level.
(1) Position the vehicle on level ground.
(2) Operate the engine at idle speed.
(3) Apply the parking brake.
(4) Place the gear selector in N (neutral).
(5) Remove the dipstick from the tube. Wipe it
clean and determine if the ATF is hot or warm.
Hot ATF has a temperature of approximately
82°C (180°F). Warm ATF is when its temperature
is between 29-52°C (85-125°F). (6) Wipe the dipstick clean and completely insert it
into the tube. Remove the dipstick from the tube and
observe the ATF level.
(7) If the ATF is hot, the level should be in the
crosshatched area that is marked OK.
(8) If the ATF is warm, the level should be be­
tween the two dimples.

0
- 24
LUBRICATION
AND
MAINTENANCE

•
CAUTION:
Do not
overfill
the
transmission.
(9) Adjust
the
level
of the ATF
accordingly.
It
is
important
to use the
correct fluid
in an

automatic transmission. MOPAR®ATF PLUS
(ATF Type
7176)
should
be
used. Dexron®
II

ATF
can be
used
if the
recommended fluid
is not
available,
(10) Insert
the
dipstick into
the
tube.

DRAIN, FILTER CHANGE, BAND ADJUSTMENT AND REFILL
The chart below lists
the
intervals
at
which
the

transmission should
be
serviced. Also, refer
to the

Fluid Capacities chart
for
fill capacity.
AUTOMATIC TRANSMISSION SERVICE
IN-
TERVALS

Normal

Usage
Light
Duty
Cycle

60 000
km
37,500
miles

Heavy
Duty
Cycle

38
000 km 24,000
miles

Severe
Usage
19 000 km 12,000
miles

J9100-19

It
is
very important
to use the
correct fluid
in

an automatic transmission. MOPAR®ATF PLUS
(ATF Type
7176)
should
be
used.
An
equivalent
Dexron®
II ATF
could
be
used only
if the
recom­
mended fluid
is not
available.
The torque converter does
not
have
a
drain plug.
No attempt should
be
made
to
drain
the
converter.
Refer
to
Group
21
—Transmissions
for
transmission
drain
and
refill procedures.

TRANSFER
CASE
(4WD
VEHICLES)
INSPECTION The NP205
and
NP241 transfer cases fluid level
should
be
checked whenever maintenance
is
neces­
sary under
the
vehicle.

FLUID
LEVEL
The vehicle must
be
level when
the
fluid level
is checked.
The transfer case drain fill hole plugs
are
located
at
the
rear
of the
housing (Figs.
4 and 5).

Determine
the
transfer case fluid level according
to

the following procedure.
(1) Raise
and
support
the
vehicle.
(2) Remove
the
fill hole plug (Figs.
4 and 5)
from
the transfer case.
The
fluid level should
be at the

bottom edge
of the
fill hole.
The
level
can be
slightly
below
the
bottom edge
of the
fill hole
if the
fluid
is
cold.
(3)
If the
level
is not
acceptable, raise
the
fluid
level
to the
bottom edge
of the
fill hole with: • MOPAR®ATF PLUS
or an
equivalent Dexron
II®

ATF
for
NP241 transfer case
• Multi-purpose gear
oil (API GL-5) or
engine
oil

(API
SG,
SG/CD
OR
SG/CE)
for
NP205 transfer

cases.

Add fluid
in
small amounts
to
raise
the
level. (4) Install
the
fill hole plug (Figs.
4 and 5).

Tighten
the
fill hole plug
to 27 N-m (20
ft-lbs) torque.
(5) Remove
the
support
and
lower
the
vehicle.

Fig.
4
HP241 Transfer
Case
Fig.
5
NP205 Transfer
Case

FLUID DRAIN
AND
REFILL The transfer case fluid should
be
changed every
60

000
km
(37,500 miles).
For
vehicles subject
to the

HEAVY DUTY CYCLE Maintenance Schedule,
a 58

000
km
(36,000 miles) interval
is
recommended.
(1) Raise
and
support
the
vehicle.
(2) Remove
the
fill hole plug (Figs.
4 and 5)
from
the transfer case. (3) Place
an
appropriate container under
the
trans­
fer case drain hole plug (Figs.
4 and 5).
(4) Remove
the
drain hole plug. Drain
the
fluid
from
the
transfer case into
the
container.

2 - 28
FRONT
SUSPENSION
AND
AXLE

DISCONNECT
AXLE/SHIFT
MOTOR
DIAGNOSIS
TWO-WHEEL DRIVE
OPERATION
DIAGNOSIS
FOUR-WHEEL DRIVE
INDICATOR
LIGHT
WILL NOT GO OUT WHEN
TRANSFER CASE SELECTOR
IS
MOVED FROM 4H TO 2H POSITION.

