1993 DODGE TRUCK coolant level

•

LUBRICATION
AND
MAINTENANCE
0 - 15
DIESEL
ENGINES

The Diesel engine oil level indicator is located at
the left center of the engine, above the
fuel
injection

pump (Fig. 3).

Fig.
3
Diesel
Engine
Oil
Dipstick

ACCEPTABLE
OIL
LEVEL
To maintain proper lubrication of an engine, the
engine oil must be maintained at an acceptable level.
For gasoline engines, the acceptable levels are indi­ cated between the ADD and
FULL
marks on oil
dip­
stick. For Diesel engines, the acceptable levels are
indicated between the L (low) and H
(high) marks
on
oil dipstick. The oil level should be checked periodically. The
vehicle should be on a level surface. Wait for
five
minutes after stopping the engine. For gasoline en­
gines,
add oil only when the level indicated on the
dipstick is at or below the ADD mark. For Diesel en­
gines,
add oil only when the level indicated on the
dipstick is between the L and H marks.
Never oper­
ate a Diesel
engine when
the oil
level
is below
the L mark. The distance between the L and H
marks represents 1.9L (2 Qts) engine oil.

CAUTION:
Do not
overfill
an
engine crankcase
with

oil. This
will
cause
oil
aeration
and
result
in a de­

crease
in the
engine
oil
pressure.
ENGINE
OIL
CHANGE AND FILTER REPLACEMENT

WARNING: PROTECTIVE CLOTHING
AND
GLOVES SHOULD
BE
WORN. EXPOSED SKIN SHOULD
BE

WASHED
WITH
SOAP
AND
WATER
TO
REMOVE
USED
ENGINE
OIL.
DO NOT
USE
GASOLINE, THIN­
NER,
OR
SOLVENTS
TO
REMOVE ENGINE
OIL

FROM
SKIN.
DO NOT
POLLUTE. DISPOSE
OF
USED
ENGINE
OIL
PROPERLY.
ENGINE
OIL
FILTER

All engines are equipped with a throw-away type
oil filter. The same type of filter is recommended
when the filter is changed.

OIL CHANGE
AND
FILTER
REPLACEMENT
Bring engine up to normal operating temperature.
A more complete drainage of oil will result.
(1) Remove the drain hole plug and drain the en­
gine oil from the crankcase.
(2) Install the drain hole plug with a replacement
gasket. For gasoline engines, the oil filter should be
replaced during every second engine oil change.
For Diesel engines, the oil filter should be re­
placed during every engine oil change.
(3) Rotate the oil filter counterclockwise to remove
it.
(4) Clean the engine cylinder block oil filter boss. (5) Apply a light coat of new engine oil to the rub­
ber seal on the oil filter.
(6) Install and hand tighten the oil filter 1/2 to 3/4
of a turn clockwise. (7) Add new engine oil at the fill hole location on
top of the engine cylinder head cover. Wipe off any spilled oil.
(8) Observe the oil level on the dipstick.

CAUTION:
Do not
overfill
the
engine crankcase
with

oil.
(9)
Start the engine. Observe the oil pressure
gauge or warning lamp (as applicable). If the oil
pressure does not increase, stop the engine immedi­ ately. Check oil level.

COOLING SYSTEM

WARNING:
USE
EXTREME CAUTION WHEN
THE
ENGINE
IS
OPERATING.
DO NOT PUT
YOUR
HANDS NEAR
THE
DRIVE BELT(S), PULLEYS
OR
FAN BLADE.
DO NOT
STAND
IN A
DIRECT LINE
WITH
THE FAN
BLADE.

INSPECTION SCHEDULE
Determine the coolant level. Inspect the cooling
system hoses/clamps after each service interval has
elapsed.

COOLANT LEVEL
It is recommended that the engine coolant level be
inspected at least once a month during periods of hot
weather.
With the engine at normal operating temperature,
check the coolant level in the coolant reserve tank.
The coolant level must be at least above the ADD mark. Add coolant to the coolant reserve tank only.

