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Dodge D250 1990, Service Manual

The Dodge D250 1990 Service Manual is essential for owners of this classic truck. You can easily download the manual for free from manualshive.com. This manual provides detailed instructions for maintenance, repairs, and troubleshooting, ensuring your D250 remains in top condition for years to come.

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Summary of Contents for D250 1990

Page 1: ...1 9 9 0 SERVICE MANUAL REAR WHEEL DRIVE RAM TRUCK Diesel Supplement 4 C H R Y S L E R W M O T O R S...

Page 2: ...means electronic mechanical photocopying recording or otherwise withoutthe prior written permission of Chrysler Motors and Cummins Engine Company Inc Chrysler Motors and Cummins Engine Company Inc re...

Page 3: ...CHRYSLER MOTORS DODGE Turbo Diesel...

Page 4: ...sis charts inthe Engine Section aredesigned to help you locate and correct problems with a systematic approach The tab locator at the right side of this page will help you to quickly locate the first...

Page 5: ...logic presented in Section 9A To fix a problem find the logic chart for the particular symptom Follow the steps specified until the problem is corrected The left column of the charts indicate a proba...

Page 6: ...an assembly or the engine can be damaged if the caution instructions are not followed W Indicates a REMOVAL or DISASSEMBLY step INSPECTION is required Indicates an INSTALLATION or ASSEMBLY step CLEAN...

Page 7: ...ry steps to set or adjust the component assemblies or system in the required setting or position Visually Inspect Look for any obvious damage or problem Remove Take off a component or assembly Clean R...

Page 8: ...ations are generic and might not look exactly like the engine or parts used in your application Some illustrations contain symbols to indicate an action required and an acceptable or unacceptable cond...

Page 9: ...rysler Motors Cummins Engine Company Inc does not recommend or authorize any modifications or repairs to engines or components except for those detailed in Chrysler Cummins Service information In part...

Page 10: ...coolant is hot allow the engine to cool before you slowly loosen the J m filler cap and relieve the pressure from the cooling system Do not work on anything that is supported ONLY by lift jacks or a...

Page 11: ...use the same fastener part number or equivalent when replacing fasteners Do not use a fastener of less quality if replacements are necessary ANever spray or pour diesei fuel flammable liquid starting...

Page 12: ...important during the repair of a diesei engine Contamination ofthe engine during repair will reduce the life of an engine Perform the Inspections Specified in the Procedures Replacement of worn and d...

Page 13: ...System 25 Engines 9 Engine Air Cleaner 0 11 Engine Block Heater 7 Engine Front Mounts 9 Engine Lubrication 0 9 Equipment Identification Label Intro Engine Serial Number Intro Engine Rear Support 9 Ex...

Page 14: ...8 Starter Relay 8 Symbols Fuses and Connectors 8 Thermostat 7 Timing Gear Cover and OB Seal 9 Torque References 9 Transmission 21 Transmission Identification Intro Transmission Oil Coder 7 Valves and...

Page 15: ...ce of the driver s door or on the post on ail models Equipment Identification Plate The equipment identification plate as shown contains information regarding the vehicle model wheel base V I N Vehicl...

Page 16: ...flange See Group 21 of this manual for additionai information For manual transmission models an identification number is permanently stamped into the right side of the transmission case or a metal ta...

Page 17: ...mportant to salvage metric fasteners nuts bolts etc for reassembly If the fastener Is not salvageable a fastener of equivalent specification should be used Caution Use of an incorrect fastener may res...

Page 18: ...eck Digit for VIN Verification 10 L 1990 Model Year 11 S Dodge City Assembly Plant 12 thru 17 6 digits Sequence Number 1990 DODGE Ram Pickup and Chassis Cab Model Line Up and Weights Model Vehicle Whe...

Page 19: ...0 131 8700 O O Chassis Cab D250 131 8510 O S O D350 131 8700 O s O 135 10 100 O s O 159 10 500 O s 0 W350 135 8700 O s 0 159 10 100 O s 0 11 000 O s 0 S Standard O Optional 1990 Standard Truck Body Di...

Page 20: ...75 4 763 11 0 6875 17 463 13 0 2031 5 159 45 0 7031 17 859 7 0 2188 5 556 23 0 7188 18 256 15 0 2344 5 953 47 0 7344 18 653 1 4 0 2500 6 350 3 4 0 7500 19 050 17 0 2656 6 747 49 0 7656 19 447 9 0 2813...

Page 21: ...Introduction Page 20 CHRYSLER MOTORS DODGE Turbo Diesel...

Page 22: ...nance Section 0 Contents Subject Page I Introduction 0A 1 Operating Instructions 0B 1 Maintenance Guidelines 0C 1 Engine Systems Row Diagrams 0D 1 Specifications 0E 1 Scheduled Maintenance for Vehicle...

Page 23: ...Lubrication and Maintenance DODGE Turbo Diesel...

Page 24: ...se Control Systems A 2 Exhaust System OA 2 Air Cleaner Assembly OA 2 Tampering with Noise Control System Prohibited OA 3 Classification of Lubricants OA 3 Parts Requiring No Lubrication 0 A _ 3 Parts...

Page 25: ...on 5 Commerciai type operation 6 Operated in water Noise Control Systems All vehicles built over 4535 kg 10 000 lbs Gross Vehicle Weight Rating and manufactured after 1 1 78 for sale and use in the Un...

Page 26: ...Requiring No Lubrication There are many points that should not be lubricated some because they are permanently lubricated some because lubricants will be detrimental to their operating characteristics...

Page 27: ...Fuel pump data plate Use the Information from the fuel pump data plate when discussing service or sourcing parts for the fuel system...

Page 28: ...DGE Turbo Diesel Introduction Page OA 5 Identifying Your Engine The following pictures shew the location and name of the major external components filters and other service points on your engine Front...

Page 29: ...Filter Water Inlet Connection Turbocharger Oil Return Freon Compressor Mounting Bracket Right Engine Mounting Bracket Rear of Engine Rear Engine Lifting Bracket Fuel Heater Element Fuel Heater Plug F...

Page 30: ...t OB 6 Anti Lock OB 7 LowFuel OB 7 Normal Starting Procedure OB 7 Cold Weather Starting OB 8 Engine Warm Up OB 8 Hand Throttle OB 8 Engine idling OB 9 Stopping the Engine OB 9 Operating the Engine OB...

Page 31: ...amage The engine is equipped with an automatic electric air preheating system If the instructions in this manual are followed the engine will start in all conditions unaided Warning Never use diesei f...

Page 32: ...ATTERY CONDITION INDICATOR O K TO JUMP START DO NOT JUMP START DARKENED INDICATOR WITH GREEN DOT BATTERY CHARGE OK FLUID LEVEL OK DARKENED INDICATOR NO GREEN DOT BATTERY CHARGE LOW FLUID LEVEL OK LIGH...

Page 33: ...nal of the discharged battery Warning do not permit vehicles to touch each other as this could establish a ground connection and counteract benefit of this procedure Connect one end of the other jumpe...

Page 34: ...ortant that their operating voltage does not exceed 12 Volts D C because damage to battery starter motor alternator or electrical system may occur New Engine Break in The care given the engine during...

Page 35: ...vent of a hydraulic brake failure BRAKE B CUMMINS TURBO DIESEL LOW FUEL DIESEL FUEL ONLY WATER IN FUEL WAIT TO START ANTI LOCK A Water in Fuel The Water In Fuel light is connected to a sensor located...

Page 36: ...S TURBO DIESEL LOW F U E L DIESEL FUEL ONLY Normal Starting Procedure Observe the following when starting the engine Apply emergency brake Manual Transmission Disengage the clutch by depressing the cl...

Page 37: ...engine up to operating speed slowly to allow the oil pressure to stabilize as the engine warms up If temperatures are below 0 C 32 F operate the engine at moderate speeds for 5 minutes before full to...

Page 38: ...combustion chamber bearings and internal components This is especially important for turbocharged engines like your Turbo Ram Operating the Engine Avoid overheating the engine The temperature of the...

Page 39: ...ne damage Fuel Requirement Warning Do not use alcohol or gasoline as a fuel blending agent They can be unstable under certain conditions and be hazardous or explosive when mixed with diesei fuel Use o...

Page 40: ...ss to guttering and valve burning A maximum sulfated ash content of 1 85 mass is recommended for all oil used in the engine Do not use special break in lubricating oils In the Cummins Turbo Diesel Eng...

Page 41: ...the minimum viscosity at 100 C 212 FJ Coolant Use antifreeze during all seasons to protect the cooling system from corrosion as well as freezing damage The antifreeze should be changed every two years...

Page 42: ...evel Check OC 5 Draining fuel water separator filter OC 5 Fan Inspection OC 5 Drive belt Inspection OC 5 Maintenance Every 6 Months or 9 700 Km 6 000 Miles OC 6 Lubricating oil and filter Change OC 6...

Page 43: ...ing Oil Lubricating Filter Fuel Filter Lubricating Oil Lubricating Filter Fuel Filter Air Cleaner Antifreeze Lubricating Oil Lubricating Filter Fuel Filter Air Cleaner Antifreeze Oil Level Coolant Lev...

Page 44: ...e Guidelines DODGE Turbo Diesel Page 00 3 Maintenance Record MAINTENANCE RECORD ENGINE SERIAL NO ENGINE MODEL OWNER S NAME EQUIPMENT NAME NUMBER DATE MONTHS OR KM MILES ACTUAL MILEAGE MAINTENANCE CHEC...

Page 45: ...oose parts frayed belts etc Oil level Check Check the engine oil level Never operate the engine with the oil level below the L LOW mark or above the H High mark The oil capacity between the low mark a...

Page 46: ...to allow any accumulated water to drain Close Release Valve the drain when clean fuel is visible Caution Diesel fuel will damage Black Top paving surfaces Drain the filter into an appropriate contain...

Page 47: ...perature reaches 60 C 140 F Shut the engine off Remove the oil drain plug Use a container that can hold at least 14 liters 15 U S quarts to hold the used oil 6 6 Fuel Oil Fuel Dilution Thin Black Good...

Page 48: ...5 LF3349 Manufacturer Chrysler Fleetguard H m o p a r Fleelguard i CHRYSLER MOTORS I I GENUINE PARTS I 4429615 V 17mm Check the condition of the threads and sealing surface on the oil pan and drain pl...

Page 49: ...ned in the Oil Specifications Section OE Fill the engine with the correct grade of new oil The engine capacity is 10 4 liters 11 U S quarts in the crankcase and 95 liter 1 U S quart in the lubricating...

Page 50: ...place the element as necessary Caution All air entering the engine Intake must be filtered The abrasive particles In un flltered air will Mmmk cause rapid wear to engine components Inspect the filter...

Page 51: ...es Maintenance Procedures and the following Check the antifre z e concentration Refer to Cooling System Section 7 Change the fuel filter Refer to Fuel System Section 14 Note This maintenance procedure...

Page 52: ...section 11 Change coolant and flush system See Sections 0C 0G OH and 7 Adjust the valves See section 9F Check the fan hub See section 7 Check the belt tensioner bearing See section 7 Check the belt t...

Page 53: ...ne Attach the water supply to the lower radiator connection and back flush the radiator If the radiator shows mineral build up scale rust or oil use a heavy duty radiator cleaner and follow the manufa...

Page 54: ...ap Start the engine and operate it until it re ches a temperature of 80 C 180 F Check the system for leaks Warning If the engine has been operating and the coolant is hot wait until the temperature id...

Page 55: ...Maintenance Guidelines Lubrication and Maintenance Page 00 14 DODGE Turbo Diesel...

Page 56: ...D 1 Engine Systems Flow Diagrams Section OD Contents Subject Page Engine Diagrams OD 2 Fuel System OD 2 Air System OD 2 Coding System OD 3 Lubricating Oil System OD 3 Lubrication for the Turbocharger...

Page 57: ...ter in Fuel Thermistor Bleed Screw Low Pressure Supply Line Robert Bosch Robert Bosch VE Distributor Type Injection Pump Turbo Boost Control Line Control Module Fuel Drain Manifold Return Fuel to Tank...

Page 58: ...nd forces it through the lubrication system The pressure regulation valve controls the oil pressure in the system The filter bypass valve ensures a supply of oil In the event the filter becomes plugge...

Page 59: ...Engine Systems Row Diagrams Page OD 4 Lubrication and Maintenance DODGE Turbo Diesel Lubrication for the Turbocharger Lubrication for the Power Components...

Page 60: ...Lubrication and Maintenance DODGE Turbo Diesel Lubrication for the Overhead Engine Systems Flow Diagrams Page OD 5...

