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D250 1990
Service manual
Dodge D250 1990 Service Manual
Rear wheel drive ram truck, diesel supplement
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Service manual
(1135 pages)
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Table Of Contents
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
How to Use the Manual
Generic Symbols
Definition of Terms
Star Pattern Torque Sequence
General Safety Instructions
Component and System Index
Vehicle Identification Number
Vehicle Identification Plate
Vehicle Safety Certification Labels
Engine Serial Number
Fastener Classification
Transmission Identification
Metric System
Model Line-Up and Weights
VIN Code Charts
Power Team Availability
Standard Truck Body Dimensions
Fraction, Decimal, Millimeter, Conversions
Lubrication and Maintenance
Table of Contents
General Information
Required Maintenance for Noise Control Systems
Exhaust System
Air Cleaner Assembly
Heavy Duty Cycle
Noise Control Systems
Severe Service
A Word about Maintenance
Parts and Lubrication Recommendations
Tampering with Noise Control System Prohibited
Classification of Lubricants
Parts Requiring no Lubrication
Engine Data Plate
Fuel Pump Data Plate
Engine View and Parts Identification
Front of Engine
Fuel Side of Engine
Exhaust Side of Engine
Rear of Engine
Operating Instructions
Flammable Fluid Spills
Starting Fluids (Warning)
Assist (Jump) Starting
Maintenance Free Battery
With a Booster Battery
First Start up of the Day
New Engine Break-In
Starting the Engine
Anti-Lock
Brake Light - Diesel Powered Trucks
Message Center Lights
Waittostart
Waterinfuel
Lowfuel
Normal Starting Procedure
Cold Weather Starting
Engine Warm-Up
Hand Throttle
Avoid Low Coolant Temperature Operation
Avoid Overheating the Engine
Do Not Operate the Engine with Low Oil Pressure
Engine Idling
Operating the Engine
Stopping the Engine
Avoid Using Contaminated Fuel
Bulk Fuel Storage
Do Not Operate the Engine with Failed Parts
Fuel Requirement
Prevent Over-Speeding the Engine Going down Hill
Break-In Oils
Oil Performance Recommendations
Oil Viscosity Recommendations
Arctic Operation
Coolant
Maintenance Guidelines
DODGE Turbo Diesel
Maintenance Schedule
Maintenance Record
Coolant Recovery Tank Coolant Level - Check
Cooling System - Check
Daily Maintenance
Oil Level - Check
Draining Fuel/Water Separator Filter
Drive Belt - Inspection
Fan - Inspection
Radiator Coolant Level - Check
Lubricating Oil and Filter - Change
Maintenance Every 6 Months or 9,700 Km (6,000 Miles)
Air Cleaner Dement - Inspection
Antifreeze Concentration - Check 0G-10
Fuel Filter - Change 0C-10
Maintenance Every 12 Months or 19,300 Km [12,000 Miles] 0C-10
Coolant Drain
Maintenance Every 24 Months or 38,600 Km [24,000 Miles] 0C-11
Cooling System - Flush
Maintenance Every 48 Months or 77,200 Km [48,000 Miles]
Engine Systems - Flow Diagrams
Air System Diagram
DODGE Turbo Diesel
Engine Diagrams
Engine Systems - Flow Diagrams
Fuel System Diagram
Cooling System Diagram
Lubricating Oil System Diagram
Lubrication for the Power Components
Lubrication for the Turbocharger
Lubrication for the Overhead
Engine Specifications
Coolant Specifications
Arctic Operations
Fuel Specifications
Scheduled Maintenance for Vehicle Emission Control and Performance
Fluid Capacities
Recommended Lubricants, Fuels and Fluids
Service Brakes
Message Center Lights - Brake System
Power Steering and Vacuum Pump
Service Brakes DODGE Turbo Diesel
Reassembly
Specifications
Clutch
Clutch Pedal and Bracket
Cooling System
Cooling System Components and Flow
Cylinder Block Diagram
Cylinder Head Diagram
