1993 DODGE TRUCK jump start

•
• —
LUiRICATlON
AND
MAINTENANCE
0 - 1
CONTENTS

page
page

CHASSIS
AND
BODY
28
ENGINE MAINTENANCE
14
DRIVETRAIN
.,,, 22
GENERAL INFORMATION
1

GENERAL
INFORMATION INDEl

page

Classification
of
Lubricants
. 3

Components
Requiring
No
Lubrication
4

Fuel Requirements
. 2
Introduction
1

Lubrication
and
Replacement Parts Recommendation
3
page

Routine Maintenance
2

Starting
Assistance (Jump Starting)
9

Vehicle
Lifting
Recommendations
............ 10

Vehicle Noise
Control
2

Vehicle Towing Recommendations
11

INTRODUCTION
Lubrication and maintenance is divided into re­
quired and recommended service tasks. The required service tasks must be completed to verify the emis­
sion controls function correctly. The recommended
service tasks should be completed to maintain safety
and durability. This information will assist the service personnel
in providing maximum protection for each owner's
vehicle. Conditions can vary with individual driving habits.
It is necessary to schedule maintenance as a time in­
terval as well as a distance interval. It is the owner's responsibility to determine the ap­
plicable driving condition. Also to have the vehicle serviced according to the maintenance schedule, and
to pay for the necessary parts and labor. Vehicles with a Gross Vehicle Weight Rating
(GVWR) of 3 855 kg (8,500 lbs.) or less must conform
to light duty emission standards. Vehicles with a Gross Vehicle Weight Rating (GVWR) of 3 856 kg
(8,501 lbs.) or more must conform to heavy duty
emission standards. The GVWR for each vehicle is listed on the Safety
Certification Label. This label is affixed to the driver
side door pillar (Fig. 1).
Additional maintenance and lubrication informa­
tion is listed in the Owner's Manual.
Mm
rv
CHRYSLER
DATE
OF MFR
MFD BY CORPORATION
GVWR
GAWR FRONT
GAWR REAR
WITH
TIRES

WITH
TIRES
RIMS
AT

RIMS
AT

PSI
COLD

PSI
COLD THIS VEHICLE CONFORMS
TO
ALL APPLICABLE FEDERAL MOTOR VEHICLE SAFETY

STANDARDS
IN
EFFECT ON
THE
DATE
OF
MANUFACTURE SHOWN ABOVE.

SINGLE
DUAL

BAR
CODE

VEHICLE MADE
IN

4648503
J9UN-25

Fig. 1 Vehicle Safety
Certification
Label

SEVERE DRIVING
CONDITIONS
Vehicles subjected to severe driving conditions
should decrease the interval between component
maintenance. Severe driving conditions are defined
as:

• Frequent short trip driving less than 24 km (15
miles)
• Frequent driving in dusty conditions
• Trailer towing
• Extensive engine idling
• Sustained high speed operation
• Desert operation
• Frequent starting and stopping
• Cold climate operation

LUBRICATION
AND
MAINTENANCE

•
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.

0-10
LUBRICATION
AND
MAINTENANCE

•

O.K.TO

JUMP
START BATTERY
CONDITION
INDICATOR DO NOT

JUMP
START J9100-26 DARKENED
INDICATOR
WITH
GREEN
DOT
•
LETTERS
Uk-
FLUID
Lt- E:L .

DARKENED
INDICATOR
NO
GREEN
DOT •
BATTERY CHARGE
10'//
• Ft UID
L
EVEl
OK
LIGHT
OR
BRIGHT
INDICATOR

•
RAT-cci,
C
H
A
P
C;
F
R^'^Owh

AM.w-GE
FlAf StIll BE
r-
•
!
F-
r tjr r
?
STA
F
•
r
O U n
C
AI:

Fig.
5
Battery
Condition indicator
(4) Attach a red jumper cable connector clamp to
the positive (4-) terminal on the booster battery. At­
tach the other red cable connector clamp to the pos­ itive (+) terminal on the discharged battery (Fig. 6).