Page 61: ...Engine Systems Flow Diagrams Lubrication and Maintenance Page OD 6 DODGE Turbo Diesei...

Page 62: ...rbo Diesel Engine Specifications Page OE 1 Engine Specifications Section OE Contents Subject Page Engine Specifications OE 2 Coolant Specifications OE 3 Oil Viscosity Recommendations OE 3 Arctic Opera...

Page 63: ...of Oil Filter liter U S quart 95 1 Cooling System Total Cooling System Capacity Manual liters U S quarts 14 7 15 5 Total Cooling System Capacity Automatic liters U S quarts 15 7 16 5 Coolant Recovery...

Page 64: ...s where antifreeze availability may be limited use a corrosion inhibitor Cummins liquid DCA or equivalent to protect the engine cooling system Oil Viscosity Recommendations The use of a multi grade lu...

Page 65: ...els within the following specifications Fuel Property Specification Lab Test Method Viscosity ASTMD 445 1 3 to 5 8 CentiStroke 1 3 to 5 8 mrr per Second at 40 C 104 F CetaneNumber ASTMD 613 40 minimum...

Page 66: ...X X X X X X X X X X X X NON EMISSION RELATED Alternator Brushes Replace X Engine Coolant Flush and Replace at 24 Months Or 24 000 Miles 38 600 Km X X X X Engine Coolant Condition Coolant Hoses and Cla...

Page 67: ...Scheduled Maintenance for Vehicle Emissions Lubrication and Maintenance PageOFr2 DODGE TurtoDlesd...

Page 68: ...E Turbo Diesel Page OG T Fluid Capacities Section OG Contents Subject Page Fluid Capacities OG 2 Engine Crankcase OG 2 Cooling System OG 2 Front Axle OG 2 Rear Axle OG 2 Transmission OG 2 Transfer Cas...

Page 69: ...ront Axle Dana 60 61 3 0 liter Rear Axle Dana 70 71 3 3 liters Transmission Manual Shift 5 speed 3 3 liters Automatic Chrysler A 727 Diesel 10 4 liters Transfer Case 4WD Models NP 205 2 1 liters Fuel...

Page 70: ...n OH Contents Subject Page Recommended Lubricants Fuels and Fluids OH 2 1 Fuel OH 2 ZEngineOil OH 2 3 Automatic Transmission Fluid OH 2 4 Manual Transmission Oii OH 2 5 Antifreeze OH 2 6 Power Steerin...

Page 71: ...extro II 4 Manual Transmission Oil 5W 30 Engine Oil MOPAR P N 4467717 0 95 liter 1 U S quart Note lf not available use SAE 5W 30 A P I Classification for service S G or SG1CD 5 Antifreeze MOPAR P N 42...

Page 72: ...SF CC or SF CD SAE Viscosity Grades Multipurpose Gear Oils If the anticipated minimum atmospheric temperature will be Use SAE 140 Above 32 C 90oF Use SAE 90 32 C 90 F to 23 C 10 F Use SAE 80 Below 23...

Page 73: ...Recommended Lubricants Fuels and Fluids PageOH 4 Lubrication and Maintenance DODGE Turbo Diesei...

Page 74: ...E Turbo Diesel Service Brakes Page 5 Section 5 Contents Subject Page Power Steering and Vacuum Pump 5 2 Power Steering Pump 5 2 Message Center Lights 5 2 Vacuum Pump 5 2 Disassembly 5 3 Reassembly 5 6...

Page 75: ...anual for the Rear Wheel Drive Trucks D W 150 350 Ramcharger for diagnostic and service procedures CUMMINS TURBO DIESEL LOW FUEL DIESEL FUEL ONLY BRAKE B CD WATER IN FUEL WAIT TO START ANTI LOCK Messa...

Page 76: ...r will activate the brake light on the warning light panel in 10 seconds or less when the vacuum drops to 8 5 in Hg or less In the brake system 15mm Remove the vacuum and the power steering pump assem...

Page 77: ...do not separate them However if there is damage press the eccentric out of the gear Use a flat plate over a new gear and press it on to the eccentric until it bottoms f j Visually inspect and rotate t...

Page 78: ...m pump housing Remove the push rods from the vacuum pump housing Inspect the push rods They should slide smoothly in the bushings but should not move side to side 10mm Remove the diaphragm assemblies...

Page 79: ...s on the power steering pump Install the gear eccentric bearing assembly by pulling it onto the power steering shaft with a 3 8 inch 18 thread capscrew with a flat washer threaded into the power steer...

Page 80: ...15mm install the assembly onto the engine with a new gasket Torque Value 77 N m 57 ft lbs Specifications Power Steering Pump to Vacuum Pump Torque Value 24 N m 18 ft lbs Vacuum Pump to Vacuum Pump Dr...

Page 81: ...Specifications Page 5 8 Service Brakes DODGE Turbo Diesei...

Page 82: ...S General Information 6 2 Clutch Pedal and Bracket 6 2 Service Diagnosis 6 2 Service Procedures 6 3 Replacement 6 3 Installation 6 7 Specifications 6 8 Application 6 8 Cover and Pressure Plate Identi...

Page 83: ...and reservoir must be replaced asah assembly The upper end of the clutch pedal pivots in the pedal bracket on two nylon bushings These bearings do not require periodic lubrication Condition Clutch Ch...

Page 84: ...embly Handle the clutch and the disc carefully to avoid contaminating the friction surfaces Replacement Remove the transmission 8 16 Inch Remove the clutch housing release fork and bearing assembly Ma...

Page 85: ...on the flywheel may be improperly mounted or sprung In either case a dial indicator mounted on the clutch housing with the plunger in contact with the wear circle should show no more than 76mm 003 inc...

Page 86: ...ing the facings Replace the disc if the facings show evidence of grease or oil soakage or wear to within less than 015 Inch of the rivet heads The hub splines and splines on the transmission main driv...

Page 87: ...rm wear pattern f p j Using a surface plate test the cover for flatness All sections around the attaching bolt holes should be in contact with surface plate Examine the condition of the clutch release...

Page 88: ...tch cover assembly and disc on the flywheel being careful to properly align the alignment marks made before removal Insert a universal clutch alignment tool through the clutch disc into the pilot bear...

Page 89: ...429153 Disc Assembly 4429151 Cover and Pressure Plate Identification Plate Load Springs Assembly Part Number 4429152 in Pounds 2340 No Color Diaphragm Spring Raymark M8400 Permanently Lubricated Bail...

Page 90: ...rive Belt Replacement 7 10 Belt Tensioner Replacement 7 10 Fan Pulley Replacement 7 11 Coolant Draining 7 11 Water Pump Replacement 7 12 Thermostat Replacement 7 13 Cup Plugs Replacement f 7 15 Fan Hu...

Page 91: ...thermostat is closed and the coolant flow bypasses the radiator and goes to the water pump inlet via internal drillings in the block and cylinder head When operating temperature is reached the thermos...

Page 92: ...he rod journals are submerged in oil Overfilling the engine with oil raises the oil temperature This additional heat is transferred to the coolant system at the oil cooler The system is designed to us...

Page 93: ...e is required for operation of the engine in temperature environments above 37 C 34 F A mixture of 40 water and 60 antifreeze is recommended for temperatures below 37 C 34 F Caution The small holes In...

Page 94: ...e system causing the cap to open Similarly coolant can be displaced through the overflow if the head gasket leaks compression gasses to the coolant system o 1 a D The operating pressure of the coolant...

Page 95: ...the inlet hose to the water pump collapses A hose will usually not collapse while the engine Is running at low speed Check the hose while the engine is running at rated speed Note Be sure the engine...

Page 96: ...r can be the problem Note Check the bearings in the fan hub and other pulleys to make sure they are not causing excessive belt slippage and vibration Thermatic fans operate only as needed to keep the...

Page 97: ...diator Caution Never operate the engine without a thermostat Without a thermostat the path of least resistance for the coolant is through the bypass to the pump Inlet This will cause the engine to ove...

Page 98: ...engine coolant temperature Gauges Overfueling and Loading Gauges and sensors are used in the system to measure the coolant temperature These can malfunction and provide an incorrect temperature indic...

Page 99: ...lt WithAir f ConditioningL Water Pump Belt Tensioner Freon Compressor Belt Tensioner Two variations of Belt Drives are available on the 5 9 Liter Diesei 1 With an Air Conditioning Option 2 Without Air...

Page 100: ...n 3 8 inch Drive Bar 10mm Remove the fan belt Remove the six capscrews and replace the fan pulley Torque Value 9 N m 7 ft lbs Coolant Draining Warning Walt until the temperature is below 50 C 120 F be...

Page 101: ...E Turbo Diesel Water Pump Replacement Preparatory Steps Drain the coolant Remove the drive belt 13 mm Remove the two capscrews and water pump from the cylinder block CD y v j Clean the sealing surface...

Page 102: ...Cooling System DODGE Turbo Diesel Cooling System Replacement Procedures Page 7 13 10mm Remove the thermostat housing lifting bracket and thermostat...

Page 103: ...ooling System Replacement Procedures Page 7 14 Cooling System DODGE Turbo Diesel Be sure the tang is in the slot in the housing 2 This ensures the correct positioning of the jiggle pins in the housing...

Page 104: ...Coding System DODGE Turbo Diesel Cooling System Replacement Procedures Page 7 15 Fan Hub Replacement Preparatory Steps Remove the fan Remove the drive belt Remove the fan pulley...

Page 105: ......

Page 106: ...diameter push pin Note Approximately 6 tons of pressure Is required 2 Inch Black Pipe 2 3 8 Inch O D X 4 Inch long Support the bearing housing and push the bearing out using a tool of suitable diamet...

Page 107: ...Value 77 N m 57 ft lbs Thermostat Inspection Check the thermostat operation by placing it in a flask of heated water The thermostat operate as follows 1 Maximum start to open at 83 C 181 F 2 Maximum...

Page 108: ...pection Check the belt for intersecting cracks Transverse across the belt width cracks are acceptable Longitudinal direction of belt length cracks that intersect with transverse cracks are NOT accepta...

Page 109: ...nd follow the manufacturer s directions Remove the top heater hose Attach the water supply to the heater line and back flush the engine if the radiator shows mineral build up scale rust or oil use a h...

Page 110: ...m for leaks Warning If the engine has been operating and the coolant is hoty wait until the temperature Is below 50 C 120 F before removing the pressure cap Failure to do so ran cause personal Injury...

Page 111: ...iter Diesei W250 350 4 Wheei Manual 30 19 14 7 15 5 Component Capscrew Torque Values N m Inch N m Foot Pounds Pounds Water Pump C S 24 N m 18 ft lbs Viscous Fan Drive Attaching Nut 57 N m 42 ft lbs Fa...

Page 112: ...Oil Pressure Switch Sending Unit Check 8 11 Coolant Temperature Sensor Check 8 11 Coolant Heater Check 8 11 Engine Electrical System Replacement Procedures 8 12 Sterling Motor Replacement 8 12 Alterna...

Page 113: ...poses of this manual the electrical system consists of the starting motor alternator heaters and control devices The injection pump uses an electrical fuel shut off valve The engine has water temperat...

Page 114: ...Bectrical System DODGE Turbo Diesel Alternator Electrical System Description Operation Page 8 3 Voltage Regulator To Ignition Switch...

Page 115: ...ld Heater System Intake Manifold Heater System 5 9 Liter Diesel Engine A6 6 BKw Waft to Start Ignition On Light 12V Supply E5 20 DG WT J2A 14 DB I S20 18 LB Air Heater Controller Electronic Control Mo...

Page 116: ...BK PK H4D 22 BK TO Fuel LL Tank Module G40 20 DB RD Air Heater Controller Electronic Control Module Ground K9C 18 BK Engine Wiring Ignition Run Circuit J2A 14 DB ECM 12V Supply J2A 14 DB KSB Valve J32...

Page 117: ...ection 3 8x16 inch Switch Connection 8 32 inch 1 1 Diagnosing Electrical Malfunctions l J Starting Motor Before you troubleshoot the starting motor make sure the battery terminals are not loose or cor...

Page 118: ...inal check Check the fuses Check the voltage at the ignition switch Check the clutch switch or the neutral safety switch Check starter relay switch If the solenoid does make an audible sound turn the...

Page 119: ...tion of engine rotation to make sure the engine is free and does not have an internal malfunction 9 6 to 12V 0 to 9 6 if the engine is free check the voltage at the starter during cranking if the volt...

Page 120: ...Ammeter Stopped Off o Stopped On Running On Switch On Negative on Ammeter Engine 6 Running If the ammeter is indicating a discharge during engine operation inspect the alternator drive pulley and dri...

