1989-1991 Dodge Ram W150 Truck Service & Repair Manual

CHRYSLER MOTORS 1990 Diesel Supplement Service Manual DODGE TRUCKS CHRYSLER MOTORS CUMMINS ENGINE COMPANY, INC. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form, or by any means, electronic, mechanical, photocopying, recording, or otherwise without the prior written permission of Chrysler Motors and Cummins Engine Company, Inc. Chrysler Motors and Cummins Engine Company, Inc. reserve the right to change testing procedures, specifications, diagnosis, or repair methods at any time without prior notice or incurring obligation. Lltho in U.S.A. Copyright © 1988 Chrysler Motors and Cummins Engine Company, Inc.

CHRYSLER MOTORS DODGE Turbo Diesel

CHRYSLER MOTORS FOREWORD DODGE Turbo Diesel Page 3 FOREWORD SECTION TITLE The information contained in this service manual has been prepared for the professional automotive technician involved in daily repair operations. Information in this manual is divided into groups. Each group covers a general vehicle system (brakes, steering, body, etc.). Each group is further divided to address individual components or systems within the group. The Component ami System Index will assist you in locat- ing the correct group for the component or system you re- quire. These groups contain general information, diagnosis, testing, adjustment, removal and installation, assembly and disassembly procedures for the components. The diagnosis charts in the "Engine Section" are designed 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 of each group. The first page of each group contains an alphabetical index to assist in the location of the component or system. The information, descriptions, testing procedures and specifications were in effect at the time this manual was released for printing. Information describing the operation and use of standard and optional equipment is included in the Operating Instruc- tions and Product Information manual located In the glove box. Introduction 0 Lubrication and Maintenance 5 Service Brakes 6 Clutch 7 Cooling System 8 Electrical System 9 Base Engine Components 11 Exhaust System and Intake Manifold 14 Fuel System 19 Steering 21 Transmission 24 Heating and Air Conditioning 25 Emission Control System

Introduction Page 4 CHRYSL£R MOTORS DODGE Turbo Diesel Introduction About the Manual The procedures in this manual were developed for an in-ehassis and out~of-ehassis environment. The information has been grouped by the main engine systems. The Table of Contents defines the systems. The index at the beginning of each section subdivides the instructions for the various components of the system. Wrench sizes and special tools are identified in the procedures as needed. How to Use the Manual The organization of this manual is based on the troubleshooting 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 probable cause. The right column provides a brief description of the corrective action with a reference to the repair procedure or diagnostic discussion when appropriate. The logic charts reflect three basic considerations: 1. Assumes the engine has provided satisfactory service prior to the problem. 2. Performing the easiest things first. 3. Most logical cause in descending order. If the problem occurs with a new engine or after repair of the engine, the diagnostics discussion for each major system will provide guidance for sorting out the cause of the problem.

CHRYSLER MOTORS DODGE Turbo Diesel Introduction Page 5 Generic Symbols The following group of symbols have been used in this manual to help communicate the intent of the instructions. When one of the symbols appears, it conveys the meaning defined below. WARNING - Serious personal injury or extensive property damage can result if the warning instructions are not followed. A CAUTION - Minor personal injury can result or a part, 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 the part or assembly. PERFORM a mechanical or time MEASUREMENT. LUBRICATE the part or assembly. si Indicates that a WRENCH or TOOL SIZE will be given. TIGHTEN to a specific torque. PERFORM an electrical MEASUREMENT. Refer to another location in this manual or another publication for additional information. The component weighs 23 kg [50 lb] or more. To avoid personal injury, use a hoist or get assistance to lift the component.

Introduction Page 6 CHRYSLER MOTORS DODGE Turbo Diesel Definition of Terms The following is a list of guidelines for each procedure in the "Repair Sections" of the Troubleshooting and Repair Manual, The procedure will be given first; followed by a definition of the step or steps involved. - Check - Examine a component or system for damage, excessive wear, accuracy, safety, or performance. • Inspect - Examine a component or dimension to make sure it meets the required specifications. • Test - Check or compare the performance of a component or system to established specifications. - Adjust - Complete the necessary 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 - Remove dirt, grease or other contamination. « Disassemble - Take the component or assembly apart. • Repair - Restore a component or assembly to a serviceable condition within the established specifications. NOTE: Only the easiest and simplest repairs will be made to a component or assembly. If a component or assembly must be rebuilt, it must be replaced with a new or reconditioned component or assembly. • Replace - Install a new, properly rebuilt reconditioned component or assembly in place of one which is removed. • Install - Place a component or assembly in the correct position. Star Pattern Torque Sequence

CHRYSLER MOTORS DODGE Turbo Diesel Introduction Page 7 Illustrations The illustrations used In the Diagnosis Sections of this manual are intended to give an example of a problem, show what to look for and where to look for the problem. Most of the illustrations 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 condition. The illustrations used in the Replacement Sections are intended to show replacement procedures when the engine is installed in a chassis. The illustration may differ from your application but the procedure given will be the same. Acceptable

