Dodge D250 1990 User manual

1 99 0
SERVICE
MANUAL
REAR WHEEL DRIVE
RAM TRUCK
Diesel
Supplement
4^ CHRYSLER
WMOTORS

CHRYSLER
MOTORS
1990
DieselSupplement
Service Manual
DODGE TRUCKS
CHRYSLER
MOTORS
CUMMINS ENGINE
COMPANY,INC.
No part ofthispublicationmaybereproduced,storedina retrievalsystem
ortransmittedinanyform,orbyanymeans,electronic,mechanical,
photocopying,recording,orotherwise without theprior written permission
ofChrysler Motors andCumminsEngineCompany,Inc.
Chrysler Motors andCumminsEngineCompany,Inc.reservethe right to
changetestingprocedures,specifications,diagnosis,orrepairmethods
atany time without priornoticeorincurringobligation.
LlthoinU.S.A.Copyright© 1988 Chrysler Motors andCumminsEngineCompany,Inc.

CHRYSLER MOTORS
DODGE TurboDiesel

CHRYSLER MOTORSFOREWORD
DODGE TurboDieselPage3
FOREWORD
SECTION TITLE
Theinformationcontainedin this service manual has been
preparedfortheprofessionalautomotivetechnicianin-
volvedindailyrepairoperations. Information inthismanual
is divided into groups. Each group covers a generalvehicle
system (brakes,steering,body,etc.). Each group is further
dividedto address individualcomponentsor systems within
thegroup.
TheComponentami System Index will assist you in locat-
ingthecorrectgroupforthecomponentorsystemyoure-
quire.
These groupscontaingeneralinformation,diagnosis,
testing,adjustment,removalandinstallation, assembly and
disassembly proceduresforthecomponents.
The diagnosis charts inthe "Engine Section" aredesigned
tohelpyoulocateandcorrectproblems with a systematic
approach.Thetablocatoratthe right sideofthispage will
helpyoutoquicklylocatethefirstpageofeachgroup.The
first pageofeachgroupcontainsanalphabeticalindexto
assist in thelocationofthecomponentor system.
Theinformation,descriptions,testingproceduresand
specifications wereineffectatthe time thismanualwas
released forprinting.
Information describing theoperationand use ofstandard
andoptionalequipment is included in theOperatingInstruc-
tionsandProduct Information manuallocatedIntheglove
box.
Introduction
0LubricationandMaintenance
5 ServiceBrakes
6Clutch
7CoolingSystem
8ElectricalSystem
9 Base EngineComponents
11ExhaustSystemandIntake Manifold
14FuelSystem
19Steering
21Transmission
24HeatingandAirConditioning
25 Emission ControlSystem

Introduction
Page 4 CHRYSL£RMOTORS
DODGE TurboDiesel
Introduction
Aboutthe Manual
The proceduresinthismanualweredevelopedforan in-ehassis and out~of-ehassis environment.Theinformation
has beengroupedbythemainengine systems. TheTableofContentsdefinesthe systems. Theindexatthe
beginningof each section subdivides the instructions forthe various componentsofthe system. Wrench sizes and
special toolsareidentifiedinthe procedures as needed.
Howto Use the Manual
The organizationofthismanualisbasedonthetroubleshootinglogicpresentedinSection9A.Tofixa problem,
find thelogicchartfortheparticular symptom. Follow the steps specified until theproblem is corrected.
The left columnofthechartsindicatea probable cause. The right columnprovidesa briefdescriptionofthe
corrective action with a referencetotherepairprocedureor diagnostic discussion whenappropriate.
The logic charts reflectthree basic considerations:
1. Assumes theengine has provided satisfactory service priortotheproblem.
2. Performingthe easiest things first.
3.Mostlogical cause in descending order.
Iftheproblem occurs with a newengineor after repairoftheengine,the diagnostics discussion foreachmajor
system will provide guidance for sorting outthe cause oftheproblem.