Page 121: ...ircuit With all accessories turned off connect a voltmeter across the battery Operate engine at moderate speed If voltage is 12 Volts or less repair the alternator or voltage regulator as necessary Fu...

Page 122: ...sure drops to 55 kPa 8 PSI The pressure switch wilt activate a Low Pressure Warning Light on the dash of the truck Coolant Temperature Sensor Check Replace the sensor and rerun engine to confirm the t...

Page 123: ...Identify each electrical wire with a tag indicating location 8mm 10mm 12 point socket 15mm Remove the starting motor Install the starting motor in the reverse order of removal Torque Value Starter mou...

Page 124: ...omplete the following steps 13mm Remove the alternator link capscrew 13mm 15mm Remove the alternator mounting capscrew 7mm 8mm 10mm 13mm 15mm install the alternator Tighten the upper mounting capscrew...

Page 125: ...the valve Clean the area around the valve thoroughly ISMnra ACaution When removing the valve be careful not to drop _ the piston and spring from inside the valve housing Replace the valve and connect...

Page 126: ...lacement Warning Walt until the temperature Is below 50 C 120 F before removing the coolant system pressure cap Failure to do so can cause personal injury from heated coolant spray Drain the coolant s...

Page 127: ...nnect wiring Remove thermistor Apply liquid teflon sealant to threads Tighten the thermistor Torque Value 24 N m 18 ft lbs Location B Head Water Jacket Warning Wait until the temperature is below 50 C...

Page 128: ...ct the wiring harness Tighten the sensor Refill Cooling System Torque Value 24 N m 18 ft lbs Fuel Heater Replacement 75 80mm Filter Wrench Clean the area around the fuel filter and fuel heater thoroug...

Page 129: ...apter Install the fuel heater and adapter Tighten the adapter Torque Value 32 N m 24 ft lbs Apply a light film of lubricating oil to the sealing ring of the fuel water sensor Install the sensor in the...

Page 130: ...diator A drain pan with a capacity of 20 liters 5 U S gallons will be adequate to hold the coolant Engine Electrical System Replacement Procedures Page 8 19 Disconnect the block heater electrical cord...

Page 131: ...fill the cooling system Intake Manifold Heater Replacement Remove 10mm Disconnect the throttle rod from the throttle lever Remove the four mounting capscrews A Loosen the throttle control bracket low...

Page 132: ...orque Value 24 N m 18 ft lbs Tighten the throttle bracket lower mounting capscrew B Torque Value 24 N m 18 ft lbs Tighten the hose clamp C Torque Value 5 N m 44 in lbs A 24 N m 18 ft lbs 24 N m It18 f...

Page 133: ...ould be no voltage at the KSB valve if the intake manifold temperature is less than 15 C 59 F 20 Seconds CLICK M m JWATERIN RJELI BRAKE B 0 w rr TO START J The WAIT to START light should stay on Prehe...

Page 134: ...t will come on and the heater solenoids should activate with an audible CLICK BRAKE 0 f I M S S J 3 I E S E L X WAIT TO START AWTI J OCK CLICK P L Check the voltage at both heater terminals There shou...

Page 135: ...ifold temperature Above 15 C 59 F 9 C 15 F to 15 C 159 F 18 C 0 F to 9 G 15 F1 25 C 15 F to 18 C 0 F Below 26 C 150F Preheat Cycle time ignition key ON Before crank cycle 0 Seconds 10 Seconds 15 Secon...

Page 136: ...ue Values Alternator Lower Mounting Capscrew 43 N m 32 ft lbs Alternator Pulley Retainer Nut 80 N m 60 ft lbs Alternator Upper Mounting Capscrew 24 N m 18 ft lbs Cylinder Block heater 12 N m 9 ft lbs...

Page 137: ...Specifications Page 8 26 Electrical System DODGE Turbo Diesel...

Page 138: ...g System 9C General Overview In and Out of Chassis Repairs 9D In Chassis Repairs General 9E In Chassis Diagnostic Procedures 9F In Chassis Repairs 9G Out of Chassis Repairs General 9H Out of Chassis D...

Page 139: ...Base Engine Components DODGE Turbo Diesel...

Page 140: ...Components DODGETurbo Diesel Troubleshooting Logic Page9A 1 Troubleshooting Logic Section 9A Contents Subject Page Engine Diagrams Problem Isolation and Correction 9A 2 Troubleshooting Logic List of S...

Page 141: ...eries of fault logic charts given do not provide all the answers but they should stimulate a train of thought that will lead you to the source of the trouble Be sure to consider any maintenance or rep...

Page 142: ...hard to start or will not start Smoke from exhaust 9A 7 Engine RPM will not reach rated speed 9A 14 Engine runs rough or misfiring 9A 12 Engine starts but will not keep running 9A 9 Engine will not c...

Page 143: ...ankshaft Rotation Restricted Bar the Engine to Cheek for Rotational Resistance OK Starting Circuit Connections Loose or Corroded Clean and Tighten Connections OK Neutral Safety Switch or Starter Relay...

Page 144: ...al Shut Off Lever is in the Run Position OK t Air Intake or Exhaust Plugged Visually Check Remove the Obstruction OK t Fuel Filter Plugged With Water Other Drain Fuel Water Separator and Contamination...

Page 145: ...Engine Components DODGE Turbo Diesel Engine Cranks But Will Net Start No Smoke From Exhaust Continued Cause Correction Internal Pump Timing Incorrect Verify Time the Pump OK Camshaft Out of Time Check...

Page 146: ...d Wiring Connections Bar the Engine to Check for Internal Rotational Resistance Cold Starting Aids Not Working or Are Needed Verify the Aids are Operating OK t Intake Heater System Not Working Verify...

Page 147: ...asoline Drain and Flush Fuel Supply Tanks Replace Fuel Water Separator Filter Contaminated with Gasoline Verity by Operating the Engine with Clean Fuel from a Temporary Tank Check for Presence of Gaso...

Page 148: ...ilter and Bleed the System Locate and Correct the Air Source Supply is inadequate Check the Flow Through the Filter and Bleed the System Locate and Correct the Air Source OK Fuel Waxing Due to Extreme...

Page 149: ...cessories OK High Pressure Fuel Leak Inspect Correct Leaks in the High Pressure Lines Fittings and Delivery Valve Sealing Washers Inspect Correct Leaks in the High Pressure Lines Fittings and Delivery...

Page 150: ...ow Idle Screw OK Engine Mounts Damaged or Loose Verify Condition of Mounts Engine Mounts Damaged or Loose Verify Condition of Mounts OK High Pressure Fuel Leak Inspect Correct Leaks in the High Pressu...

Page 151: ...lter and Bleed the System Locate and Correct the Air Source inadequate Check the Flow Through the Filter and Bleed the System Locate and Correct the Air Source OK Contaminated Fuel Fuel Contaminated V...

Page 152: ...Troubleshooting Logic Page9A 13 Engine Runs Rough Or Misfiring Continued Cause Correction Camshaft Out of Time Check Correct Gear Train Timing Alignment OK Damaged Camshaft or Tappets Inspect Camshaf...

Page 153: ...d OK Malfunctioning Tachometer Verify Engine Speed with Hand Tachometer Correct as Required OK Throttle Linkage Worn or Incorrectly Adjust Linkage for Stop to Stop Fuel Adjusted Control Lever Travel O...

Page 154: ...Malfunctioning Accessories or Driven Units Brakes Dragging and Other Changes in Vehicle Loading OK t If the Condition is Slow Throttle Response Leaking Air Fuel Control Tube or Malfunction Control in...

Page 155: ...hat Fuel Heater is Off During Warm Weather Check for a Restricted Fuel Drain Manifold Robert Bosch VE OK t Poor Quality Fuel Fuel Contaminated with Gasoline Verify by Operating From a Temporary Tank W...

Page 156: ...Correction Valve Clearances Incorrect Check Adjust Valves OK Injection Pump Internal Malfunctioning Check Time Pump OK Worn or Malfunctioning Injectors Check Replace Injectors OK t Malfunctioning inj...

Page 157: ...ther Restrictions OK Air Leak Between the Turbocharger and the intake Manifold Check Correct Leaks in the Air Crossover Tube Hoses Gaskets Mounting Capscrews or Through Holes in the Manifold Cover OK...

Page 158: ...iesel Troubleshooting Logic Page9A 19 Excessive Exhaust Smoke Continued Cause Correction Malfunctioning or Overtueled Injection Replace Injection Pump Pump OK Piston Rings Not Sealing Blue Smoke Perfo...

Page 159: ...for Coolant Loss G Incorrect Malfunctioning Pressure Cap Replace Cap with the Correct Rating for the System OK High Lube Oil Level Check Drain Oil to Correct Level OK t Loose Drive Belt on Water Pump...

Page 160: ...e Thermostat Thermostat OK Air in the Cooling System Make sure the Fill Rate is not Being Exceeded and the Correct Vented Thermostat is Installed OK OK t I Check for Loose Hose Clamps If Aeration Cont...

Page 161: ...Turbo Diesel Coolant Temperature Above Normal Continued Cause Correction Plugged Cooling Passages in Radiator Flush the System and Fill with Clean Head Head Gasket or Block Coolant OK Engine Overload...

Page 162: ...scous Fan as Required OK t Incorrect Thermostat Broken Thermostat Jiggle Pin or Contamination In Thermostat Check Replace Thermostat Incorrect Thermostat Broken Thermostat Jiggle Pin or Contamination...

Page 163: ...nal Engine Leak Visually Inspect the Engine and Components for Seal or Gasket Leaks OK Overheating or Leaking Compression Gases Resulting in Loss Through the Radiator Overflow Review the Operation for...

Page 164: ...ents DODGE Turbo Diesel Troubleshooting Logic Page 9A 25 Coolant Loss Continued Cause Correction Cracked or Porous Head Check Replace the Head OK Leak In Cylinder Block Coolant Passages Check Replace...

Page 165: ...h Gage Verify the Pressure Switch is Functioning Correctly OK t Relief Valve Stuck Open Check Replace Valve OK Plugged Oil Filter Change Oil Filter Review Change Interval OK t If Cooler was Replaced S...

Page 166: ...Lube Pump Check Replace Lube Pump OK Suction Tube Loose or Seal Leaking Check Replace Seal OK Loose Main Bearing Cap Check Install New Bearings and Tighten Cap OK t Worn Bearings or Wrong Bearings In...

Page 167: ...erify the Pressure Switch is Functioning Correctly OK t Engine Running Too Cold Refer to Troubleshooting Logic for Coolant Temperature Below Normal OK t Oil Viscosity Too Thick Make Sure the Correct O...

Page 168: ...ation or Viscosity Make Sure the Correct Oil is Being Used OK Look for Reduced Viscosity from Dilution with Fuel Review Reduce the Oil Change Intervals r Oil Cooler Leak Check for Oil in the Coolant m...

Page 169: ...Loss Continued Cause Correction Turbocharger Leaking Oil to the Air Inspect the Air Crossover Tube for Intake Evidence of Oil Transfer OK Worn Valve Seals Inspect Replace the Valve Seals OK Piston Ri...

Page 170: ...sty Cooiant Operation Without Correct Mixture of Antifreeze and Water Drain and Flush the Cooling System Fill with Correct Mixture of Antifreeze and Water OK Review the Coolant Change Interval Leaking...

Page 171: ...Sludge Review Oil and Filter Change Intervals Excessive Oil Sludge Review Oil and Filter Change Intervals Make Sure the Correct Oil is Being Used Fuel in the Oil Engine Operating Too Review the Operat...

Page 172: ...take Air Restriction Check Replace Fitter Element Review Operation for Excessive Idling Injector Needle Valve Stuck Open Locate and Replace Malfunctioning injector OK Obstructed Turbocharger Drain Lin...

Page 173: ...y Operating from a Temporary Poor Quality Fuel Gasoline Tank with Good Fuel Clean and Flush Poor Quality Fuel Gasoline the Fuel Supply Tanks Replace Fuel Water Seperator Filter OK Engine Overloaded Ve...

Page 174: ...OK t Operator Technique Review Operation for Correct Gear Shifts Deceleration and Idling OK Poor Quality Fuel Make Sure Quality No 2 Diesel Fuels are Being Used OK t Inadequate Intake Air or Exhaust...

Page 175: ...el Pump Check Replace Sealing Washer Piston and Spring OK Engine Running on Fumes Drawn into Check the Air Intake Ducts for the the Air Intake Source of the Fumes ATo stop an engine that is runnng on...