DIAGNOSIS

PRELIMINARY
CHECKS

ENGINE COOLING SYSTEM OVERHEATING Establish what driving conditions caused the com­
plaint. Abnormal loads on the cooling system such as
the following may be the cause:

1.
PROLONGED IDLE, VERY HIGH AMBI­
ENT TEMPERATURE, SLIGHT TAIL WIND AT
IDLE, SLOW TRAFFIC, TRAFFIC JAMS, HIGH SPEED OR STEEP GRADES.
Driving techniques that avoid overheating are:
• Idle with A/C off when temperature gauge is at
end of normal range. * Increasing engine speed for more air flow is recom­
mended.

2.
TRAILER TOWING: Consult Trailer Towing section of owners manual.
Do not exceed limits.

3.
AIR CONDITIONING; ADD-ON OR AFTER
MARKET: A maximum cooling package should have been or­
dered with vehicle if add-on or after market A/C is
SYMPTOM AND ACTION

SYMPTOM
installed. If not, maximum cooling system compo­
nents should be installed for model involved per
manufacturer's specifications.

4.
RECENT SERVICE OR ACCIDENT RE­
PAIR:
Determine if any recent service has been performed
on vehicle that may effect cooling system. This may

be:

• Engine adjustments (incorrect timing)
• Slipping engine accessory drive belt(s) • Brakes (possibly dragging)
• Changed parts. Incorrect water pump or pump ro­
tating in wrong direction due to belt not correctly
routed
• Reconditioned radiator or cooling system refilling (possibly under filled or air trapped in system).
If investigation reveals none of the above as a
cause for an engine overheating complaint, refer to
the following Symptom and Action chart:
PRELIMINARY FIRST) ACTION
Blinking Engine Temperature
Warning Light or High Gauge indication - Without Coolant Loss
Normal during temporary operation
with
heavy load, towing
a
trailer,
high
outdoor temperatures, and/or on
a
steep
Loss
grade.

Coolant Loss
Hot Vehicle (Not Engine) Heat Damage,
Hot Carpet, Seat,
Hot
Catalytic
Converter,
Smoke, Burnt Odor
Hot Engine Crackling Noise Hot Smell
Severe Local Hot Spots
Coolant Color
Coolant Reserve Bottle Level Changes
Coolant Not Returning To Radiator
Improper refilling procedures
can
result
in
trapped air
in
the
system.
Subsequent
operation
of the
pressure cap and coolant reserve system
will
deaereate
the

cooling
system.
A low
coolant
level
will
then result
in the
Coolant Reserve
Tank. Add coolant.
If
condition persists,
refer
to
System
Diagnosis.

Check
heat shielding, exhaust
system,
engine emission controls, ignition
timing, engine misfiring.

A
moderate amount
of
sound from heating
metal
can
be
expected
with
any

vehicle. However,
a
crackling sound from
trie
thermostat
housing,
a hot
smell and/or severe local
hot
spots on
an
engine can indicate blocked coolant

passages,
bad castina, core sand deposits and subsequent blockage,
cracked cylinder block
or
head,
or
blown cylinder head gasket. Usually
accompanied
with
coolant
loss.

Coolant
color is
not
necessarily
an
indication
of
adequate
temperature
or

corrosion
protection.
Level changes
are to be
expected as coolant volume fluctuates
with
engine
temperature.
If the
level
in the
bottle
is
between
the
Maximum and Minimum
marks
at
normal engine operating temperature,
the
level
should
return
to

within
that
range
after
operation
at
elevated temperatures.

Coolant
will
not
return
to the
radiator
if the
radiator cap vent valve does
not

function,
if
an
air
leak destroys vacuum,
or if the
overflow
passage
is
blocked
or
restricted. Inspect
all
portions
of the
overflow
passage,
pressure

cap,
filler
neck nipple, hose, and
passages
within
the
bottle
for
vacuum leak
only. Coolant
return
failure
will
be
evident
by a low
level
in the
radiator.
Reserve
bottle
level
should increase during heat-up.

J9207-31

•
COOLING
SYSTEM
7 - 6 COOLING SYSTEM DIAGNOSIS (EXCEPT DIESEL)

CONDITION
AND
CHICK

OPTIONAL
M°¥
GAUGE
READS
LOW
(!) Verify
gauge
reading. Is a low temperature indicated?
(2) Is code 17 recorded in On Board
Diagnostics
memory?
(3) Is the
gauge
reading in the cold
range?

(4) Low coolant level during cold ambient temperatures
(accompanied
with poor heater performance).
(5) Coolant level is correct.