RAISE
VEHICLE SO ALL FOUR WHEELS ARE
FREE
TO ROTATE. INSPECT INDICATOR
SWITCH AND WIRING ON SHIFT MOTOR HOUSING FOR DAMAGE AND SHORT-CIRCUIT.

REPAIR
AS NECESSARY.
YES
i
START ENGINE DEPRESS BRAKE
PEDAL.
PLACE TRANSFER

CASE
SELECTOR IN 2H POSITION AND TRANSMISSION IN
DRIVE
(AUTOMATIC)
OR FIRST

GEAR
(MANUAL). EASE OFF FROM
BRAKE
AND LET WHEELS ROTATE SLOWLY. TEST COMPLETE
FRONT DRIVE SHAFT DOES
NOT ROTATE. FRONT DRIVE
SHAFT ROTATES.
FOUR-WHEEL DRIVE INDICATOR
LIGHT
REMAINS
ON. INSPECT TRANSFER

CASE
LINKAGE.

PLACE
TRANSMISSION IN NEUTRAL. TEST FOR VACUUM
IN VACUUM HOSE

THAT
CONNECTS TO INBOARD SHIFT MOTOR PORT.
(VACUUM SHOULD BE
BETWEEN 10-20 IN. HG.)
CHECK
TRANSFER

CASE.
REPAIR

AS
NECESSARY.
NO VACUUM
OR LOW VACUUM. VACUUM OK
INSPECT INTAKE MANIFOLD
VACUUM SUPPLY HOSE CONNECTION,
TRANSFER CASE VACUUM SWITCH
CONNECTION, VACUUM RESERVOIR, AND SHIFT SYSTEM VACUUM HOSES
FOR PROPER CONNECTION, RESTRICTION,
AIR LEAKS, AND DAMAGE. REPAIR OR REPLACE
AS
NECESSARY. STOP ENGINE
—r~
FRONT AXLE

DISCONNECTS.

INSPECT VACUUM

HOSES
FOR AIR LEAKS, KINKS, ETC.
REPAIR
AS NECESSARY. FRONT AXLE

DOES
NOT
DISCONNECT.
REMOVE SHIFT MOTOR
HOUSING COVER. CONNECT VACUUM PUMP TO
SHIFT MOTOR PORT.

REPLACE
SHIFT MOTOR
IF ARMATURE DOES
NOT MOVE IN AND OUT FREELY. FRONT AXLE
WILL NOT DISCONNECT.

J9002-95
REMOVE SHIFT MOTOR HOUSING
COVER. INSPECT SHIFT FORK, COLLAR, AND AXLE SHAFTS.
REPAIR
OR REPLACE AS
NECESSARY

FRONT
SUSPENSION AND
AXLE
2 - 29
DISCONNECT AXLE/SHIFT MOTOR DIAGNOSIS
(CONT'D)

FOUR-WHEEL
DRIVE
OPERATION
DIAGNOSIS
FOUR-WHEEL DRIVE INDICATOR
LIGHT
DOES NOT
LIGHT
WHEN TRANSFER CASE SELECTOR IN 4H OR 4L POSITION.

RAISE
VEHICLE SO ALL FOUR
WHEELS ARE FREE TO ROTATE.
START ENGINE, DEPRESS BRAKE PEDAL.

PLACE
TRANSFER CASE SELECTOR IN 4H
POSITION AND TRANSMISSION LEVER IN DRIVE
(AUTOMATIC)
OR IN FIRST GEAR
(MANUAL) TO CONFIRM TRANSFER CASE ENGAGEMENT IN 4H. LET WHEELS ROTATE SLOWLY.
FRONT DRIVE SHAFT DOES
NOT ROTATE. FRONT DRIVE
SHAFT TURNS.
INSPECT TRANSFER
CASE
LINKAGE.

CHECK
TRANSFER
CASE.
REPAIR AS
NECESSARY.
FRONT AXLE
CONNECTS.
FOUR-WHEEL DRIVE INDICATOR
LIGHT
DOES
NOT LIGHT.
INSPECT FWD INDICATOR SWITCH, WIRING, AND
LAMP FOR DAMAGE.