Page 176: ...or Broken Engine Mounts Check Replace Engine Mounts OK t Damaged Fan or Malfunctioning Accessories Check Replace the Vibrating Component OK Malfunctioning Vibration Damper Inspect Replace the Vibratio...

Page 177: ...ents DODGE Turbo Diesel Excessive Vibration Continued Cause Correction Loose or Broken Power Component Inspect the Crankshaft and Rods for Damage that Cause an Unbalance OK t Worn or Unbalanced Drive...

Page 178: ...nator Turn Freely OK Intake Air or Exhaust Leaks Refer to Troubleshooting Logic for Excessive Exhaust Smoke OK Excessive Valve Lash Adjust Valves Make sure the Push rods are Not Bent and Rocker Levers...

Page 179: ...Charging Or Insufficient Charging Cause Correction Loose or Corroded Battery Connections Clean Tighten Battery Connection OK Alternator Belt Slipping Check Replace Belt Tensioner OK t Alternator Pull...

Page 180: ...9B 8 Coolant Diluted Oil 9B 8 Fuel Diluted Oil 9B 9 Injection Pump Shaft Seal 9B 10 Fuel Leakage by the Rings 9B 11 Lift Pump Leakage 9B 12 Cylinder Head Leakage 9B 12 Oil Leaks 9B 12 Lubricating Oil...

Page 181: ...ton pins are lubricated by the splash from the piston cooling nozzles The oil pump idler gear bushing is pressure lubricated The remainder of the front gear train is lubricated by oil carry over and s...

Page 182: ...through the element where it is cooled by engine coolant flowing past the plates of the element Oil Filters After the oil is cooled it flows through the full flow oil filter From the filter oilflowsto...

Page 183: ...s in the crankshaft supply oil to the connecting rod bearings The oil is supplied to the camshaft journals through drillings in the main bearing saddle Smaller drillings in the main bearing saddle sup...

Page 184: ...r head gasket From the transfer slot the oil flows around the outside diameter at the cylinder head capscrew across a slot in the bottom of the rocker lever support and up a vertical drilling in the s...

Page 185: ...ve The pressure regulating valve components are machined to a size that will relieve the excessive pressure created by cold engine oil ft t Z To Oil Cooler From Pump Oil Pressure Regulating Valve The...

Page 186: ...sending unit to make sure they are operating correctly by verifying the pressure with a manual gauge Oil Suction Tube A loose suction tube damaged gasket or crack in the suction tube can cause a temp...

Page 187: ...ge f Check the condition of the oil Thin black oil is an indication of fuel in the oil Milky discoloration is an indication of coolant in the oil Coolant in the oil can be caused by Cup plugs leaking...

Page 188: ...ollowing an engine shutdown the residual pressure in the coolant system can cause coolant to seep through the leak path into the oil Fuel Diluted Oil Fuel dilution is limited to four sources 1 Injecti...

Page 189: ...pressure is low Caution A worn seal can not be detected by pressurizing the pump with normal operating pressure By Increasing the pressure In the pump the sealing force will also be increased The bus...

Page 190: ...e by the Rings Incomplete combustion in the cylinders can result in unburned fuel draining into the oil pan This condition can be caused by a leaking injector or reduced compression caused by inadequa...

Page 191: ...he drain hole would have to be plugged Cylinder Head Leakage Another remote possibility is a crack or porosity in the head casting could allow fuel to leak to the air intake and on to the cylinders A...

Page 192: ...als will result in oil being blown out the breather tube and or consumed by the engine Lubricating Oil Level Check Check the engine oil level Never operate the engine with the oil levei below the M L...

Page 193: ...15 U S quarts to hold the used oil Fuel Dilution Thin Black Good Oil 6 6 H2 0 Oil Water In Oil Milk Color Always check the condition of the used oil This can give you an indication of some engine pro...

Page 194: ...rface before installing the filter 17mm Check the condition of the threads ami sealing surface on the ill pan and drain plug mn the drain plug and the sealing surface of the pan Install J s ew drain p...

Page 195: ...the correct grade of new oil The engine capacity is 10 4 liters 11 U S quarts in the crankcase and 95 liter 1 U S quart in the lubricating oil filter Lubricating System Replacement Procedures Oil Pres...

Page 196: ...mbled Height 44 98mm 1 77 inch Load 60 N 13 5 lb 19mm Clean and Inspect the plunger bore and seat before assembly Note The plunger must move freely in the valve bore Assemble the valve in the reverse...

Page 197: ...ase Engine Components DODGE Turbo Diesel Oil Cooler Element and or Gasket Replacement Preparatory Step Drain the coolant Clean around the oil cooler cover 5 8 Inch 19mm Disconnect the turbocharger sup...

Page 198: ...cooler cover gaskets and coder element t tm Clean the sealing surfaces Apply 483 kPa 70 PSI air pressure to the element to check for 3 M leaks 10mm Assemble the oil cooler gaskets element and cover T...

Page 199: ...t Install the oil filter Fill the coolant system and operate the engine to check for leaks Stop the engine and check the coolant and oil level Oil Pan Suction Tube and or Gaskets Replacement 17mm 10mm...

Page 200: ...tem Page9B 21 10mm 13mm If required remove the suction tube ami gasket Ciean the sealing surfaces Install the suction tube and gasket Caution Be sure to connect the support bracket Torque Value 24 N m...

Page 201: ...ove the drive belt Remove the radiator Remove the fan clutch assembly Remove the fan hub Remove the oil fill Note Removal is easier if the crankshaft vibration damper is loosened before removing the b...

Page 202: ...bo Diesel Engine Lubricating System Page9B 23 Remove the Lubricating Oil Pump 13mm Remove the four mounting capscrews Remove the pump from the bore in the cylinder block Mark TOP on the gerotor planet...

Page 203: ...inspect for excessive wear or damage Clean ail parts In solvent and dry with compressed air j Inspect the pump housing and gerotor drive for damage and excessive wear Caution Be sure the gerotor plane...

Page 204: ...78mm 0 007 inch Measure the clearance of the gerotor drive gerotor planetary f to port plate L S Limit Maximum Clearance 0 127mm 0 005 inch Measure the clearance of the gerotor planetary to the body l...

Page 205: ...Engine Lubricating System Page 9B 26 Base Engine Components DODGE Turbo Diesei...

Page 206: ...alling a new S n pump Measure gear backlash A Idler to Pump Drive 08 to 0 33mm 003 to 013 Inch Backlash Limits B Idler to Crankshaft 08 to 0 33mm 003 to 013 inch Note If the adjoining gear moves when...

Page 207: ...m the seal kit to align the cover to the crankshaft 10mm C j Tighten the front cover capscrews Torque Value 24 N m 18 ft lbs Remove the alignment installation tod Caution Always use a seal pilot when...

Page 208: ...eal carrier hit the alignment installation tool alternately at the 12 3 6 and 9 o clock positions Use the alignment installation tool and a plastic hammer to install the seal to the correct depth 17mm...

Page 209: ...Engine Lubricating System Page9B 30 Base Engine Components DODGE Turbo Diesei p j U Drive the cup plugs in until they bottom in the bore...

Page 210: ...Base Engine Components Engine Lubricating System DODGE Turbo Diesel Page 9B 31 Fili the engine with oil Run the engine and check for leaks Stop the engine and check the oil level with the dipstick...

Page 211: ...g oil that meets the following requirements SAE 5W30 viscosity grade synthetic oils may be used provided they meet the minimum viscosity at 100 C 212 F Parameter Test Method Specifications Performance...

Page 212: ...h are not Included in the other major engine systems They are Cylinder head and valve train front gear housing and gear train flywheel housing and flywheel camshaft tappets and push rods front cranksh...

Page 213: ...machine shop using the appropriate service parts The cylinder head has a cast intake manifold fuel filter head thermostat housing and an internal water bypass The injectors are mounted in the head for...

Page 214: ...rt for the injection pump the timing pin ami the accessory drive gear Front Crankshaft Seal In Chassis Repair The front crankshaft seal is mounted in the front gear cover A double lipped Teflon seal i...

Page 215: ...engines The center line of the tappet is slightly offset from the center line of the cam lobe This design feature and the slightly convex surface of the tappet causes the tappet to rotate as it is li...

Page 216: ...a keystone profile for the top piston ring Always check the part number to be sure the correct configuration is used during piston replacement The piston ring sets consist of three rings the top ring...

Page 217: ...1 000 mm 0394 in Oversize service rod bearings are available for use with re ground crankshafts Crankshaft and Main Bearings Out of Chassis Repair The crankshaft is a balanced forged steel unit with 7...

Page 218: ...djacent holes is aligned with a drilling to the camshaft journal and serves as an orifice for lubrication flow to the journal The other adjacent hole supplies oil for piston cooling The hole does not...

Page 219: ...General Overview In and Out of Chassis Repairs Base Engine Components Page 9C 6 DODGE Turbo Diesel...

Page 220: ...der walls Check the oil and oil filter to be sure the lube system is not thoroughly contaminated with metal Also check for rust In the coolant Rust in the coolant can indicate build up in the passages...

Page 221: ...In Chassis Repairs General Base Engine Components Page 9D 2 DODGE Turbo Diesei...

Page 222: ...ubject Page Air and Fuel Systems Check 9E 2 Valve Train and Head Assembly SE 2 Valve Adjustment Check 9E 3 Valve Seal Wear 9E 3 Injector Protrusion 9E 4 Rocker Lever Valve Stem Push Rod Tappet and Cam...

Page 223: ...oblem first troubleshoot the air and fuel systems to make sure the engine is receiving adequate intake air and fuel Valve Train and Head Assembly The sound emitted from the overhead can indicate a val...

Page 224: ...torque sequence Valve Adjustment Check Verify that the valves are adjusted correctly Valve Lash Intake 254 mm 010 in Exhaust 508 mm 020 in Valve Seal Wear Worn valve seals are typically detected by bl...

Page 225: ...as been refaced The head gasket is marked to indicate the thickness One notch means the gasket is standard for use with blocks that have not been refaced Two notches identify that the gasket is for us...

Page 226: ...If an inspection of the levers valve stems and push rods does not show wear tappet and or cam lobe wear can be suspected Caution Anytime a new camshaft Is Installed new tappets must also be installed...

Page 227: ...damper for visible wobble when routing Verify that the index lines A are aligned If the lines are more than 1 59mm 1 16 Inch out of alignment replace the damper Inspect the rubber member B for deterio...

Page 228: ...s If a ring gear is damaged on an automatic transmission drive plate the drive plate must be replaced Rear Crankshaft Seal The rear crankshaft seal is mounted In a housing that bolts to the rear of th...

Page 229: ...In Chassis Diagnostic Procedures Page9E 8 Base Engine Components DODGE Turbo Diesel...

Page 230: ...ding Depth 9F 16 Inspect the Valve Springs 9F 20 Measure Valve Spring Force 9F 20 Assembly of the Cylinder Head 9F 20 Cylinder Head and Gasket Installation 9F 22 Front Crankshaft Seal Replacement 9F 2...

Page 231: ...ODGE turbo Diesel Rocker Levers and Push Rods Replacement 15mm f Preparatory Step Remove the valve covers 13mm 18mm Remove the 8mm and 12mm capscrews from the robker lever pedestals Remove the pedesta...

Page 232: ...are to be inspected for follow these steps Remove the retaining rings ami thrust washers In Chassis Repairs Page9F 3 Remove the rocker levers Caution Do not disassemble the rocker lever shaft and ped...

Page 233: ...j Use compressed air to dry the parts after rinsing in clean hot water Note The pedestals are made from powdered metal and may continue to show wetness after they have been cleaned and dried S Inspect...

Page 234: ...the pedestal and shaft Measure the shaft diameter Minimum Diameter 18 94mm 0 746 inch Rocker Levers Assembly install the adjusting screw and lock nut Lubricate the shaft with engine oil Caution Be su...

Page 235: ...In Chassis Repairs Page 9F 6 Base Engine Components DODGETurbo Diesei fez Check the push rods for roundness and straightness...

Page 236: ...tals are installed into the dowel bores in the cylinder head Note If the push rod is holding the pedestal off of the cylinder head bar the engine until the pedestal will set on the head surface withou...

Page 237: ...In Chassis Repairs Page 9F 8 Base Engine Components DODGE Turbo Diesel se shown to tighten ALL of the 12mm cylinder N m 29 ft lbs N m 62 ft lbs N m 93 ft lbs pedestal capscrews 4 N m 18 ft lbs...

Page 238: ...the clearance for the valves shown in the illustration Intake 0 254mm 0 010 inch Exhaust 0 508mm 0 020 Inch Torque Value 24 N m 18 ft lbs 6 5 4 3 2 1 Cylinder Head Removal Drain the coolant and oil D...