Thermostat Diagram
Cooling System Malfunctions - Diagnosis
Pressure Caps
Water (Coolant) Pump
Radiator Air Flow
Thermostat
Gauges, Overfueling and Loading
Belt Tensioner - Replacement
Cooling System Replacement Procedures
Drive Belt - Replacement
Coolant - Draining
Fan Pulley - Replacement
Water Pump - Replacement
Thermostat Replacement
Cup Plugs Replacement
Fan Hub - Replacement
Fan Hub Disassembly
Fan Hub Inspection
Fan Hub Assembly
Thermatic Fan - Check
Thermostat - Inspection
Thermatic Fan - Remove
Thermatic Fan Installation
Flush the Coding System
Component Capacrew Torque Values
Cooling System Capacity
Cooling System Specifications
Electrical System
Electrical System Description/Operation
Starting Motor
Alternator
Intake Manifold Heater System
Message Center and Run Circuit
Diagnosing Electrical Malfunctions
Electrical System Specifications
Engine Does Not Crank
Starting Motor Troubleshooting
Engine Cranking Speed too Slow
Abnormal Ammeter Operation
Abnormal Charging System Operation
Switch On, Negative (-) on Ammeter, Engine Running
Fuel Shut off Valve - Check
Oil Pressure Switch and Temperature Sensor
Coolant Heater - Check
Coolant Temperature Sensor - Check
Oil Pressure Switch/Sending Unit - Check
Alternator - Replacement
Engine Electrical System Replacement Procedures
Starting Motor Replacement
Electric Fuel Shut off Valve - Replacement
Oil Pressure Switch - Replacement
Oil Pressure Switch/Sending Unit Socket
Temperature Sensor - Replacement
Thermistor - Replacement
Fuel Heater - Replacement
Screwdriver Adapter
Engine Block Water Heater Replacement
Intake Manifold Heater - Replacement
Remove
Battery Voltage - Check
Install
Intake Manifold Heater Controls - Check
Operating Temperature
Thermistor - Check
Preheat/Postheat Cycle - Check
Intake Manifold Heater Check
Temperature/Cycle Time Chart of Normal Operation
Specifications
Base Engine Components
Troubleshooting Logic
Engine Diagrams
Problem Isolation and Correction
Engine will Not Crank or Cranks Slowly
Engine Cranks but will Not Start - no Smoke from Exhaust
Engine Hard to Start or will Not Start - Smoke from Exhaust
Engine Starts but will Not Keep Running
Surging (Speed Change)
Rough Idle (Irregularly Firing or Engine Shaking)
Engine Runs Rough or Misfiring
Engine RPM will Not Reach Rated Speed
Low Power
Excessive Exhaust Smoke
Coolant Temperature above Normal
Coolant Temperature below Normal
Coolant Loss
Lubricating Oil Pressure Low
Lubricating Oil Pressure too High
Lubricating Oil Loss
Contaminated Coolant
Contaminated Lubricating Oil
Fuel or Oil Leaking from Exhaust Manifold
Compression Knocks
Excessive Fuel Consumption
Engine will Not Shut off
Excessive Vibration
Excessive Engine Noises
Alternator Not Charging or Insufficient Charging
Engine Lubricating System
Lubricating Oil Pump
Lubricating System Flow
Pressure Regulating Valve
Lubrication for the Turbocharger
Oil Coolers
Oil Filter Bypass Valve
Oil Filters
General Description of Oil Flow
Lubrication for the Power Components
Lubrication for the Overhead
Diagnosing Lubricating System Malfunctions
Bearings and Oil Pump
Oil Filter
Oil Gauge
Oil Suction Tube
Coolant Diluted Oil
Oil Dilution
Fuel Diluted Oil
Injection Pump Shaft Seal
Fuel Leakage by the Rings
Cylinder Head Leakage
Lift Pump Leakage
Oil Leaks
Lubricating Oil Level - Check
Lubricating Oil and Filter - Change
Lubricating System Replacement Procedures
Oil Pressure Regulator Spring
Replacement of the Filter Bypass Valve
Oil Cooler Element And/Or Gasket - Replacement
Oil Pan, Suction Tube And/Or Gaskets - Replacement
Oil Pump - Replacement
Remove the Lubricating Oil Pump
Installing the Lubricating Oil Pump