CHRYSLER MOTORS
DODGE TurboDiesel Introduction
Page 5
Generic Symbols
The followinggroupof symbols havebeenusedinthismanualtohelpcommunicatethe intent oftheinstructions.
Whenoneofthe symbols appears, it conveys themeaningdefinedbelow.
WARNING- Seriouspersonalinjuryorextensivepropertydamagecanresultifthewarning
instructions arenotfollowed.
A
CAUTION- Minor personal injury can resultora part,an assembly ortheengine can bedamaged
ifthecautioninstructionsarenotfollowed.
WIndicatesa REMOVALor DISASSEMBLY step.
INSPECTION isrequired.
Indicates anINSTALLATIONor ASSEMBLY step.
CLEAN the part orassembly.
PERFORM a mechanicalor time MEASUREMENT.
LUBRICATE the part orassembly.
si
Indicates that a WRENCHorTOOL SIZE will begiven.
TIGHTEN toa specifictorque.
PERFORM anelectricalMEASUREMENT.
Refer toanotherlocationinthismanualoranotherpublicationforadditionalinformation.
The componentweighs23kg[50lb]ormore.Toavoidpersonalinjury,usea hoistorget
assistance to lift thecomponent.

Introduction
Page6
CHRYSLER MOTORS
DODGE TurboDiesel
Definition ofTerms
The following isa listofguidelinesforeachprocedureinthe"Repair Sections" oftheTroubleshootingandRepair
Manual,Theprocedure will begivenfirst; followed bya definition ofthestepor steps involved.
-Check- Examinea componentor system fordamage, excessive wear, accuracy, safety,orperformance.
•Inspect- Examinea componentordimensiontomakesureitmeetstherequiredspecifications.
•Test- Checkorcomparetheperformanceofa componentor system toestablishedspecifications.
-Adjust- Completethe necessary steps tosetoradjustthecomponent, assemblies, orsystemintherequired
settingorposition.
•VisuallyInspect- Lookforanyobviousdamageorproblem.
•Remove-Takeoffa componentor assembly.
•Clean- Remove dirt, greaseor other contamination.
« Disassemble - Takethecomponentor assembly apart.
•Repair- Restorea componentor assembly toa serviceablecondition within theestablishedspecifications.
NOTE: Onlythe easiest andsimplestrepairs will bemadetoa componentor assembly. Ifa componentorassembly
mustbe rebuilt, itmustbereplaced with a neworreconditionedcomponentor assembly.
•Replace- Installa new, properly rebuilt reconditionedcomponentorassemblyinplaceofonewhichis
removed.
•Install- Placea componentor assembly in thecorrectposition.
Star Pattern TorqueSequence

CHRYSLER MOTORS
DODGE TurboDiesel
Introduction
Page 7
Illustrations
TheillustrationsusedIntheDiagnosis Sections ofthismanualareintendedtogiveanexampleofa problem,show
what tolookforandwheretolookfortheproblem. Most oftheillustrationsaregenericand might notlookexactly
liketheengineorpartsusedinyourapplication.Someillustrationscontain symbols toindicateanactionrequired
andanacceptableorunacceptablecondition.
TheillustrationsusedintheReplacement Sections areintendedtoshowreplacementprocedureswhentheengine
is installedina chassis. Theillustrationmay differ from yourapplicationbuttheproceduregiven will bethe same.
Acceptable

Introduction
Page8
CHRYSLER MOTORS
DODGE TurboDiesel
GeneralSafetyInstructions
Important Safety Notice
Read amiunderstandallsafetyprecautionsandwarnings before performing repairs.
This symbolappearsinthemanualwhena potential safetyhazard exists that cancausepersonalinjuryordeath.
These hazardsarenotalwaysapparenttoa trainedmechanic.ItisnotpossibleforChryslerMotors/Cummins
Engine Co.,Inc. toanticipateevery possible circumstance that caninvoivea potential hazard.
WARNING;ChryslerMotors/CumminsEngineCompany,Inc.doesnotrecommendorauthorizeany
modificationsorrepairstoenginesorcomponentsexceptforthosedetailedinChrysler/Cummins
Service information.
Inparticular,unauthorizedrepairtosafety-relatedcomponentscancausepersonalinjury.Belowisa partial
listingofcomponents classified assafety-related.
•CoolingFan
•FanHub Assembly
•Fan Mounting Brackets)
•Fan Mounting Capscrews
•FanHubSpindle
•Flywheel
-Flywheel Mounting Capscrews
•FuelShutoff Assemblies
•FuelSupplyTubes
•LiftingBrackets
- Throttle Controls
•Turbocharger Compressor Casing
•TurbochargerOilDrainUne(s)
•TurbochargerOilSupplyUne(s)
•TurbochargerTurbineCasing
• Vibration Damper Mounting Capscrews