Page 239: ...meter 102 116 mm 4 0203 inch Out of Roundness 038 mm 0015 inch Taper 076 mm 003 inch Refer to the limits for the oversize cylinder bores Note Do not proceed with in chassis repair if the bores are dam...

Page 240: ...und can be replaced with service seats Service valve guides are also available to replace worn valve guide bores Caution Seats that have been previously re ground should be marked as illustrated Disas...

Page 241: ...12 Base Engine Components DODGE Turbo Diesei Remove the remaining collets retainers springs and valves Caution Keep the wives in a labeled rack Remove the valve stem seals J Scrape the gasket residue...

Page 242: ...scuffing or scoring Measure the valve guide bore Diameter mm in 8 019 8 089 MIN MAX 0 3157 0 3185 Note If the valve guide bore is over the maximum limit refer to engine Alternative Repair Section 9K...

Page 243: ...g the Valves Clean the valve heads with a soft wire wheel Polish the valve stems with crocus cloth Caution Re mark the wives according to head location V w Inspect for abnormal wear on the valve heads...

Page 244: ...Caution Mark the new valves if required for the replacement location Mmm Grinding the Valves Grind the face of valves to be reused Check for and replace bent valves Seat Angle intake 30 Degrees Exhau...

Page 245: ...e Engine Components DODGE Turbo Diesel Grinding the Seats Caution The illustrated marks indicate valve seats have been ground previously Replacement valve seat inserts must be installed if the valve s...

Page 246: ...DGE Turbo Diesel In Chassis Repairs Page F 17 Grind the valve seats to remove scores scratches and bums Seat Angle Intake 30 Degrees Exhaust 45 Degrees Install the valves In their respective bores and...

Page 247: ...f each valve as B Calculate grinding depth GD as follows GD B A V n J Umk G D 0 254mm 0 010 inch Note Service valve seats are available for seats that are over the limit Refer to the Egnine Alternativ...

Page 248: ...ution Replace the valve if the depth is over the limit Apply a light coat of valve lapping compound to each valve and lap each valve to its companion seat Remove the valves and clean the lapping compo...

Page 249: ...nch Inspect the Valve Springs Measure the valve spring Limits Approximate Free Length L 55 63mm 2 190 inch Maximum Inclination 1 0mm 0 039 inch Measure Valve Spring Force Force Required 289 32 N 65 lb...

Page 250: ...Page 9F 21 Install new valve collets and release the spring tension Plastic Hammer j Warning Wear protective equipment and do not stand in L line with the valve stem when tapping the wive Mm After as...

Page 251: ...ligned with the holes in the cylinder block The cylinder block and head must be clean and dry Position the gasket onto the dowels cJl info Lijoi vL fojfU U Install the push rods and levers Lubricate t...

Page 252: ...N m 18 ft lbs 14mm Screwdriver Adjust the valve clearance Note Refer to Valve Clearance Adjustment Section for valve set procedure 15mm Install the valve covers Torque Value 24 N m 18 ft lbs Install t...

Page 253: ...apart as shown No 10 Sheet Metal Screw Slide Hammer Dent Puller Use a slide hammer tool with a 10 metal screw as shewn alterantingfromside to side until the seal is free A install Caution The sealing...

Page 254: ...r of the seal install the pilot from the seal kit onto the crankshaft Install the seal onto the pilot and start it Into the front cover bore Remove the pilot Alignment Installation Tool Plastic Hammer...

Page 255: ...ing the retaining ring out with a small screwdriver Replace the retaining ring if it is damaged during removal Camshaft Gear Engine Timing Pin tax Gear Housing Is Note If the timing pin assembly is re...

Page 256: ...old the pin A in the hole B in the camshaft gear to align the housing Torque Value 5 N m 44 in lbs Timing Pin Housing Assembly Installation With Head On The location of the timing pin assembly on the...

Page 257: ...njector nozzles from all of the cylinders Note This step is Important to vent the cylinders so the crankshaft can be rotated smoothly to locate TDC for Cylinder Number 1 10mm 15mm Temporarily install...

Page 258: ...xtreme care that the piston does not against the exhaust valve with so much force that it t the push rod Rotate the crankshaft slowly in the direction of engine re until the piston touches the exhaust...

Page 259: ...ligned with the TDC mark Look through the back side of the gear housing for the timing pin hole in the camshaft gear Reset valves on No 1 cylinder and install cover T 2STorx Apply a coat of Loctite 59...

Page 260: ...mponents DODGE Turbo Diesel In Chassis Repairs Page9F 31 Gear Cover Removal Preparatory steps Remove Fan Drive Assembly Remove Fan Belt Remove Belt Tensioner Remove Oil Fill Tube ami Adapter Remove Vi...

Page 261: ...g Gear Cover Installation Lubricate the front gear train with clean engine oil ACaution The seal lip and the sealing surface on the crankshaft must be free form all oil residue to prevent seal X J tea...

Page 262: ...when you install a seal Apply a bead of Loctite 277 to the outside diameter of the seal 0 t Install the pilot from the seal kit onto the crankshaft Install the seal onto the pilot and start into the f...

Page 263: ...In Chassis Repairs Page9F 34 Base Engine Components DODGE Turbo Diesei 15mm Torque value 125 N m 92 ft lbs...

Page 264: ...ove the lift pump Camshaft Removal Camshaft Removal Service Tool Plastic Hammer Insert the dowels through the push tube holes and into the top of each tappet securely When properly installed the dowel...

Page 265: ...Base Engine Components DODGE Turbo Diesel 13mm Remove the capscrews from the thrust plate Remove the camshaft and thrust plate NjJ Inspection of the Camshaft and Gear Clean the camshaft and gear with...

Page 266: ...Diameter 53 962mm 2 1245 inch Valve Lobes Minimum Diameter at Peak of Lobe Intake Minimum Height 47 040mm 1 852 inch Exhaust Minimum Height 46 770mm 1 841 inch Lift Pump Lobe Diameter Minimum 35 5mm 1...

Page 267: ...In Chassis Repairs Page9F 38 Base Engine Components DODGE Turbo Diesel...

Page 268: ...or excessive wear Measure the diameter of each bore The limit for the bushing in the No 1 bore is the same as for the other bores without bushings Limit Inside Diameter 54 133mm 2 1312 inch Note If th...

Page 269: ...ylinder block using a universal cam bushing installation tool Caution The oil hole must be aligned 2 h A 3 2mm 0 128 inch diameter rod must be able to through the hole Measure the installed bushing Li...

Page 270: ...installed in their original locations Only remove one tappet at a time Remove the rubber band from the two companion tappets securing the tappet not to be removed with the rubber band Pull the wooden...

Page 271: ...the end terrier of the trough Carefully pull the trough and tappet from the cam bore and remove the tappet Repeat the process until all tappets are removed T Tappet Inspection Inspect the tappet sock...

Page 272: ...bore Feed the installation tool down the tappet bore and into the trough Feed the installation tool through the cam bores by carefully pulling the trough installation tool out the front The barrier a...

Page 273: ...out of the tappet several times before installing the tappets Place the tappet and tool in the trough and slide the trough back into the cam bore Note If difficulty is experienced in getting the tappe...

Page 274: ...he round side of the trough up which will hold the tappet in place Remove the installation tool from the tappet Install a wooden dowel into the top of the tappet and secure it with a rubber band Repea...

Page 275: ...washer Align the timing marks as iliustrated 13mm H Install the thrust washer capscrews and tighten to 24 N m n o ft i l i d 18ft Ibs 2h Verify the camshaft has the correct amount of back lash and S...

Page 276: ...ar Replacement Preparatory Step Remove the transmission Remove the clutch cover Remove the clutch plate 19mm Remove the flywheel Brass Drift Pin Warning Wear eye protection when you drive the gear fro...

Page 277: ...nstall the gear The gear must be installed so the bevel on the teeth is towards the crankshaft side of the flywheel Flywheel Installation Caution Never use the timing pin to hold the crankshaft in pos...

Page 278: ...ry Step Remove the transmission Remove the clutch cover Remove the dutch plate Remove the flywheel Rear Seal Installation Caution The seal Hp and the sealing surface on the crankshaft must be free fro...

Page 279: ...sealant Rubber O D rear crandshaft seals are lubricated with soapy water Seals without rubber O D use Loctite 277 11264 or no 2654422 sealant Use the alignment tool to install the seal to the correct...

Page 280: ...ibed in the next two Sections 9H and 91 are considered out of chassis procedures and include those service repairs associated with the following engine parts and functions Oil Pan Crankshaft Suction T...

Page 281: ...Out of Chassis Repairs General Base Engine Components Page9G 2 DODGE Turbo Diesel...

Page 282: ...DODGE Engine Components Out of Chassis Diagnostic Procedures Page9H 1 Out of Chassis Diagnostic Procedures Section 9H Contents Subject Page Piston and Rod Assembly 9H 2 Crankshaft and Main Bearings 9H...

Page 283: ...urement can help detect the problem Verification of the damaged or worn component requires visual dimensional inspection of rings pistons and cylinder walls The cause of piston ring wear can range fro...

Page 284: ...g to the previously discussed power problems Overheating of the engine from a loss of coolant will cause the cylinder to overheat resulting in seizure of the piston Improper maintenance of the lubrica...

Page 285: ...ain bearing life A malfunction of the crankshaft main bearing will usually be detected by reduced oil pressure As with rod bearings continued operation with low oil pressure will lead to a rapid deter...

Page 286: ...em Sections The potential problems with the cylinders the camshaft bore and the crankshaft main journals have also been discussed in this section Malfunctions of the block such as leaks tappet bore we...

Page 287: ...on 9K Alternative Repair for procedures o _ o _ foooi Y Q S Q l h Note The head surface of the block is also critical to sealing the bores Inspect the surface carefully during repair before assembly T...

Page 288: ...Piston Rings Installation 91 10 Cylinder Block Inspection 91 12 Cylinder Bores De glaze 91 13 Connecting Rod Bearings Install 91 16 Piston and Rod Assembly Install 91 16 Crankshaft Removal 91 20 Cran...

Page 289: ...n will require engine removal Drain the oil and remove the pan and gasket j 10mm 13mm Caution Be sure to connect the support bracket If required remove the suction tube and gasket NJ Clean the sealing...

Page 290: ...to the bore Do not remove more metal than V Is necessary to remove the ridge If the cylinder bores have ridges use a ridge reamer to cut the ridge from the top of the cylinder bore before removing the...

Page 291: ...m ft Remove the connecting rod capscrews and rod caps Caution Use care so the cylinder bores and connecting rods are not damaged Use a hammer handle or similar object to push the piston and connecting...

Page 292: ...retainer ringsfromthe piston Remove the piston pin Note Heating the piston is not required Remove the piston rings Piston Pin and Connecting Rod Clean Caution Do not use bead blast to clean the pisto...

Page 293: ...o not use a ring groove cleaner and be sure not to scratch the ring sealing surface in the piston 1 groove Clean the remaining deposits from the ring grooves with the square end of a broken ring Wash...

Page 294: ...e Maximum Clearance The upper groove only needs to be inspected for damage Check the clearance as shown with a new ring and feeler gauge If the clearance of the intermediate ring exceeds 150mm 0 006 I...

Page 295: ...part can cause stress risers which will progress to breakage Inspect the rod for damage and wear Measure the pin bore Maximum Diameter 40 053mm 1 5769 inch Piston and Rod Assembling Caution Be sure th...

Page 296: ...l the pin Note Pistons do not require heating to install the pin however the piston does need to be at room temperature or above Determine the piston diameter and obtain the appropriate ring f 5 n set...

Page 297: ...he gap Limits Ring Minimum Maximum Top 0 4mm 0 0160 inch 0 70mm 0 0275 inch Intermediate 0 25mm 0 0100 inch 0 55mm 0 0215 inch Oil Control 0 25mm 0 0100 inch 0 55mm 0 0215 inch 2TM Piston Rings Instal...

Page 298: ...Base Engine Components DODGETurbo Diesel Out of Chassis Repairs Page 91 11 Position the rings as shewn in the Illustration...

Page 299: ...meter Overall variation end to end or side to side 075mm 003 inch If the surface exceeds the limit refer to the Alternative Repair section of this manual f Inspect the main bearing bores for damage or...

Page 300: ...ore the correct surface finish required to seat the rings The size of the bore is not changed by proper de glazing Note Completely disassemble engine before de glazing cylinders Glazed De Glazed Q Q 0...