CAUTION:
Do not
allow
the
positive (
+
)
and
nega­

tive
(-)
cable clamps
to
contact each other.
Do not
lean over
the
battery when connecting
the
cable

clamps.

WARNING:
DO NOT
CONNECT
A
JUMPER CABLE CONNECTOR CLAMP
TO THE
NEGATIVE POST
OF

THE DISCHARGED BATTERY.

(5) Connect a black jumper cable connector clamp
to the negative (-) terminal on the booster battery. Connect the other black jumper cable connector
clamp to a good ground source on the engine that is
to be started (Fig. 7).
Verify the engine ground (negative) contact
surface area is free of grease. Make sure there is
a good connection to bare metal. The engine
ground (negative) connection must provide good
electrical continuity.
(6) Start the engine.

WARNING:
THE
USE
OF ANY
JUMPER CABLE
DIS­
CONNECTION PROCEDURE OTHER THAN
THAT
DESCRIBED
BELOW COULD RESULT
IN:
• PERSONAL INJURY CAUSED BY BATTERY
ACID SQUIRTING FROM THE BATTERY VENTS
• PERSONAL INJURY AND/OR PROPERTY DAM­
AGE CAUSED BY BATTERY EXPLOSION
• DAMAGE TO THE BOOSTER VEHICLE OR THE
DISABLED VEHICLE CHARGING SYSTEM. (7) After the engine is started, the jumper cables
must be disconnected in the following order:
• Black (negative) cable connector clamp from the
engine ground contact • Black (negative) cable connector clamp from the
negative terminal (-) on the booster battery
• Red (positive) cable connector clamps from the pos­ itive
(
+ ) terminals on both batteries

BATTERY NEGATIVE
CABLE
TERMINAL POSITIVE
JUMPER
CABLE
BATTERY

J9000-37

Fig.
6 Positive
Jumper
Cable
Connection
ENGINE BATTERY
•GROUND NEGATIVE NEGATIVE
CABLE
-JUMPER
CABLE

BATTERY
J9000-38

Fig.
7
Both
Jumper
Cables
Connected
On
Disabled
Vehicle PORTABLE STARTING UNIT
There are many types of portable starting units
available for starting engines. Follow the manufac­
turer's instructions.

VEHICLE
LIFTING RECOMMENDATIONS
Refer to the Owner's Manual for emergency vehicle
lifting procedures.
FLOOR JACK When properly positioned, a floor jack can be used
to lift a vehicle (Fig. 8). Support the vehicle in the
raised position with jack stands at the front and rear ends of the frame rails.

CAUTION:
Do not
attempt
to lift a
vehicle with
a

floor jack positioned under:

0
- 21
LUBRICATION
AND
MAINTENANCE

• SERVICE INFORMATION
All vehicles are equipped with a maintenance-free
(MF) battery when shipped from the factory (Fig. 10).
A maintenance-free battery does not have removable
cell caps and does not require additional water. Each MF battery has a visual battery condition in­
dicator (Fig. 11). When an adequate battery charge

exists,
the indicator will have a GREEN dot. When
battery charging is necessary, the indicator will be dark. When the indicator is light brown colored or
yellow, the battery should be replaced.
INSPECTION

WARNING; WEAR SAFETY
GLASSES,
RUBBER
GLOVES
AND
PROTECTIVE CLOTHING WHEN SER­
VICING
A
BATTERY.
THE
BATTERY ELECTROLYTE CONTAINS SULFURIC ACID
AND
WILL CAUSE HARM
IF IT
CONTACTS SKIN, EYES
OR
CLOTHING.
IF SULFURIC ACID CONTACTS SKIN
OR
EYES,
GET

IMMEDIATE MEDICAL ATTENTION.
DO
NOT
SMOKE
IN
THE
VICINITY
OF A
BATTERY. KEEP OPEN
FLAMES
AND
SPARKS AWAY FROM BATTERY
FILLER CAPS BECAUSE EXPLOSIVE
GAS IS AL­

WAYS
PRESENT.