CHRYSLER MOTORS
DODGE TurboDiesel Introduction
Page9
GeneralSafetyInstructions
Important SafetyNotice
Read andunderstandaiiofthesafetyprecautionsamiwarningsbeforeperforminganyrepair.Thislistcontainsthe
generalsafetyprecautions that mustbefollowedtoprovidepersonalsafety. Special safetyprecautionsareIncluded
in theprocedureswhentheyapply.
Warning;ThisistheWARNINGSYMBOL,itappearsinthemanualwhena potentialsafetyhazardexists that
can causepersonalinjuryordeath.Thesehazardsarenotalwaysapparenttoa trainedmechanic.
Note; ItIsnotpossibleforChrysler Motors andCumminsEngineCompany,inc.toanticipateeverypossible
circumstance that caninvolvea potentialhazard.
J^Be sure theworkareasurroundingtheproduct is safe. Beawareofhazardousconditions that canexist.
Always wearprotective glasses amiprotective shoes whenworking.
A,Donotwearloose-fittingor torn clothing.Removealljewelry such as rings, watches,etc.,whenworking.
A
Disconnect the battery amidischargeanycapacitorsbeforebeginninganyrepairwork.Puta "DoNotOperate"
tag intheoperator'scompartmentoronthecontrols.
AUseONLYtheproperenginebarringtechniquesformanually
rotating theengine.Donot attempt to rotate the
enginebypullingorpryingonthetan. Thispracticecancauseseriouspersonalinjury,propertydamage,or
damagetothefan blade(s),causingprematurefanfailure.
A Ifanenginehasbeenoperatingandthecoolantishot,allowtheenginetocoolbeforeyouslowlyloosenthe
-Jm filler capandrelievethe pressure from thecooling system.
•
Donotworkonanything that issupportedONLYby lift jacks ora hoistAlwaysuseblocksorproper stands to
supporttheproductbeforeperformingany service work.
•
Relieveall pressure intheair,oil,andthecooling systems beforeany lines, fittings, orrelateditemsareremoved
ordisconnected.Bealertforpossiblepressurewhendisconnectinganydevice from a system that utilizes
pressure. Donot check for pressure leaks with yourhand. High pressure oilorfuelcan cause personalinjury.
•
Topreventsuffocationandfrostbite,wearprotectiveclothingandONLYdisconnectliquidrefrigerant (freon)
lines ina wellventilatedarea.
Toavoidpersonalinjury,usea hoistorget assistance when lifting components that weigh23kg(50lbs)or
more.Besureallchains,hooks, slings, etc.,areingoodconditionandareofthecorrectcapacity.Besure
t hooks arepositionedcorrectly.Always use a spreaderbarwhen necessary. The lifting hooksmustnotbeside-
loaded.
Corrosion inhibitorcontainsalkali.Donotgetthe substance inyour eyes. Avoidprolongedorrepeatedcontact
•
with skin. Donotswallowinternally.In case ofcontact,immediately wash skin with soapamiwater.In case of
contact,immediately flood eyes with largeamountsofwaterfora minimumof15minutes.IMMEDIATELY
CALL A PHYSICIAN. KEEP OUTOF REACH OFCHILDREN.
•
Napthaand Methyl EthylKetone(MEK)areflammable materialsandmustbeused with caution.Followthe
manufacturer'sinstructionstoprovidecompletesafetywhen using thesematerials. KEEP OUTOF REACH OF
CHILDREN.