Page 301: ...al splits and SAE 30W engine oil to de glaze the bores 300 to 400 RPM Stroke f J Per Second The Crosshatch angle is a function of drill speed and how fast the hone is moved vertically This illustratio...

Page 302: ...block over or close to a floor drain Caution Clean the cylinder bores Immediately after de glazlng Rinse the bores until the detergent is removed and blow the block dry with compressed air Caution Be...

Page 303: ...0394 in Q Connecting Rod Bearing install JS Determine the size of the bearing removed and obtain the same size bearing for installation Refer to the dimensions of the standard and undersize connectin...

Page 304: ...f using a strap type ring compressor make sure the inside end of the strap does not hook on a ring gap and break the ring Compress the rings Bar the crankshaft so the rod journal for the piston to be...

Page 305: ...e top of the piston is approximately 50mm 2 inch below the top of the block Carefully pull the connecting rod onto the crankshaft journal Note The following series of illustrations show the engine in...

Page 306: ...ate freely Check for freedom of rotation as the caps are installed If the crankshaft does not rotate freely check the installation of the rod bearing and the bearing size Caution Do not measure the cl...

Page 307: ...Out of Chassis Repairs Page 91 20 Base Engine Components DODGE Turbo Diesel off the...

Page 308: ...haft Clean the crankshaft oil drillings with a nylon brush Rinse in clean solvent and dry with compressed air Inspecting the Crankshaft inspect the front and rear seal contact areas of the crankshaft...

Page 309: ...the rod journal at the location shown Calculate the average diameter for each side of the journal A Rod Journal Diameter Limits mm in 63 962 69 013 MIN MAX 2 7150 2 7170 Out of Roundness 0 050mm 0 002...

Page 310: ...aximum Taper 0 013mm 0005 inch Maximum Bearing Clearance 0 119mm 0 0047 inch Maximum Main bore diameter with bearings installed Crankshaft main journal diameter Crankshaft Gear Replacement Heavy Duty...

Page 311: ...he gear with the timing mark out and install it on the crankshaft making sure it contacts the shoulder Crankshaft Installation Center Punch Caution Use only hand force to push the nozzle in place If d...

Page 312: ...x main bearing location Lubricate the bearings with Lubriplate 105 Warning Use a hoist to Install the crankshaft to avoid A Injury m Install the crankshaft Crankshaft Weight 55 3 Kg 123 lb Caution Cra...

Page 313: ...Out of Chassis Repairs Page 91 26 Base Engine Components DODGETurbo Diesel Place the caps in their respective positions...

Page 314: ...Base Engine Components DODGE Turbo Diesel Out of Chassis Repairs Page 91 27...

Page 315: ...l Housing and Seal Replacement 8mm Remove the rear seal housing and gasket Hammer Pin Punch Support the seal area of the rear seal housing and press drive out the seal Clean the rear seal housing 2 s...

Page 316: ...rail Tighten the capscrews Torque Value 9 N m 7 ft lbs Remove the alignment tool and trim the gasket even with the oil pan mounting surface Rear Crankshaft Installation Seal O D Lubrication Sealant Ru...

Page 317: ...bending the seal carrier during Installation Use the alignment and installation tool packaged in the seal kit Drive the seal into the housing until the driver bottoms I Gear Housing and Gasket Replac...

Page 318: ...cated HI housing or other than the original d the timing pin assembly must be Install a new gasket and gear housing Torque Value 24 N m 18 ft lbs Timing Pin Installation Cylinder Head Off Caution The...

Page 319: ...ate the assembly temporarily install the vibration damper and a fabricated wire pointer Put a fiat washer between the pointer and gear housing to prevent damage to the gear housing Rotate the cranksha...

Page 320: ...on damper Mark the vibration damper for TDC TDC will be one half the distance between the first two marks 19mm Remove the plate and rotate the engine In the direction of rotation until the pointer ali...

Page 321: ...octite 59241 liquid teflon to the threads of the torx headscrews Push the pin into the hole in the cam gear to align the housing Hold the pin in while tightening the torx headscrew Torque Value 5 N m...

Page 322: ...emoval S J 2 Preparatory Steps SJ 2 Engine Replacement Listing of Steps 9J 2 Engine Removal Procedure 9J 3 Engine Replacement Procedure 9J 4 Engine Testing 9J S Operating Conditions for Run in and Tes...

Page 323: ...in the lubricating oil Disconnect the transmission cooler lines Hoist the engine Disconnect the power steering lines Disconnect the fuel lines Remove the motor mounts Remove the transmission bolts Eng...

Page 324: ...fy the lines Put a cover or tape over all engine openings Use the lifting eyes to lift the engine Apply tension to the hoist to hold the engine while you disconnect the engine mounts from the chassis...

Page 325: ...ne is the same model and rating as the engine that was removed Note Install all accessories and brackets that had been removed from the previous engine Use the lifting eyes to lift the engine Keep ten...

Page 326: ...ters 1 U S quart engine oil filter Note Check the oil level after the engine has run for 2 to 3 minutes Oil held in the oil filter and oil passages will cause the oil level In the oil pan to be lower...

Page 327: ...ent Coolant Temperature Lubricating OH Temperature Lubricating Oil Pressure Air Inlet Temperature Air Inlet Restriction Boost Pressure Exhaust Temperature Smoke Bosch Smoke Meter Celesco Smoke Meter L...

Page 328: ...ency cylinder pressure and turbo contribution Note The blow by values are for 100 percent load at the given speed Blowby Measurement Blowby is generally recorded in Liters Minute but a water manometer...

Page 329: ...ion Chart 5 613 mm 0 221 in Orifice of Water Uters Minute Inches of Water Uters MIn 1 27 19 121 2 40 20 124 3 49 21 128 4 58 22 131 5 64 23 135 6 71 24 137 7 76 25 140 8 81 26 144 9 86 27 147 10 90 28...

Page 330: ...nect the fuel solenoid if disconnected ami move to the RUN position Note Bleeding of the fuel system may be required to start the engine 3 Start the engine and run at 1000 1200 RPM for 30 minutes Obse...

Page 331: ...Engine Removal Replacement and Testing PageSJ 10 Base Engine Components DODGE Turbo Diesel...

Page 332: ...edure All Main Journals 9K 13 Optional Procedure Not to be Used when Thrust Surface Width is Reground 9K 13 Crankshaft Rod Journal Regrind Specifications 9K 14 Crankshaft Rod Journal Radius Regrind 9K...

Page 333: ...own time are the considerations that will influence the decision Inspection The procedures assume the component was inspected and the discrepancy noted during repair or overhaul Only those inspection...

Page 334: ...ylinder Block Repair Procedures Repair Tools Camshaft Bore Boring Bar Camshaft Bushing Driver Cylinder Boring Bar Cylinder Block and Head Surface Grinder Cylinder Hone Set Note The repairs can be perf...

Page 335: ...00mm 0 10 12 7165 inch 0039 322 85mm 0 10 12 7106 inch 0039 322 50mm 0 10 12 6968 inch 0039 First reface Second additional reface Total Allowed Standard First reface Second reface Surface finish requi...

Page 336: ...m 125 inch rod to pass through freely Caution The standard front bushing cannot be used to repair intermediate or rear bores Consult the parts manual for correct oversize aim bushing part numbers Cyli...

Page 337: ...mm First rebore 4 0362 008 Inch 103 020 020mm Second rebore 4 0559 0008 inch After boring to size use a honing stone to chamfer the edge of the bore to Dimension C Approximately 1 25mm 049 inch X 15 D...

Page 338: ...ompound Repair Sleeve Installation If more than a 1 00mm 03937 inch diameter oversize bore is required the block must be rebored and a repair sleeve installed The repair sleeve must be bored and honed...

Page 339: ...Diesel Cool the repair sleeve s to a temperature of 12 C 10 F or below for a minimum of one hour Be ready to install a sleeve immediately after removing it from the freezer Using a sleeve driver drive...

Page 340: ...to chamfer the comer of the repair sleeve s to dimension C C Approximately 1 25mm 049 inch X15 Degrees A correctly honed surface will have a cross hatch appearance f with the lines at 15 to 25 degree...

Page 341: ...s Page9K 10 Base Engine Components DODGETurbo Diesel j Wipe the bore with a white lint free lightly oiled cloth Make sure there is no grit residue present Apply a rust preventing compound if the block...

Page 342: ...es a preferred and an optional will be given for regrinding all crankshaft journals except when the thrust width surface requires regrinding Then the preferred procedure is the only accepted procedure...

Page 343: ...procedure must be used When the thrust surface width requires regrinding the main Journal must be reground to the same undersize dimension Available Undersize Regrind To Thrust Journal Thrust Surface...

Page 344: ...inder of the fillet C 0 4 micrometer 16 microinch journal surface D Original radius E New undercut radius Optional Procedure Not to be Used when Thrust Surface Width is Reground Smoothly blend a 1 25...

Page 345: ...within 0 03mm 0 001 inch Out of roundness 0 005mm 0 0002 inch maximum Taper 0 005mm 0 0002 inch maximum Journals are to be ground in the opposite direction of rotation clockwise as viewed from the fr...

Page 346: ...25 020mm 0482 0008 Inch radius to the reground journal Surface finish A 0 4 micrometer 16 microinch journal surface B 0 8 micrometer 32 microinch for a minimum of 45 degrees into the fillet beyond th...

Page 347: ...Components DODGETurbo Diesel Cylinder Head Repair Tools Valve Refacer Valve Seat Grinder Valve Guide Installation Tool Valve Seat Installation Tool Note The repairs can be performed with standard gaso...

Page 348: ...inish and flatness tolerancing as long as the combined total of stock removed does not exceed 1 00mm 0393 inch The amount of stock removed each time must be steel stamped just above the edge of the co...

Page 349: ...35mm 01378 inch diameter and are to be square with the combustion face within 0 10mm 0004 inch at 50 0mm 1 9685 inch radius the valve guides as illustrated Lubricate with oil and press the guides flu...

Page 350: ...uld have been identified with one X stamped into the head casting as shown Two X s stamped on the head Indicate service seats have been Installed Service seats can be reground Caution On the integral...

Page 351: ...rmining that all values meet specifications Install the valves in their designated locations and measure valve depth i x J r 777T v J Note The valve depth is the distance from the valve face to the he...

Page 352: ...their respective bores and measure the T p j depth again jL Record the depth of each valve B Calculate the grinding depth GD as follows GD B A Grinding Depth Maximum Limit Integral Seats Only GD 254mm...

Page 353: ...easure the depth of each D jxsxr j V a v e Depth Limit Integral and Inserted Seats C 0 99mm to 1 52mm 039 to 060 inch Note Replace the valve if the depth is over the limit Apply a light coat of valve...

Page 354: ...alve Seat Width Limits 1 1 5mm Minimum 060 inch 2 0mm Maximum 080 inch Installing Service Valve Seats Inspect the valve guide bores as described in the valve guide section of this manual If it is nece...

Page 355: ...inch C 43 650 0 013mm 1 7185 0005 inch diameter D 0 40mm 0157 inch maximum radius E 3 2 micrometers 128 microinch surface finish Valve Seat Insert Part Number 4429111 p Valve Seat Insert Staking Tool...

Page 356: ...l the wives in their respective locations and measure the depth Valve Depth Limit C 0 99mm to 1 52mm 039 to 060 inch Apply a light coat of valve lapping compound to each valve and lap each valve to it...

Page 357: ...t on the valve face Maintain the valve seat width limits 1 5mm Minimum 060 inch 2 0mm Maximum 080 inch Replacing Service Seats To replace service seat inserts machine the insert in the same manner as...

Page 358: ...Base Engine Components DODGE Turbo Diesel Alternative Repair Procedures Page9K 27 Inspect the end of the valve stem for flatness...

Page 359: ...ings Measure the valve spring length Valve Spring Dimensional Limits Approximate Free Length 55 63mm 2 190 inch Maximum Inclination 1 Omm 039 inch Measure the valve spring force Valve Spring Minimum L...

Page 360: ...talling the valves Compress the valve spring after installing the spring and p retainer Install new valve collets and release the spring tension Tap the ends of the valve stems with a mallet to verify...

Page 361: ...Alternative Repair Procedures Base Engine Components Page 9K 30 DODGE Turbo Diesel...

Page 362: ...Plugs Fittings and Adapters Engine Component Torque Value 9L 5 Engine Sealants 9L 7 Engine Lubricants 9 L 8 Engine Specifications 9L 9 Coolant Specifications 9L 10 Fuel Specifications 9L 10 Base Engin...

Page 363: ...2 in Square Drive 1 omm Rat Screwdriver 12mm Ratchet 3 8 in Square Drive 13mm Ratchet 1 2 in Square Drive 14mm open end Filter Wrenches 75 80mm and 15mm open end 90 95mm 16mm Drill Motor 1 4 inch 17m...