Battery maintenance should be completed before
the beginning of every winter season.
Use the following battery maintenance and inspec­
tion procedure. (1) Disconnect the battery negative cable and then
the positive cable.
(2) Clean the battery cables and terminal posts
with a wire brush and a battery terminal cleaner. (3) Remove the battery holddown strap. Clean the
battery tray with a solution of baking soda and wa­
ter. Rinse and dry the battery tray.
(4) Position the battery in the tray and install the
holddown strap. Do not over-tighten the nuts.
(5) Connect the battery positive cable and then the
negative cable to the battery.
(6) Apply a small amount of chassis lubricant (or
an equivalent protective coating) to the cable termi­

nals.

RUBBER/PLASTIC
COMPONENTS

INSPECTION Components should be inspected at the same time
as scheduled underhood maintenance is conducted.
Rubber/plastic components should be replaced imme­ diately if there is any evidence of wear. Inspect the exterior surface of rubber hoses and ny­
lon tubing for evidence of heat damage. The rubber
hose and nylon tubing located close to an exhaust
manifold should be given special attention. Verify
the nylon tubing located at these areas has not col­ lapsed.
INCREASED

ELECTROUTE CAPACITY
SEALED

VENT
CAPS TEST
INDICATOR ENVELOPE

SEPARATORS
BATTERY
HOLD DOWN
RK92

Fig. 10 Maintenance-Free (MF)
Battery

O.K. TO
JUMP START
BATTERY

CONDITION
INDICATOR
J9100-26
DARKENED
INDICATOR
WITH
GREEN
DOT
•
BATTERY CHARGE
OK '
•
FLUID LEVEL
OK

DARKENED
INDICATOR
NO
GREEN
DOT
•
BATTERY CHARGE
LOW
FLUID LEVEL
OK
LIGHT
OR
BRIGHT INDICATOR

•
BATTERY CHARGE UNKNOWN

•
FLUID uEv'EL
LOW
(CHARGE
MAY
STILL
BE
SUFFICIENT
TO
START YOUR
CAR)
Fig. 11
Battery
Condition Indicator
Inspect all the hose connections. Verify they are se­
cure and there is no fluid leakage.
ENGINE MOUNTS Inspect the rubber in the engine mounts for exces­
sive wear. Slight wear at the ends will not affect the
functioning of an engine mount. If excessive engine
movement is detected, the engine mount(s) should be
replaced.

DRIVE
BELTS

MAINTENANCE SCHEDULE Replace the drive belt(s) and adjust the drive ten­
sion at the interval specified in maintenance sched­

ule.
If necessary, refer to Group 7—Cooling Systems.

•

ELECTRICAL
8A - 13 GENERATOR TEST PROCEDURES ON
VEHICLE

INDEX

page
Current
Output
Test
......................
14
Diagnostic Procedures
13

General
Information
13
Generator
Output
Wire Resistance Test
.......
13
page
How
to
Use
Malfunction
Indicator
(Check Engine) Lamp
for
Fault
Codes
17

Operational Check
with
Voltmeter
............
13
Using
On-Board Diagnostic System
15

GENERAL
INFORMATION
The generator
is
belt-driven
by the
engine.
All en­

gines
use
serpentine drive. The amount
of DC
current produced
by the
gener­
ator
is
controlled
by the
Powertrain Control Module (PCM).
All vehicles
are
equipped with
On
Board Diagnos­
tics (OBD).
All OBD
sensing systems
are
monitored
by
the PCM. The PCM
will store
in
electronic mem­ ory
any
detectable failure within
the
monitored cir­

cuits.
Refer
to
USING ON-BOARD DIAGNOSTIC SYSTEM
in
this group
for
more information.

OPERATIONAL CHECK
WITH
VOLTMETER
When
the
ignition switch
is
turned
to the RUN po­

sition, battery potential will register
on the
voltme­
ter. During engine cranking
a
lower voltage will appear
on the
meter. With
the
engine running,
a

voltage reading higher than
the
first reading (igni­
tion
in RUN)
should register.