Gear Cover - Installation
Lubricating Oil Viscosity Recommendations
Lubricating Oil, Arctic Operation
Lubrication System Specifications
In and Out-Of-Chassis Repairs
Base Engine Components Description
Cylinder Head and Valve Train In-Chassis Repair
Front Crankshaft Seal In-Chassis Repair
Front Gear Housing and Gear Train
Flywheel Housing and Flywheel In-Chassis Repair
Piston and Connecting Rod Assemblies Out-Of-Chassis Repair
Crankshaft and Main Bearings Out-Of-Chassis Repair
In-Chassis Repairs - General
In-Chassis Diagnostic Procedures
Air and Fuel Systems - Check
Valve Train and Head Assembly
Valve Adjustment Check
Valve Seal Wear
Injector Protrusion
Rocker Lever, Valve Stem, Push Rod, Tappet and Camshaft
Flywheel Housing and Flywheel
Front Gear Housing Cover and Gear Train
Rear Crankshaft Seal
Rear Gear
In-Chassis Repairs
Rocker Levers and Push Rods - Replacement
Rocker Levers - Disassembly
Rocker Levers Assembly
Rocker Lever Assembly Installation
Valve Clearance Adjustment
Cylinder Head Removal
Cylinder Head Overhaul
Grinding the Valves (Cylinder Head)
Grinding the Seats (Cylinder Head)
Assembly of the Cylinder Head
Inspect the Valve Springs
Measure Valve Spring Force
Plastic Hammer
Valve Spring Compressor
Cylinder Head and Gasket - Installation
Front Crankshaft Seal - Replacement
Replacing the Timing Pin
Timing Pin Assembly or Gasket - Replacement
Timing Pin Housing Assembly - Installation (with Head On)
Gear Cover - Removal
Camshaft, Gear and Tappet - Replacement
Camshaft Inspection
Camshaft Gear - Replacement
Camshaft Bushing - Inspection
Tappet - Removal
Tappet Inspection
Tappet Stem Specifications
Tappet Installation
Camshaft Installation
Flywheel Ring Gear - Replacement
Flywheel - Installation
Rear Seal - Replacement
Out-Of-Chassis Repairs - General
Out-Of-Chassis Diagnostic Procedures
Base Engine Components DODGE Engine Components
Piston and Rod Assembly
Crankshaft and Main Bearings
Cylinder Block
Out-Of-Chassis Diagnostic Procedures
Out-Of-Chassis Repairs
Oil Pan, Suction Tube And/Or Gasket Replacement
Base Engine Components Out-Of-Chassis Repairs
DODGE Turbo Diesei
Piston and Rod Assembly - Removal
Piston and Rod - Disassembly
Piston, Pin and Connecting Rod - Clean
Piston, Pin and Rod - Inspection
Piston and Rod - Assembling
Piston Ring Gap - Check
Piston Rings Installation
Cylinder Block - Inspection
Straight Edge, Feeler Gauge
Cylinder Bores - De-Glaze
Connecting Rod Bearings - Install
Piston and Rod Assembly Installation
Crankshaft Removal
Crankshaft - Cleaning and Inspection
Determine Main Bearing Clearance
Determine Rod Bearing Clearance
Crankshaft Gear - Replacement
Crankshaft - Installation
Rear Crankshaft Seal Housing and Seal Replacement
Rear Crankshaft Installation
Gear Housing and Gasket Replacement
Timing Pin - Installation (Cylinder Head Off)
Engine Removal, Replacement and Testing
Engine Replacement - Procedure
Engine Testing
Blowby Limits
Blowby Measurement
Blowby Conversion Chart
Engine Rating
Engine Run-In
Engine Test Check List
Alternative Repair Procedures
Cylinder Block Repair Procedures
Combustion Deck
Cam Bore(S)
Cylinder Bore(S) Repair - General
Repair Sleeve Installation
Crankshaft Grinding - General
Crankshaft Main Journal Regrind Specifications
Crankshaft Repair Tools
Thrust Journal/Thrust Surface Width Regrinding
Crankshaft Main Journal Radius - Regrind
Crankshaft Rod Journal Radius - Regrind
Crankshaft Rod Journal Regrind Specifications
Cylinder Head Repair Tools
Cylinder Head Combustion Deck Inspection and Refacing
Valve Guides: Inspection and Installation
Valve Seats - General
Calculating the Grinding Depth
Grinding the Valve Seats