Page 364: ...33 216 159 16 195 144 266 196 319 235 Notes 1 Do not use these values when the torque values are specified in another section of the manual 2 These values are based on dean dry threads Reduce the valu...

Page 365: ...mponent Torque Value Socket Or Wrench Size mm inch 12 Air Fuel Control Banjo Screw in Pump 1 2 Air Fuel Control Fitting In Head 13 Alternator Ground Cable Mtg to Block 13 15 Alternator Mtg to Water Pu...

Page 366: ...o Screw In Injector 8 6 80 95 Fuel Filter 1 2 Turn After Contact Fuel Heater Assembly Mounting 32 24 3 8 Fuel Heater Ground Mtg to Intake Manifold 12 m 17 Fuel Une Fitting High Press 24 18 14 Fuel Low...

Page 367: ...age Bracket Mtg to Transmission 41 30 Transfer Case Mtg to Transmission 47 35 13 Transmission Cooler Tubing Mtg to Oil Pan Flange 24 18 11 16 Transmission Kick Down Cable Bracket Mtg to Transmission 6...

Page 368: ...or Loctite 59 241 liquid teflon Apply Three Bond 1207 C or Permatex 2C to the four T joints and smear into the joints with finger until full Self adhesive tappet cover side K W Copper Coat 1504 block...

Page 369: ...15W40 Engine Oil 15W40 Engine Oil 15W40 Engine Oil 15W40 Engine Oil Lubriplate 105 in Cup Capscrews under head and on threads as follows Main Capscrews Cylinder Head Capscrews Connecting Rod Capscrews...

Page 370: ...Capacity of Oil Filter Liter U S Quarts 95 1 Cooling System Total Cooling System Capacity Manual Liter U S Quarts 14 7 15 5 Total Cooling System Capacity Automatic Liter U S Quarts 15 7 16 5 Coolant R...

Page 371: ...Property Specification Lab Test Method Viscosity ASTMD 445 1 3 to 5 8 CentiStroke 1 3 to 5 8 mm2 per Second at 40 C 104 F Cetane Number ASTMD 613 40 Minimum except in cold weather or in service with p...

Page 372: ...0 25mm 0 010 inch Exhaust 0 51 mm 0 020 Inch Specifications Page9L 11 Valve Guide Diameter mm in 8 019 8 089 MIN MAX 0 3157 0 3185 Valve Stem Diameter mm 7 935 7 960 MIN MAX in 0 3126 0 3134 1 1 i i...

Page 373: ...ng Length 55 63mm 2 19 inch Inclination Maximum 1 Omm 039 inch Minimum acceptable load at 49 25mm 1 94 inch 289 32 N 65 lb Valve Rim Thickness Minimum 79mm 031 inch Valve Seating Angle of Face Intake...

Page 374: ...area Gear Train Gear Backlash all gears 0 08 to 0 33mm 0 003 to 0 013 inch Camshaft End Clearance 0 152 to 0 254mm 0 006 to 0 010 inch Camshaft Journal Diameter Minimum 53 962mm 2 1245 inch Valve Lob...

Page 375: ...the diameter on a vertical axis only Ring Groove Check wear by Inserting a new ring into the groove and inserting a feeler gauge between the ring and the top side of the ring groove If maximum feeler...

Page 376: ...imum 40 053mm 1 5769 inch Side Clearance 0 10 to 0 30mm 0 004 to 0 012 inch Crankshaft Main Bearing Journal Diameter Minimum Wear Limit Standard Machined 0 25mm Machined 0 50mm Machined 0 75mm Machine...

Page 377: ...ch Journal Taper Maximum 0 013mm 0 0005 inch Oil Clearance Maximum 0 089mm 0 0035 inch Cylinder Block Top Surface Flatness Maximum overall variation 0 075mm 0 003 inch Maximum Variation within any 50...

Page 378: ...Camshaft Bore Diameter Maximum 57 258mm 2 2543 inch without bushing No 1 only 54 133mm 2 1312 inch No 1 with bushing 54 133mm 2 1312 inch No 2 through No 7 Tappet Bore Diameter Maximum 16 055mm 0 632...

Page 379: ...omponents DODGE Turbo Diesel Gerotor Drive Gerotor Planetary to Port Plate Clearance Maximum 0 127mm 0 005 inch Gerotor Planetary to Body Bore Clearance Maximum 0 381mm 0 015 inch Gear Backlash Used P...

Page 380: ...Base Engine Components DODGE Turbo Diesel Rocker Lever Specifications Rocker Lever Bore Maximum 19 05mm 0 75 Inch Specifications Page 9L 19 Shaft Diameter Minimum 18 94mm 0 746 inch...

Page 381: ...Specifications Page 9L 20 Base Engine Components DODGE Turbo Diesei...

Page 382: ...ck 11 9 Check Battery Voltage 11 9 Check Thermistor 11 9 Check Preheat Cycle 11 1 Start the Engine 11 12 Air System Replacement Procedures 11 12 Air Crossover Replacement 11 12 Intake Manifold Cover a...

Page 383: ...gines the flow is from the filter to the turbocharger and then through the air crossover to the manifold From the intake manifold air is forced into the cylinder and used for combustion The exhaust ga...

Page 384: ...on Results in Excess Smoke and Low Power Restriction increases as the filter removes contaminants from the intake air Restricted air flow changes the air to fuel ratio reducing power and increasing sm...

Page 385: ...sure is described in this Section Exhaust Leaks Inspect for exhaust leaks at the exhaust manifold and turbocharger Also check for exhaust pipe restrictions Leaks or restrictions will cause the turbine...

Page 386: ...nd Leaks Engine lubricating oil is used to lubricate the bearings and provide some cooling for the turbocharger The oil is supplied to the turbocharger through the supply line at engine operating pres...

Page 387: ...xhaust side of the turbocharger will look like oil leakage This may occur because of injector overfueling or excessive engine operation under no load conditions Turbocharger Noise It is normal for the...

Page 388: ...not caused by leaks in the air system components Look for loose turbocharger mounting exhaust manifold gasket leaks and cracks in the exhaust manifold D1 Rotor Assembly Clearance Measure Measure the s...

Page 389: ...rocedures will preclude excessive engine starter motor use and minimize white exhaust smoke when the engine is first started Normal Operation of the Intake Manifold Heater System Engine Intake Manifol...

Page 390: ...heat to occur Check the voltage output of the battery Minimum 6 5 volts Check Thermistor Disconnect the thermistor Turn the ignition switch to the ON position Note The Wait to Start light should come...

Page 391: ...C a V O L T S o O H M S a MIL LIAMPS The multimeter should show voltage at the KSB Valve wire terminal This voltage reading is an indication that the thermistor is sensing a temperature of 15 C 59 C...

Page 392: ...ycle Above 15 C 59 F1 0 Seconds No 9 Ct15 F 10 15 C p9 F 10 Seconds Yes 18 C 0 F to 9e CI15 F 15 Seconds Yes 2Se C 1S F tO 17 5 Seconds Yes Below 2S C 15 F1 20 Seconds Yes NOTE The KSB valve activatio...

Page 393: ...17 5 Seconds Yes Below 26 C C 15 FJ 20 Seconds Yes NOTE The KSB valve activation voltage is independent of the intake manifold heater control system The KSB valve wilt be activated any time he manifo...

Page 394: ...atory Steps Remove the throttle control bracket and linkage Remove the high pressure fuel lines Disconnect the intake manifold heater Disconnect the fuel heater ground wire from intake manifold Remove...

Page 395: ...t to the m 18 ft lbs 5 16 Inch 10mm 3 8 inch Install the intake manifold heater power supply connections Assemble the intake piping and intake manifold heater Install the throttle control bracket and...

Page 396: ...ODGE Turbo Diesel Air System Page 11 15 17mm Install and bleed the high pressure fuel lines Torque Value 24 N m 18 ft lbs Turbocharger Replacement Preparatory Steps Loosen the air crossover hose Disco...

Page 397: ...aution If the turbocharger Is not to be Installed Immediately cover the opening to prevent materia from felling Into the manifold Install a new gasket and apply antiseize compound to the mounting stud...

Page 398: ...clean engine lubricating oil before start up Pour 50 to 60cc 2 to 3 ounces of oil into supply fitting Note Rotate the turbine wheel to allow oil to enter the turbocharger 5 8 inch Install the oil sup...

Page 399: ...tem and Intake Manifold DODGE Turbo Diesel Exhaust Manifold and or Gasket Replacement Preparatory Steps Loosen the air crossover hose clamp Disconnect the air intake and exhaust piping Remove the turb...

Page 400: ...lbs Drain line capscrews 24 N m 18 ft lbs Turbocharger mounting nuts 32 N m 24 ft lbs Turbocharger oil supply line 15 N m 11 ft lbs Cab heater supply and return lines 24 N m 18 ft lbs Operate the eng...

Page 401: ...old f v r T3 i i i i i i i A 24 N m 18 ft lbs Install Install the new gasket and the intake manifold heater Connect the electrical wiring Torque Value 14 N m 10 ft lbs Install the air crossover and ga...

Page 402: ...engine cylinders Supplying increased air mass flow to the engine provides improved engine performance lowers exhaust smoke density improves operating economy altitude compensation and noise reduction...

Page 403: ...iffuser 1 6 Rectangular Ring Seal 1 7 V Band Clamp 1 8 Split Ring Seal 1 9 Oil Slinger 1 10 Oil Baffle 1 11 Rat Head Capscrew 3 12 Thrust Bearing 1 13 Thrust Collar 1 REF NO DESCRIPTION QUANTITY 14 Re...

Page 404: ...Exhaust System and Intake Manifold DODGE Turbo Diesel Exploded View of the Turbocharger Turbocharger Rebuddlng Page 11 23...

Page 405: ...y of the Turbocharger Scribe the housings so they can be reassembled in the same position as before disassembly Clamp the turbocharger in a bench vise 7 16 Inch Remove the compressor housing v band cl...

Page 406: ...Remove the dtffuser and discard the o ring...

Page 407: ...Turbocharger Rebuilding Page 11 26 Exhaust System and Intake Manifold DODGE Turbo Diesel piston ring p Remove the thrust collar Inspect the collar for excessive wear...

Page 408: ...s and clamp plates Remove the bearing housing Remove the turbine shaft and heat shield Inspect the turbine blades and the shaft for excessive wear Remove and discard the piston ring type seal Caution...

Page 409: ...m and intake Manifold DODGETurbo Diesel Cleaning of the Turbocharger Caution Do not use a wire brush on the compressor Use a stiff bristle nylon brush and solvent to clean all parts Caution Do not use...

Page 410: ...29 Remove the carbon build up from the housing with a scraper and 240 grit emery cloth Inspection of the Turbocharger in addition to the inspection specified during disassembly rf inspect all parts af...

Page 411: ...Turbocharger The balance marks must be aligned to make sure the wheel and shaft assembly is balanced Install the piston ring and lubricate the groove with engine oil Install the heat shield 16mm Clam...

Page 412: ...the bearing Lubricate the turbocharger bearings with engine oil and install the bearings in the housing Install the outer retainer ring Caution The beveled face must be towards the bearings Assemble t...

Page 413: ...n the shaft Mark the top surface with a marker pen so alignment can be verified after installing the thrust bearing til As T20 Torx Lubricate the thrust bearing with engine oil and install it on the h...

Page 414: ...ge 11 33 Mark the top surface of the oil slinger in line with the balance mark Lubricate the oil slinger with engine oil and Install it into the diffuser Install the o ring into the diffuser Install t...

Page 415: ...stall the impeller j S Caution Be careful not to move the bearing housing 1 2 Inch j S Caution Impeller nut and shaft have left hand threads M Do not allow the Impeller to turn when Installing the nut...

Page 416: ...kplates and capscrews Torque Value 11 3 N m 100 in lbs Install the lockplates and capscrews into the diffuser After tightening the capscrews bend the lockplate tabs to lock the capscrews Caution Be su...

Page 417: ...aution Be sure the scribe marks are aligned Install the compressor housing and v band clamp t Torque Value 8 N m 72 in lbs Note Apply anti seize compound to the v band bolt threads Tighten the clamp t...

Page 418: ...lbs Turbocharger Oil Supply Line Fitting 15 N m 11 ft lbs Exhaust Manifold Capscrews 43 N m 32 ft lbs Throttle Control Bracket Mounting Capscrews 24 N m 18 ft lbs Turbocharger Impeller Nut 14 N m 129...