REPAIR
AS NECESSARY. RECOMMENDATION:

CHECK
VACUUM SHIFT SYSTEM FOR PROPER
OPERATION.
PLACE
TRANSMISSION
LEVER IN NEUTRAL POSITION. FRONT AXLE

DOES
NOT
CONNECT.
REMOVE VACUUM HOSES FROM AXLE SHIFT MOTOR PORTS.
START ENGINE. TEST FOR VACUUM AT HOSE REMOVED FROM
OUT­

BOARD
PORT ON SHIFT MOTOR,
SHOULD BE BETWEEN 10-20 IN HG.
NO VACUUM
OR LOW VACUUM. STOP ENGINE
H VACUUM OK
INSPECT INTAKE MANIFOLD
VACUUM SUPPLY HOSE CONNECTION, TRANSFER CASE VACUUM SWITCH
CONNECTION, VACUUM RESERVOIR, AND SHIFT
SYSTEM VACUUM HOSES FOR PROPER CONNECTION, RESTRICTION, LEAKS, AND DAMAGE.
REPAIR
OR REPLACE AS NECESSARY. CONNECT A VACUUM PUMP
TO THE OUTBOARD
SHIFT MOTOR PORT.
APPLY 15 INCHES HG. VACUUM AND ROTATE LEFT WHEEL.
NO VACUUM FRONT AXLE
CONNECTED.

CHECK
TRANSFER CASE
VACUUM SWITCH. REPLACE OR REPAIR IF SWITCH
PLUNGER IS DIFFICULT TO MOVE OR BINDS. FRONT AXLE

DOES
NOT
CONNECT.
INSPECT VACUUM HOSES FOR LEAKS, KINKS, ETC.
REPAIR
AS NECESSARY. REMOVE SHIFT MOTOR
HOUSING COVER. CONNECT VACUUM PUMP TO
SHIFT MOTOR PORT.

REPLACE
SHIFT MOTOR
IF ARMATURE DOES
NOT MOVE IN AND OUT FREELY. REMOVE SHIFT MOTOR HOUSING
COVER. INSPECT SHIFT FORK, COLLAR, AND AXLE SHAFTS.
REPAIR
OR REPLACE AS
NECESSARY.
*
REMOVE SHIFT MOTOR HOUSING
COVER. INSPECT SHIFT FORK, COLLAR, AND AXLE SHAFTS.
REPAIR
OR REPLACE AS
NECESSARY.
FRONT AXLE
WILL NOT CONNECT.
REMOVE SHIFT MOTOR HOUSING
COVER. INSPECT SHIFT FORK, COLLAR, AND AXLE SHAFTS.
REPAIR
OR REPLACE AS
NECESSARY.
FRONT AXLE
WILL NOT CONNECT.
REMOVE SHIFT MOTOR HOUSING
COVER. INSPECT SHIFT FORK, COLLAR, AND AXLE SHAFTS.
REPAIR
OR REPLACE AS
NECESSARY.

J9002-96

3
- 28
REAR
SUSPENSION
AND
AXLE

•
SURE-GRIP
DIFFERENTIAL
SERVICE

GENERAL
INFORMATION
The Sure-Grip differential
is an
option available
in

the
8 1/4 and 9 1/4
inch rear axles
(Fig. 1).
EXCITER
RING RING

GEAR
DIFFERENTIAL

CASE

BEARING BEARING

J9003-119
Fig.
1
Sure-Grip
Differential

With
the
exception
of the
Sure-Grip differential

case,
all the
axle components
are
identical
to the

standard axle.
The
Sure-Grip
has a
two-piece differ­
ential case.
The
case
is
completely interchangeable
with
a
standard differential case
(Fig. 2).
Sure-Grip differential removal
and
installation
is
same
as
stan­
dard differential.
DIFFERENTIAL

CASE

PINION
GEAR

COIL SPRING LUBRICATION
WELL
SIDE
GEAR

CLUTCH

LUBRICATION
GROOVES

J9003-120

Fig.
2
Sure-Grip
Differential
Components
The action
of a
standard differential will allow
the

rear wheels
to
rotate
at
different speeds when
the ve­

hicle
is
turning. This differential will divide
the en­
gine torque equally between them. This
is a
desirable
and
normal function
of a
differential.
A

Sure-Grip differential transfers additional engine
torque
to the
rear wheel that
has the
better traction surface.
The
Sure-Grip differential allows
the
driving
wheel with better traction
to
develop more driving
torque than
the
other wheel.
The
Sure-Grip
is not a
locking type differential.
IDENTIFICATION Raise both rear wheels
off the
surface
and
rotate
them.
If
both rear wheels rotate
in the
same direc­
tion,
the
vehicle
is
equipped with
a
Sure-Grip differ­ ential. Another method
of
identification
is by

removing
the
housing cover fill hole plug. Examine (with
a
flashlight)
the
differential case components
through
the
lubricant fill hole.
SERVICE INFORMATION When Sure-Grip differential service
is
necessary,
both rear wheels must
be
raised
off the
surface
so
they
are
free
to
rotate.
A Sure-Grip differential case
is not
repairable.
If defective,
it
must
be
replaced
as a
complete
unit only.
Do not
attempt
to
disassemble
and re­

pair
the
case components.
Follow
the
same procedure outlined under Stan­
dard Differential
for
Removal
and
Installation.
DIFFERENTIAL TEST