Installing Service Valve Seats
Replacing Service Seats
Specifications
Tools Required
Capscrew Markings and Torque Values - Metric
Metric Capscrew Nomenclature
Engine Component Torque Value
Pipe Plugs, Fittings, and Adapters
Engine Sealants
Engine Lubricants
Coolant Specifications
Fuel Specifications
Base Engine Components Specifications
Valve Train
Valve Rim Thickness
Valve Seat Width
Valve Seating Angle of Face
Valve Spring
Camshaft Data
Gear Train Data
Tappets Data
Pin Bore Diameter
Piston Pin Diameter
Pistons Data
Ring Groove Data
Connecting Rod Data
Crankshaft Data
Cylinder Block Data
Cylinder Bores Data
Oil Pump Specifications
Rocker Lever Specifications
Exhaust System and Intake Manifold
Air System Flow
Air Flow Restriction Results in Excess Smoke and Low Power
Diagnosing Air System Malfunctions
Exhaust Leaks
Malfunctioning Turbocharger
Oil Consumption and Leaks
Turbocharger Noise
Rotor Assembly Clearance Measure
Normal Operation of the Intake Manifold Heater System
White Smoke
Check Battery Voltage
Check Thermistor
Intake Manifold Heater - Check
Check Preheat Cycle
Air Crossover - Replacement
Air System Replacement Procedures
Start the Engine
Intake Manifold Cover and Gasket - Replacement
Turbocharger - Replacement
Exhaust Manifold And/Or Gasket - Replacement
Air Cleaner Element Replacement
Intake Manifold Heater - Replacement
Remove
Install
Description
Identification
Turbocharger - Rebuilding
Exploded View of the Turbocharger
Disassembly of the Turbocharger
Cleaning of the Turbocharger
Inspection of the Turbocharger
Assembly of the Turbocharger
Exhaust System and Intake Manifold Specifications
Fuel System
Fuel System Components and Flow
Fuel System Specification Dodge Ram 5.9 Liter Diesel
Fuel System Malfunction - Diagnosis
Lift Pump
Air in the Fuel System
Fuel Water Separator/Filter Unit
Injection Pump Identification
Fuel Control Lever Travel and Adjustment
Governor Malfunctions
Injection Pump
Manual Shut down Lever
Advance Timing Mechanism
Electrical Shut off Valve
Injection Pump Timing
High Pressure Fuel Lines
Injectors
Fuel Drain Manifold
Fuel System Replacement Procedures
Fuel System - Bleeding
Fuel Filter - Replacement
High Pressure Lines - Venting
Injection Pumps - Venting
Low Pressure Fuel Line - Replacement
Lift Pump - Replacement
High Pressure Lines - Replacement
Fuel Drain Manifold Replacement
Injection Pump Supply Line Replacement
Air Fuel Control Tube - Replacement
Injector - Replacement
Injection Pump - Replacement
Fuel System Replacement Procedures
Bosch VE Pump Timing Check
Timing Indicator
Shaft Seal - Replacement
Accelerator Pedal and Throttle Controls
General Information
Service Procedures
Throttle Controls
Throttle Linkage Adjustments
Low Idle Stop Speed
Fuel System Specifications
Steering
Transmission
Manual Transmission Removal and Replacement
Manual Transmission Specifications
Automatic Transmission Road Test
Throttle Linkage
Adjustment Procedure
Throttle Cable Adjustment
Heating and Air Conditioning
Refrigerant Compressor - Remove
Refrigerant Compressor - Install
Emission Control System
Index
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SERVICE
MANUAL
REAR WHEEL
DRIVE
RAM
TRUCK
Diesel
Supplement
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C H R Y S L E R
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Table of Contents
Troubleshooting
Electrical System Specifications
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Troubleshooting Logic
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This manual is also suitable for:
D350 1990
W250 1990
W350 1990
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