GAUGE
HEADING
HIGH.
NO
PRESSURE
BLOW
OFF
FROM
RADIATOR
PRESSURE
CAP
OR
STEAM
FROM
COOLANT

RESERVE
TANK.

(1) Verify
gauge
reading. Is a high temperature reading indicated?
(2)
Gauge
reading at
"H"
without
signs
of boiling.
(3) Low coolant level in radiator and coolant reserve tank.
(4) Coolant level in radiator is low. But not low in coolant reserve tank.
(5) Test coolant
freeze
point.
(6) Ensure proper coolant flow.
DIAGNOSIS

30° TO 40°

GAUGE
TRAVEL
IS
NORMAL

Normal
Gauge
Travel
(1) Inspect temperature
gauge
sending
unit. Refer to Group 8, Electrical. Repair or replace sending unit as necessary.
(2) If code 17 is recorded, replace the thermostat. If not, the thermostat is not the
cause
of the low
gauge
reading.
(3) Inspect for
disconnected
sending
unit electrical connector or incorrect
sending
unit. Ensure that
gauge
sending
unit is installed

and
not an indicator light switch.
(4)
WARNING:
DO NOT
REMOVE
THE
RADIATOR
CAP
OF A
HOT,
PRESSURIZED
ENGINE.
SERIOUS
INJURY
CAN

RESULT
FROM
SCALDING
COOLANT.

Inspect
coolant level in the coolant reserve tank and radiator.

Inspect
system
for leaks.
(5) Inspect heater door
controls.
Refer to Group 24, Heating and
Air
Conditioning.

TO
TOP
AMBIENT

High
Gauge
Reading
— Hot Weather — Heavy Load
(1) Compare
gauge
reading to
High
Gauge
Reading Illustration
above.

(2) Inspect for grounded
gauge,
sending
unit or circuit. Refer to
Group
8, Electrical.
(3) a — Pill to full.
b
— Inspect for leaks in
system
and repair as
necessary,

c
—
Ensure
radiator pressure cap was shut tight. Verify
proper
operation of the radiator cap upper and lower
seals.

(4) a —
Fill
to full,
b
— Inspect for leaks in the
system
and repair as
necessary,

c
— Inspect for leaks in the coolant reserve tank to radiator
hose.

d
— Verify proper operation of the radiator cap upper and lower
seals.

(5) a — Adjust coolant solution to
50/50
mixture of anti-freeze and water. Refer to Coolant in this
group,

b
— If a reading is not recorded or below
—
50, the mixture is
too
rich. Clean
system
and
fill
with a
50/50
mixture of
anti-freeze and water. Refer to Coolant in this
group.

(6) a •— With the thermostat open and a slight amount of coolant
removed,
inspect for coolant flow through the radiator at
the
filler
neck opening,

b
— Determine reason for lack of coolant flow and repair as
necessary.
J9007-69

7 - 6
COOLING
SYSTEM

• COOLING SYSTEM DIAGNOSIS (EXCEPT DIESEL)—CONTINUED
Condition and Checks
Diagnosis

(7) Other possible
causes.
(7) a — If
symptom
occurs
during high speed operation inspect for

plugged
air
inlet
side of the radiator or condenser,

plugged
radiator core tubes, add on A/C package
without
proper radiator, engine not operating
within
specifications,

dragging
brakes,
trailer
towing or
hill
climbing, or an insect screen.
b — If
symptom
occurs
during high or low
speed
operation inspect for: thermostat being stuck
partially
open if ambient

temperature
is
below
70°F
and
the vehicle
has
high

mileage,
plugged
air
inlet
side of the radiator or
condenser, add on
A/C
with
incorrect radiator.

c
— If
symptom
occurs
during low
speed
operation only, inspect the radiator fan drive. Repair as necessary.