DIAGNOSTIC PROCEDURES
If
the
indicator does
not
operate properly,
or if an

undercharged
or
overcharged battery condition
oc­

curs,
the
following procedures
may be
used
to
diag­
nose
the
charging system. Remember that
an
undercharged battery
is
often
caused
by:
• accessories being left
on
overnight
•
or by a
defective switch which allows
a
bulb, such
as a
trunk
or
glove
box

light,
to
stay
on
(refer
to
Ignition
Off
Draw).
WISUAL
INSPECTION

• Inspect condition
of
battery cable terminals, bat­
tery posts, connections
at
engine block, starter motor solenoid
and
relay. They should
be
clean
and
tight.
Repair
as
required.
• Inspect
all
fuses
in the
fuse block
for
tightness
in

receptacles. They should
be
properly installed
and

tight. Repair
or
replace
as
required.
• Inspect generator mounting bolts
for
tightness.
Re­

place
or
torque bolt
as
required (refer
to
Torque Specifications).
• Inspect generator drive belt condition
and
tension.
Tension
or
replace belt
as
required. Refer
to
Belt
Tension Specifications. • Inspect connection
at
generator
B+
output.
It

should
be
clean
and
tight. Repair
as
required.

GENERATOR
OUTPUT
WIRE RESISTANCE TEST
(FIG.
1)
Generator output wire resistance test will show
amount
of
voltage drop across generator output wire
between generator
BAT
terminal
and
battery posi­ tive post.

PREPARATION
(1) Before starting test make sure vehicle
has a

fully charged battery. Test
and
procedures
on how to
check
for a
fully charged battery
are
shown
in
Bat­
tery section
of
this Group.
(2) Turn
OFF
ignition switch.
(3)
Disconnect negative cable from battery.

(4)
Disconnect generator output wire from genera­
tor output Battery terminal. (5) Connect
a 0-150
ampere scale
D.C.
ammeter
in

series between generator
BAT
terminal
and
discon­
nected generator output wire. Connect Positive lead
to generator
BAT
terminal
and
Negative lead
to
dis­ connected generator output wire. (6) Connect Positive lead
of a
test voltmeter
(Range
0-18
volts minimum)
to
disconnected genera­
tor output wire. Connect negative lead
of
test voltme­
ter
to
battery positive cable
at
positive post. (7) Connect
one end of a
Jumper Wire
to
ground
and with other
end
probe green
K20
lead wire
at

back
of
generator
(Fig. 1).
(This will generate
a
fault
code).

CAUTION:
Do not
connect blue
A142
lead
of
wiring
to ground. Refer
to
Group
8W
-
Wiring Diagrams
for
more information.

(8) Connect
an
engine tachometer
and
connect neg­
ative cable
to
battery.
(9) Connect
a
variable carbon pile rheostat
be­

tween battery terminals.
Be
sure carbon pile
is in
"Open"
or "Off
position before connecting leads.
See

Battery Section, Load Testing
for
instructions.

TEST
(1) Start engine. Immediately after starting,
re­

duce engine speed
to
idle.

8A
- 14
ELECTRICAL

CASE
GROUND
FIELD

TERMINALS

142-DG/OR
BATTERY
VOLTAGE


ALTERNATOR
CASE

GROUND
GROUND ALTERNATOR
BATTERY
TERMINAL
ENGINE
CONTROLLER TO ENGINE
CONTROLLER TERMINAL
51

LESS
THAN

"BATTERY VOLTAGE
m^mm i
A21 DB-
20
AMP FUSE
A14
RD


AUTO

SHUTDOWN
RELAY
IGNITION
SWITCH

POWER

DISTRIBUTION
CENTER
JUMPER WIRE TO GROUND TEST
AMMETER TEST

VOLTMETER
2
i

DISCONNEaED

ALTERNATOR
OUTPUT
WIRE
ACC

OFF
J938A-17
CARBON
PILE
RHEOSTAT
Fig.
1 Generator Output
Wire
Resistance
Test
(Typical)

(2) Adjust engine speed and carbon pile to main­
tain 20 amperes flowing in circuit. Observe voltmeter
reading. Voltmeter reading should not exceed 0.5
volts.