Introduction Page 8 CHRYSLER MOTORS DODGE Turbo Diesel General Safety Instructions Important Safety Notice Read ami understand all safety precautions and warnings before performing repairs. This symbol appears in the manual when a potential safety hazard exists that can cause personal injury or death. These hazards are not always apparent to a trained mechanic. It is not possible for Chrysler Motors/Cummins Engine Co.,Inc. to anticipate every possible circumstance that can invoive a potential hazard. WARNING; Chrysler 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 particular, unauthorized repair to safety-related components can cause personal injury. Below is a partial listing of components classified as safety-related. • Cooling Fan • Fan Hub Assembly • Fan Mounting Brackets) • Fan Mounting Capscrews • Fan Hub Spindle • Flywheel - Flywheel Mounting Capscrews • Fuel Shutoff Assemblies • Fuel Supply Tubes • Lifting Brackets - Throttle Controls • Turbocharger Compressor Casing • Turbocharger Oil Drain Une(s) • Turbocharger Oil Supply Une(s) • Turbocharger Turbine Casing • Vibration Damper Mounting Capscrews

CHRYSLER MOTORS DODGE Turbo Diesel Introduction Page 9 General Safety Instructions Important Safety Notice Read and understand aii of the safety precautions ami warnings before performing any repair. This list contains the general safety precautions that must be followed to provide personal safety. Special safety precautions are Included in the procedures when they apply. Warning; This is the WARNING SYMBOL, it appears in the manual when a potential safety hazard exists that can cause personal injury or death. These hazards are not always apparent to a trained mechanic. Note; It Is not possible for Chrysler Motors and Cummins Engine Company, inc. to anticipate every possible circumstance that can involve a potential hazard. J^Be sure the work area surrounding the product is safe. Be aware of hazardous conditions that can exist. Always wear protective glasses ami protective shoes when working. A, Do not wear loose-fitting or torn clothing. Remove all jewelry such as rings, watches, etc., when working. A Disconnect the battery ami discharge any capacitors before beginning any repair work. Put a "Do Not Operate" tag in the operator's compartment or on the controls. A Use ONLY the proper engine barring techniques for manually rotating the engine. Do not attempt to rotate the engine by pulling or prying on the tan. This practice can cause serious personal injury, property damage, or damage to the fan blade(s), causing prematurefanfailure. A If an engine has been operating and the coolant is hot, allow the engine to cool before you slowly loosen the -Jm filler cap and relieve the pressure from the cooling system. • Do not work on anything that is supported ONLY by lift jacks or a hoist Always use blocks or proper stands to support the product before performing any service work. • Relieve all pressure in the air, oil, and the cooling systems before any lines,fittings,or related items are removed or disconnected. Be alert for possible pressure when disconnecting any device from a system that utilizes pressure. Do not check for pressure leaks with your hand. High pressure oil or fuel can cause personal injury. • To prevent suffocation and frostbite, wear protective clothing and ONLY disconnect liquid refrigerant (freon) lines in a well ventilated area. To avoid personal injury, use a hoist or get assistance when lifting components that weigh 23 kg (50 lbs) or more. Be sure all chains, hooks, slings, etc., are in good condition and are of the correct capacity. Be sure t hooks are positioned correctly. Always use a spreader bar when necessary. The lifting hooks must not be side- loaded. Corrosion inhibitor contains alkali. Do not get the substance in your eyes. Avoid prolonged or repeated contact • with skin. Do not swallow internally. In case of contact, immediately wash skin with soap ami water. In case of contact, immediately flood eyes with large amounts of water for a minimum of 15 minutes. IMMEDIATELY CALL A PHYSICIAN. KEEP OUT OF REACH OF CHILDREN. • Naptha and Methyl Ethyl Ketone(MEK) are flammable materials and must be used with caution. Follow the manufacturer's instructions to provide complete safety when using these materials. KEEP OUT OF REACH OF CHILDREN.

introduction CHRYSLER MOTORS Page 10 DODGE Turbo Diesel General Safety Instructions • To avoid burns, be aiert for hot parts on products that have just been turned OFF, and hot fluids in lines, tubes, and compartments. A Always use tools that are in good condition. Be sure you understand how to use them before performing any service work. Use ONLY genuine MOPAR replacement parts. A Always use the same fastener part number (or equivalent) when replacing fasteners. Do not use a fastener of less quality if replacements are necessary. A Never spray or pour diesei fuel, flammable liquid, starting fluids (ether) into the air cleaner canister, air intake piping, or turbocharger inlet in an attempt to start the vehicle. Never use gasoline or other flammable materials to clean parts. Always use approved cleaning solvents. • 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.

1989-1991 Dodge Ram W150 Truck Service & Repair Manual

You're Reading a Preview

Recently Viewed