TEMPERATURE
GAUGE
READS
HOT.
PRESSURE
CAP
VENTS
RESULTING
IN
STEAM
AND
COOLANT
TRANSFER
TO

COOLANT
RESERVE
TANK.
(1) Coolant
level
low in radiator and coolant reserve tank. (1) a —
Fill
cooling
system
and vent trapped air.
b — Inspect for leaks. Repair as necessary.

c
—
Ensure
that
pressure cap
is
completely shut and
seals.

d
— If
level
is low in radiator but normal in the coolant reserve tank, check the
filler
cap to coolant reserve
bottle

connection and pressure cap seal.
(2) Test coolant
freeze
point. (2) Adjust coolant to
50/50
mix of
anti-freeze
and
water.
Refer to

Coolant
section in this group.
(3)
Ensure
coolant
is
flowing through system. (3) a — With the coolant
level
low and the thermostat open, check
for coolant flow through the radiator at the
filler
neck.
b — If a
metal
cracking
sound
is heard, inspect for core sand restricting coolant flow through the
water
jacket
and/or a

faulty
cylinder head casting.
(4) Thermostat stuck in the
closed
position
(prevalent
in cold ambient temperatures). (4) Replace thermostat if found to be stuck in
closed
position.
Refer
to the Thermostat Testing section in this group.
(5) Cylinder head gasket leak. (5) Inspect for leaking cylinder head gasket
with
a commercially
available Block Leak Tester.
J9007-57

•

COOLING
SYSTEM
7 - 9 COOLING SYSTEM DIAGNOSIS (EXCEPT DIESEL)—CONTINUED

Condition
and Chock

Diagnosis

POOR
HEATER
PERFORMANCE.
SUSPECT

THERMOSTAT
FAILED
IN
OPEN
POSITION.

(1)
Does gauge
read
low?
(1) If YES, replace thermostat. If NO, inspect the
auxiliary
heater

vacuum
water valve. The
valve
should
be open except when the
climate
controls are
OFF
or in the
MAX
A/C mode.
(2) Is coolant level
low?
(2)
Fill
cooling system and
inspect for leaks. Repair as
necessary.

(3) Check
On-Board
Diagnostics.
Is
code
17 set in memory? (3) If
YES,
replace thermostat. If NO, inspect the auxiliary heater

vacuum
water valve. The valve
should
be open except when the climate controls are OFF or in the MAX A/C mode.
J9007-61

7-10 COOLING SYSTEM
•
DIESEL
COOLING SYSTEM
DIAGNOSIS

CONDITION AND CHECKS
DIAGNOSIS

OPTIONAL
60»F
GAUGE
READS
LOW 30° TO 40°
GAUGE
TRAVEL
IS
NORMAL
(1)
Verify
gauge reading. Is a low
temperature
indicated?
(2) Thermostat stuck in open position?
(3) Is the gauge reading in the cold range?
(4) Low coolant
level
during cold ambient temperatures (accom­ panied
with
poor
heater
performance).
(5) Coolant
level
is correct.
MID

Normal
Gauge
Travel

(1) Inspect
temperature
gauge sending unit. Refer to Group 8,
Electrical. Repair or replace sending
unit
as necessary.
(2) If
Yes,
replace the thermostat. If not, the thermostat is not the
cause
of the low gauge
reading.

(3) Inspect for disconnected sending
unit
electrical
connector or
incorrect
sending unit. Ensure
that
gauge sending
unit
is in­
stalled and not an indicator light switch.
(4) WARNING: DO NOT REMOVE THE RADIATOR CAP
OF
A HOT, PRESSURIZED ENGINE. SERIOUS IN­
JURY CAN RESULT FROM SCALDING COOLANT. Inspect coolant
level
in the coolant reserve tank and radiator. Inspect system for leaks.
(5) Inspect
heater
door
controls.
Refer to Group 24, Heating and
Air Conditioning.

GAUGE
READING HIGH. NO PRESSURE BLOW OFF FROM RADIATOR PRESSURE CAP OR STEAM FROM
COOLANT
RESERVE
TANK.
X

(1)
Verify
gauge reading. Is a high
temperature
reading indi­
cated?

(2) Gauge reading at "H"
without
signs
of boiling.
(3) Low coolant
level
in radiator and coolant reserve tank.
MAXIMUM
HOT

WEATHER

HEAVY
LOAD

MAXIMUM
UP

TO
TOP AMBIENT High Gauge
Reading
— Hot
Weather
—
Heavy
Load

(1) Compare gauge reading to High Gauge Reading Illustration
above.
(2) Inspect for grounded
gauge,
sending
unit
or circuit. Refer to

Group
8, Electrical.
(4) Coolant
level
in radiator
is
low.
But
not low in coolant reserve tank.
(5) Test coolant
freeze
point. (3) a-
b — (4) a-
b —
d —
(5) a- (6) Ensure proper coolant flow.
(6) a-
b —
Fill
to
full.