RESULTS
If a higher voltage drop is indicated, inspect, clean
and tighten all connections between generator BAT
terminal and battery Positive post. A voltage drop
test may be performed at each connection to locate
connection with excessive resistance. If resistance
tested satisfactorily, reduce engine speed, turn off carbon pile and turn off ignition switch.
(1) Disconnect negative cable from battery.
(2) Remove test ammeter, voltmeter, carbon pile,
and tachometer. (3) Remove "Jumper Wire".
(4) Connect generator output wire to generator
BAT terminal post. Tighten to 5 to 6 Nnn (45 to 75

in.
lbs.). (5) Connect negative cable to battery.
(6) Use DRB II Scan Tool to erase diagnostic trou­
ble code.

CURRENT
OUTPUT
TEST
Current output test determines whether or not gen­
erator is capable of delivering its rated current out­
put.
PREPARATION

(1) Before starting any tests make sure vehicle has
a fully charged battery. Test and procedures on how
to check for a fully charged battery are shown in
Battery section of this Group,
(2) Disconnect negative cable from battery.
(3) Disconnect generator output wire at the gener­
ator battery terminal.
(4) Connect a 0-150 ampere scale D.C. ammeter in
series between generator BAT terminal and discon­
nected generator output wire (Fig. 2). Connect posi­
tive lead to generator BAT terminal and negative
lead to disconnected generator output wire.
(5) Connect positive lead of a test voltmeter (range
0-18 volts minimum) to generator BAT terminal.
(6) Connect negative lead of test voltmeter to a
good ground.
(7) Connect an engine tachometer and connect neg­
ative cable to battery.
(8) Connect a variable carbon pile rheostat be­
tween battery terminals. Be sure carbon pile is in Open or Off position before connecting leads. See
Battery section, Load Testing for instructions.
(9) Connect one end of a Jumper Wire to ground
and with other and probe green K20 lead wire at
back of generator (Fig. 2). (This will generate a fault
code).

•

ELECTRICAL
8A - 15 a

CASE
GROUND
CAPACITOR
ALTERNATOR ~L FIELD
TERMINALS

A
142-DG/OR BATTERY
VOLTAGE K20-DG
—!

GROUND
CASE

GROUND
til

ALTERNATOR BATTERY
TERMINAL ENGINE
CONTROLLER TO ENGINE
CONTROLLER TERMINAL
51

LESS
THAN
BATTERY VOLTAGE A21
DB-
.....
IGNITION SWITCH
20 AMP FUSE
AUTO
AH ^

SHUTDOWN POWER
RELAY
DISTRIBUTION

\
CENTER TEST
AMMETER JUMPER WIRE
TO GROUND
TEST
VOLTMETER
GO
5—n
DISCONNECTED
ALTERNATOR OUTPUT WIRE GROUND

ACC
Bl
OFF
RUN OFF
START*T

|ACC

CARBON
PILE RHEOSTAT
J938A-18

Fig.
2 Generator Current Output Test—Typical

CAUTION:
Do not
connect
blue
A142
lead
of
wiring

to ground.
Refer
to
Group
8W -
Wiring
Diagrams
for
more
information.

TEST
(1) Start engine. Immediately after starting reduce
engine speed to idle. (2) Adjust carbon pile and engine speed in incre­
ments until a speed of 1250 rpm and voltmeter read­
ing of 15 volts is obtained.

CAUTION:
Do not
allow
voltage
meter
to
read
above
16 volts.

(3) The ammeter reading must be within limits
shown in generator specifications in back of this
group for that size of generator being tested.

RESULTS
(1) If reading is less than specified and generator
output wire resistance is not excessive, the generator
should be replaced. Refer to Group 8B - Generator
Service for information.
(2) After current output test is completed reduce
engine speed, turn off carbon pile and turn off igni­
tion switch.
(3) Disconnect negative cable from battery. (4) Remove test ammeter, voltmeter, tachometer
and carbon pile. (5) Remove Jumper Wire (Fig. 2).
(6) Connect generator output wire to generator
BAT terminal post. Tighten nut to 5-6 Nnn (45-75 in.

lbs.).