CAUTION:
Whenever
a
rear axle
is
being
serviced,
RAISE
BOTH
REAR
WHEELS
off the
surface.
A Sure-Grip differential
can be
tested without
re­

moving
the
differential case from
the
housing.
(1) Position
the
vehicle
on a
hoist with
the
ignition

OFF.
Put the
transmission selector lever
in
PARK
(automatic transmission)
or in
first gear (manual
transmission).
(2) Attempt
to
manually rotate each rear wheel.
(3)
If
difficult
to
manually rotate either wheel,
the

Sure-Grip differential
is
functioning normally.
If

easy,
the
differential
is not
functioning normally
and
should
be
replaced.
A Sure-Grip differential case
is not
repairable.
If defective,
it
must
be
replaced
as a
complete
unit only.
Do not
attempt
to
disassemble
and re­

pair
the
case components.
DIFFERENTIAL NOISE Noise complaints involving
a
Sure-Grip should
be

evaluated
to
determine
the
source
of the
noise.
If a

noise occurs while
the
vehicle
is
turning,
the
proba­
ble cause
is
incorrect
or
insufficient gear lubricant. The drain
and
clean procedure should
be
used
for

possible elimination
of the
noise before replacing
the
differential.

7 - 2
COOLING
SYSTEM

•

NOTE: HEATER
COOLANT FLOW
CIRCUIT
IS
ALWAYS

OPEN
EXCEPT
WHEN
IN MAX. A/C
OR
OFF
MODES
HEATER
INTAKE MANIFOLD
COOLANT FLOW "METERED" FROM REAR
TO

FRONT
AND
BELOW EXHAUST HEAT
CROSSOVER
SHUT
OFF
VALVE

A/C
ONLY COOLANT FLOW
-
PUMP
TO

CYLINDER
BLOCK,
UP
THROUGH
CYLINDER
HEADS
TO
INTAKE MANIFOLD WATER BOX
TO
RADIATOR
—
TO PUMP

•BYPASS
THERMOSTAT CLOSED-HIGH FLOW
THERMOSTAT OPEN
-
LOW FLOW

CYLINDER
HEAD
RR07B52

Fig.
2
Cooling
System
Routing—5.9L (V-8 Gas)—Typical All vehicles are equipped with either a 3.9L (V-6),
a 5.2L (V-8), a 5.9L (LDC-gas V-8), a 5.9L (HDC-gas
V-8) or a 5.9L (in-line 6 cylinder diesel) engine.
As coolant temperature reaches approximately

220°F,
the engine idle speed is increased by the pow-
ertrain control module (PCM) to provide increased
cooling system performance. The PCM was formerly
referred to as the engine controller or SBEC.

COOLING
SYSTEM
COMPONENTS—EXCEPT

DIESEL
ENGINE
The cooling system consists of:
• A down-flow radiator
• Thermal viscous fan drive
• Fan shroud
• Radiator pressure cap
• Thermostat
• Coolant reserve/overflow system
• Transmission oil cooler (automatic transmission)
• Coolant
• Water pump (to circulate coolant)
• Hoses and hose clamps Coolant flow circuits for 3.9L (V-6) and 5.2L (V-8)
engines with water cooled intake manifolds are
shown in figure 1. Coolant flow circuits for 5.9L (V-8 Gas) engines
with water cooled intake manifolds are shown in fig­ ure 2.
COOLING
SYSTEM
COMPONENTS-DIESEL

ENGINE
Coolant flow circuits for 5.9L (diesel) engines with
water cooled intake manifolds are shown in figure 3. The cooling system (Fig. 3) consists of: a cross-flow
radiator, engine driven cooling fan, thermal viscous
fan drive, fan shroud, radiator pressure cap, thermo­ stat, coolant reserve/overflow system, transmission
oil cooler (if equipped with an automatic transmis­
sion),
coolant, water pump, hoses and hose clamps.

SYSTEM
COOLANT ROUTING-DIESEL ENGINE
Coolant is drawn from radiator into the water
pump. Water pump output is directed to the engine oil cooler cavity of the cylinder block (Fig. 4). From the oil cooler cavity, the coolant circulates
around each cylinder. It then crosses to the lift pump
side of engine where it flows up into cylinder head
through openings in top of cylinder block (Fig. 4). Coolant flows past the valve bridges (Fig. 5), to ex­
haust manifold side of engine, to thermostat. As cool­ ant flows toward the thermostat, it provides cooling
for the injector nozzle.
When thermostat is closed (engine is below operating
temperature), coolant flows through bypass passage to
water pump inlet (Fig. 6). Once operating temperature is reached, the thermostat opens and blocks the bypass
passage. Coolant then flows to the radiator inlet.