Page 419: ...Specifications Exhaust System and Intake Manifoid Page 11 38 DODGE Turbo Diesel...

Page 420: ...wPressure Unesand Fuel Filter Venting 14 15 Injection Pumps Venting 14 16 High Pressure Lines Venting 14 16 Fuel Filter Replacement 14 16 Low Pressure Fuel Line Replacement 14 17 Ut Pump Replacement 1...

Page 421: ...ld The fuel drain manifold routes controlled venting from the distributor injection pump and leakage from the injectors back into the fuel tank 1 Fuel from Supply Tank 2 Lift Pump 3 Low Pressure Suppl...

Page 422: ...the pumping action Do not operate the fuel system with a suction restriction A of more than 95mm 3 75 inch Hg Caution If the diaphragm ruptures fuel will drain from the weep hole B In the housing A Ch...

Page 423: ...ugh the fuel filter and supply line to the injection pump loose connections or defective seals will show as a fuel leak The most usual place for air to enter the fuel system is between the inlet of th...

Page 424: ...close For this reason the parts can easily be damaged by rust formation and contaminants The element has a valve which can be opened regularly to drain the collected water Regular maintenance includin...

Page 425: ...rom all outlets The only exception to this would be a malfunctioning delivery valve Governor Flyweights Contrbl Spring Wwflht ForcejSpring Force Balance A Governor Malfunctions Balance between the fly...

Page 426: ...control lever Is Indexed to the shaft during pump calibration Do not remove the throttle lever from the fuel pump Manual Shut Down Lever The injection pump is equipped with a mechanical shut down lev...

Page 427: ...smoke Replacement of the spring and repair of the advance timing mechanism must be performed by an authorized injection pump service center Electrical Shut Off Valve The injection pump is equipped wit...

Page 428: ...emely critical Pump timing that is off by only a few crankshaft degrees will cause 1 Poor performance starting and power 2 Excessive smoke and emissions 3 Poor fuel economy Engine pump timing begins w...

Page 429: ...dead center for Cylinder Number 1 New and reconditioned pumps should be received with the shafts locked in this position Caution If the timing pin is Incorrectly located on the gear housing the timing...

Page 430: ...tion The high pressure lines must be clamped securely and routed so they do not contact each other or any other component Do not weld or substitute lines Use only the specified part number for the eng...

Page 431: ...ine AH engines use Robert Bosch 17mm dosed nozzles hole type injectors The injectors however can have different part numbers for different engine ratings The last four digits of the Cummins part numbe...

Page 432: ...the engine and loosen the fuel line nut at one injector and listen for a change in engine speed Note A drop in engine speed indicates the injector was delivering fuel to the cylinder Check each cylind...

Page 433: ...ain manifold Restricting the fuel drain manifold raises the case pressure of the injection pump which can prevent injection If the engine will restart after a waiting period following an unexplained s...

Page 434: ...r to installation Injection pump is replaced High pressure fuel line connections are loosened or lines replaced Initial engine start up or start up after an extended period of no engine operation 10mm...

Page 435: ...tor 17mm High Pressure Lines Venting Warning A fuel leak from high pressure fuel line has sufficient pressure to penetrate the skin and cause serious bodily harm Loosen the fittings at the injector an...

Page 436: ...the new fuel water separator filter with clean fuel Apply a light film of lubricating oil to the sealing surface before installing the filter Install a new square cut o ring on filter mounting bushin...

Page 437: ...ft lbs Note If the lever feels as though it is not pumping rotate the engine appoximately 90 degrees and proceed Caution The hand priming lever must be returned to the lock position after priming The...

Page 438: ...the bleed screw Torque Value to 8 N m 6 ft lbs Note If the lever feels as though it is not pumping rotate the engine appoximately 90 degrees and proceed Caution The hand priming lever must be returne...

Page 439: ...10mm Remove the throttle linkage and bracket from the engine JS 17mm Disconnect the high pressure lines from the injectors 13mm ft Remove the line clamp capscrews from the intake cover 14mm 17mm Remo...

Page 440: ...rate the skin and cause serious bodily harm Warning Do not bleed a hot engine as this could cause fuel A to spill onto a hot exhaust manifold creating a danger of fire Start the engine and vent one li...

Page 441: ...screws and washers 13mm Disconnect the drain line fittings Assemble the drain line and fuel drain manifold in the reverse order of disassembly Note Use new seals on all fittings 10mm t j Tighten the...

Page 442: ...t loosening the pump Inlet fitting use two wrenches when removing the supply line 14mm 17mm Install the supply line In the reverse order of removal Tighten p line securely to pump fittings Note Use th...

Page 443: ...rned to the lock position after priming The lever will be in the up position when locked Air Fuel Control Tube Replacement 12mm 1 2 inch Remove the tube from the manifold fitting and from the pump j j...

Page 444: ...th a bore brush Assemble the injector and new copper sealing washer Note Use Only One Copper Washer 24mm Deep Well Socket Caution Align the Injector s protrusion with the notch In the bore Tighten the...

Page 445: ...e ignition switch In the start position to bleed the lines Because the engine may start be sure to follow all the safety precautions Use the normal engine starting procedure x Crank the engine to allo...

Page 446: ...cement Preparatory Steps Remove the throttle linkage and bracket Disconnect the fuel drain manifold Remove the injection pump supply line Remove the high pressure lines Disconnect the electrical wire...

Page 447: ...removed to retrieve them Place a shop towel In the gear cover opening between the gear and cover This will prevent the nut or washer from falling into the gear housing Remove the gear retaining nut a...

Page 448: ...with the gear timing hole Note Check the timing marks on the flange of the injection f Tj pump Each pump and engine have unique marks It is not v l possible to exchange pumps and use the same marks f...

Page 449: ...the drive gear key Into the front cover when removing the pump Remove the 3 mounting nuts and the injection pump Remove the gasket and clean the pump mounting surface Installing the Pump Verify Cylind...

Page 450: ...A Finger tighten the three mounting nuts The pump must be free 0 k f to move in the slots 22mm Caution Do not overtighten This is not the final torque Install the pump drive shaft nut and spring washe...

Page 451: ...cylinder head Tighten the flange mounting nuts Torque Value 24 N m 18 ft lbs Permanently mark the new injection pump flange to match the mark on the gear housing 10mm Hex j Loosen the lockscrew and i...

Page 452: ...ounting capscrews 2 Tightening the bracket to injection pump capscrews 3 Tighten the throttle support bracket capscrews Torque Value 24 N m 18 ft lbs 22mm Tighten the pump retaining nut Torque Value 6...

Page 453: ...ube Tighten the banjo fitting Torque Value 12 N m 9 ft lbs 10mm j p l Install the throttle bracket and linkage When connecting the cable to the control lever adjust the length so the lever has stop to...

Page 454: ...install the timing indicator it may be necessary to disconnect one or more of the fuei lines from the fuel pump Note This indicator is marked in increments of 0 01 mm One revolution of the indicator...

Page 455: ...ting nuts Torque Value 24 N m 18 ft lbs 12mm j Remove the timing indicator install the plug and all other parts removed Tighten the plug Torque Value 10 N m 7 5 ft lbs J Cleanliness Is Important Durin...

Page 456: ...ts while meeting safety requirements Service Procedures Remove From inside the vehicle hold up the pedal and remove the cable retainer and throttle cable from the upper end of the pedal shaft Working...

Page 457: ...d attach the cable spring loaded socket with the retaining ball onto the throttle cam Install the remaining cable housing end fitting into the dash panei grommet and attach the housing retainer clip f...

Page 458: ...hat the spring load breakover lever has moved off the stop and is against the breakover spring 4 If the low idle stop screw and the breakover spring is not contacted then the throttle actuation rod mu...

Page 459: ...ect for throttle lever breakover in both idle and full positions 11 Check engine RPM from low to full throttle Low Idle Stop Speed Min Automatic 700 RPM Manual 750 RPM Full Throttle Stop Min Max 2825...

Page 460: ...Current Draw Minimum Voltage 10 Volts D C Operating Voltage 12 Volts D C Resistance 7 4 Ohms Engine Speed Full Throttle Stop Speed NO Load 2 925 RPM Max Full Throttle Stop Speed NO Load 2 825 RPM Min...

Page 461: ...Specifications Page 14 42 Fuel System DODGE Turbo Diesel...

Page 462: ...vacuum pump and is driven by the accessory drive through a common shaft For information on troubleshooting and servicing the power steering pump and all other components of the vehicle steering consul...

Page 463: ...Page 19 2 Steering DODGE Turbo Diesel...

Page 464: ...tios 2 1 2 Rear Axle Ratio 2 1 2 Removal Replacement 21 2 Specifications 2 1 2 Tightening Reference 21 2 Automatic Transmission 2 1 3 Chrysler A727 three speed Modified for Dodge Ram Cummins Turbo 5 9...

Page 465: ...trag Transmission will be sen iced as a module The only repairs that will be performed at a Dodge Service Location are as follows Removal Replacement D250 D350 Case Vent Backup Light Switch Oil Fill P...

Page 466: ...re up in any gear usually indicates clutch band or overrunning clutch problems If the condition is far advanced and overhaul will probably be necessary to restore normal operation In most cases the cl...

Page 467: ...nd and actuation pin on the throttle cam With the throttle lever seated against the low idle stop screw normal foot off throttle position the actuation pin and the slotted cable end of the throttle ca...

Page 468: ...Conditioning DODGE Turbo Diesel Page 24 1 Heating and Air Conditioning Section 24 Contents Subject Pf e Introduction z 94 2 Refrigerant Compressor Remove Preparatory Steps 2 2 Refrigerant Compressor...

Page 469: ...nt Compressor Remove Preparatory Steps 1 Remove the drive belt 2 Discharge the system 3 Disconnect the suction and discharge lines from their respective ports Immediately cap the lines and the ports t...

Page 470: ...e four capscrew bosses are aligned with the holes in the brackets Insert the capscrews A and B and tighten evenly Torque Value 47 N m 35 ft lb 10mm Remove the protective caps from suction A and discha...

Page 471: ...Refrigerant Compressor Install Heating and Air Conditioning Page 24 4 DODGE Turbo Diesel...

Page 472: ...r more must conform to heavy duty cycle emission standards All new DODGE Ram Cummins Turbo Diesels conform to heavy duty cycle emission standards Emission Related Parts Part Service Information Source...

Page 473: ...Emission Control System Page 25 2 DODGE Turbo Diesel...

Page 474: ...ic Transmission Fluid Recommended OH 2 Automatic Transmission 2 1 3 Adjustment Procedure 21 4 Chrysler A727 three speed Modified for Dodge Ram Cummins Turbo 5 9 Liter Engine 21 3 Rear Axle Ratio 2 Roa...

Page 475: ...edure Not to be Used when Thrust Surface Width is Reground 9K 13 Preferred Procedure All Main Journals 9K 13 Crankshaft Main Journal Regrind Specifications 9K 11 Crankshaft Repair Tools 9K 11 Cranksha...

Page 476: ...nning Abnormal Charging System Operation Electrical System Description Operation Alternator Electrical System Specifications Intake Manifold Heater System Message Center and Run Circuit Starting Motor...

Page 477: ...uel Pump Shaft Seal Replacement 14 36 Fuel Requirement OB 10 Avoid using contaminated fuel OB 10 Fuel Specifications OE 4 Fuel System Bleeding 14 15 High Pressure Lines Venting 14 16 Injection Pumps V...

Page 478: ...uel Diluted Oil 9B 9 Fuel Leakage by the Rings 9B 11 Injection Pump Shaft Seal 9 8 1 0 High Oil Pressure 9B 6 Lift Pump Leakage 9B 12 Low Oil Pressure 9B 6 Oil Dilution 9B 6 Oil Filter 9B 7 Oil Gauge...

Page 479: ...nd Description Base Engine Components 9C 2 Out of Chassis Repairs General G 1 Pipe Plugs Fittings and Adapters 9L 4 Piston and Connecting Rod Assemblies Out of Chassis Repair 9C 5 Piston and Rod Assem...

Page 480: ...18 Thermatic Fan Install 7 19 Thermatic Fan Remove 7 19 Thermistor Replacement 8 16 Thermostat Inspection 7 18 Thermostat Replacement 7 13 Throttle Linkage Adjustment 14 38 Thrust Journal Thrust Surfa...

Page 481: ...ats 9 K 2 2 Valve Seat Width Limit 9K 23 Valve Springs Inspect 9K 28 Valve Spring Dimensional Limits 9K 28 Valve Spring Minimum Load Limit 9K 28 Valve Train and Head Assembly Diagnostic Procedures 9E...

Page 482: ......

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