Inspect for leaks in system and
repair

as
necessary.
Ensure
radiator pressure cap was shut
tight.
Verify
proper operation of the radiator

cap
upper and lower
seals.
Fill
to
full.

Inspect for leaks in the system and
repair

as
necessary.
Inspect for leaks in the coolant reserve
tank to radiator hose.
Verify
proper operation of the radiator cap
upper and lower
seals.

Adjust coolant solution to
50/50
mixture
of
anti-freeze
and
water.
Refer to Coolant
in this group. If a reading is not recorded or below - 50.
the
mixture
is too rich. Clean system and
fill

with
a
50/50
mixture
of
anti-freeze
and
water.
Refer to Coolant in this group.
With the thermostat open and a slight amount
of coolant removed, inspect for coolant flow
through the radiator at the
filler
neck opening. Determine reason for lack of coolant flow
and
repair
as necessary.
J9107-22

•

COOLING
SYSTEM
7-11 DIESEL COOLING SYSTEM DIAGNOSIS-CONTINUED
Condition and Chocks
Diagnosis

(7) Other possible
causes.
(7) a — If
symptom
occurs
during high speed operation inspect for

plugged
air
inlet
side of the radiator or condenser,

plugged
radiator core tubes, add on
A/C
package without
proper radiator, engine not operating
within
specifications,

dragging
brakes,
trailer
towing or
hill
climbing, or an insect screen.
b — If
symptom
occurs
during
high
or low speed operation inspect for: thermostat being stuck
partially
open if ambient

temperature
is
below 70°F
and
the vehicle
has
high

mileage,
plugged
air
inlet
side of the radiator or
condenser, add on
A/C
with
incorrect radiator.

c
— If
symptom
occurs
during low
speed
operation only, inspect the radiator fan drive. Repair
as
necessary.

TEMPERATURE
GAUGE
READS
HOT.
PRESSURE
CAP VENTS
RESULTING
IN
STEAM
AND COOLANT
TRANSFER
TO

COOLANT
RESERVE
TANK.

(1)
Coolant
level
low in radiator and coolant reserve tank. (1) a —
Fill
cooling
system
and vent trapped air.
b — Inspect for leaks. Repair as necessary.

c
—
Ensure
that
pressure cap
is
completely shut and
seals.

d
— If
level
is low in radiator but normal in the coolant reserve tank, check the
filler
cap to coolant reserve
bottle
connection and pressure cap seal.
(2) Test coolant
freeze
point. (2) Adjust coolant to 50/50 mix of
anti-freeze
and
water.
Refer to

Coolant
section
in this group.
(3)
Ensure
coolant
is
flowing through system. (3) a — With the coolant
level
low and the thermostat open, check
for coolant flow through the radiator at the
filler
neck.
b — If a
metal
cracking
sound
is
heard, inspect for core sand restricting coolant flow through the
water
jacket
and/or a

faulty
cylinder head casting.
(4) Thermostat stuck in the
closed
position (prevalent in cold ambient temperatures). (4) Replace thermostat if found to be stuck in
closed
position. Refer
to the Thermostat Testing section in this group.
(5) Cylinder head gasket leak. (5) Inspect for leaking cylinder head
gasket
with
a commercially
available Block Leak Tester.
J9007-57

7 - 14 COOLING SYSTEM
• DIESEL COOLING SYSTEM DIAGNOSIS-CONTINUED

CONDITION
AND
CHECKS
DIAGNOSIS

POOR
HEATER
PERFORMANCE.
SUSPECT

THERMOSTAT
FAILED
IN
OPEN
POSITION.

(1)
Does
gauge
read
low?
(1) If
YES,
replace thermostat. If
NO,
inspect
the auxiliary

heater
vacuum
water
valve.
The valve
should
be open
except
when
the climate
controls
are
OFF
or in the
MAX

A/C
mode.
(2)
Is
coolant
level
low?
(2)
Fill
cooling
system
and
inspect
for
leaks.
Repair
as
neces­

sary.

(3) Thermostat failed in open
position?
(3) If
YES,
replace thermostat. If
NO,
inspect
the auxiliary

heater
vacuum
water
valve.
The valve
should
be open
except
when
the climate
controls
are
OFF
or in the
MAX

A/C
mode.
J9107-25