(7) Connect negative cable to battery.
(8) Use DRB II Scan Tool to erase diagnostic trou­
ble code.

USING
ON-BOARD
DIAGNOSTIC
SYSTEM
OPERATION
OF
ON-BOARD
DIAGNOSTIC

SYSTEM

The Powertrain Control Module monitors critical
input and output circuits of the charging system
making sure they are okay. Some are checked contin­
uously and some are only checked under certain con­
ditions.
If the OBD system senses that one of the critical
circuits is bad, it will consider this a real problem
and put a DTC into memory. Each input and output
circuit monitored by the OBD system has its own

DTC.
The DTC will stay in memory as long as the
circuit continues to be bad. If the problem does not
occur again after the code is put into memory, the
Powertrain Control Module will clear the memory af­
ter 50 to 100 engine starts.

*
(1) Unplug the ignition coil harness connector at
the coil (Figs. 10 or 11).

Fig.
10
Coil
Harness
Connector—3.9/5.2L/5.9L
LDC-Gas
Engine

(2) Connect a set of small jumper wires (18 gauge
or smaller) between the ignition coil and coil electri­
cal connector (Fig. 12).
IGNITION
SYSTEMS
80 - 11

Fig.
11
Coil
Harness
Connector—5.9L
HDC-Gas
Engine

IGNITION
COIL COIL CONNECTOR

J928D-13

Fig.
12
Coil
Terminals—Typical (3) Determine that sufficient battery voltage (12.4
volts) is present for the starting and ignition sys­

tems.

(4) Crank the engine for 5 seconds while monitor­
ing the voltage at the coil positive terminal (Fig. 12):
• If the voltage remains near zero during the entire
period of cranking, refer to On-Board Diagnostics in Group 14, Fuel Systems. Check the powertrain con­
trol module and auto shut down relay.
• If voltage is at near battery voltage and drops to
zero after 1-2 seconds of cranking, check the power-
train control module circuit. Refer to On-Board Diag­ nostics in Group 14, Fuel Systems.
• If voltage remains at near battery voltage during
the entire 5 seconds, turn the key off. Remove the 60-way connector (Fig. 13) from the powertrain con­
trol module (PCM). Check 60-way connector for any spread terminals.
(5) Remove test lead from the coil positive termi­

nal.
Connect an 18 gauge jumper wire between the
battery positive terminal and the coil positive termi­
nal.
WARNING: BE VERY CAREFUL WHEN THE ENGINE

IS
CRANKING.
DO NOT PUT
YOUR HANDS NEAR
THE PULLEYS, BELTS
OR THE FAN. DO NOT
WEAR LOOSE
FITTING
CLOTHING.

(2) Rotate (crank) the engine with the starter mo­
tor and observe the cable terminal for a steady arc. If steady arcing does not occur, inspect the secondary
coil cable. Refer to Spark Plug Cables in this group.
Also inspect the distributor cap and rotor for cracks
or burn marks. Repair as necessary. If steady arcing occurs, connect ignition coil cable to the distributor
cap.

(3) Remove a cable from one spark plug.
(4) Using insulated pliers, hold the cable terminal
approximately 12 mm (1/2 in.) from the engine cylin­
der head or block while rotating the engine with the starter motor. Observe the spark plug cable terminal
for an arc. If steady arcing occurs, it can be expected
that the ignition secondary system is" operating cor­ rectly. If steady arcing occurs at the spark plug ca­

bles,
but the engine will not start, connect the DRB II diagnostic scan tool. Refer to the Powertrain Diag­
nostic Procedures service manual.

FAILURE
TO START TEST To prevent unnecessary diagnostic time and wrong
test results, the previous Checking For Spark test should be performed prior to this test.

WARNING: SET PARKING BRAKE
OR
BLOCK
THE
DRIVE WHEELS BEFORE PROCEEDING
WITH
THIS
TEST.