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D250 1990
Service manual
Table Of Contents - 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
483
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
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Table of Contents
How To Use The Manual
5
Generic Symbols
6
Definition Of Terms
7
Star Pattern Torque Sequence
7
General Safety Instructions
9
Component And System Index
13
Vehicle Identification Number
15
Vehicle Identification Plate
15
Vehicle Safety Certification Labels
15
Engine Serial Number
16
Transmission Identification
16
Fastener Classification
16
Metric System
17
Vin Code Charts
18
Model Line-Up And Weights
18
Power Team Availability
19
Standard Truck Body Dimensions
19
Fraction, Decimal, Millimeter, Conversions
20
Lubrication And Maintenance
22
Table Of Contents
24
Heavy Duty Cycle
25
Severe Service
25
Noise Control Systems
25
General Information
25
Required Maintenance For Noise Control Systems
25
Exhaust System
25
Air Cleaner Assembly
25
Parts Requiring No Lubrication
26
Parts And Lubrication Recommendations
26
Tampering With Noise Control System Prohibited
26
Classification Of Lubricants
26
A Word About Maintenance
26
Engine Data Plate
27
Fuel Pump Data Plate
27
Identifying Your Engine
28
Engine View And Parts Identification
28
Front Of Engine
28
Fuel Side Of Engine
28
Exhaust Side Of Engine
29
Rear Of Engine
29
Operating Instructions
30
Starting Fluids (Warning)
31
Flammable Fluid Spills
31
Maintenance Free Battery
32
Assist (Jump) Starting
32
With A Booster Battery
32
New Engine Break-In
34
Starting The Engine
34
First Start Up Of The Day
34
Message Center Lights
35
Brake Light - Diesel Powered Trucks
35
Waterinfuel
35
Waittostart
35
Anti-Lock
35
Normal Starting Procedure
36
Lowfuel
36
Cold Weather Starting
37
Engine Warm-Up
37
Hand Throttle
37
Engine Idling
38
Stopping The Engine
38
Operating The Engine
38
Avoid Overheating The Engine
38
Avoid Low Coolant Temperature Operation
38
Do Not Operate The Engine With Low Oil Pressure
38
Fuel Requirement
39
Bulk Fuel Storage
39
Do Not Operate The Engine With Failed Parts
39
Prevent Over-Speeding The Engine Going Down Hill
39
Avoid Using Contaminated Fuel
39
Oil Performance Recommendations
40
Oil Viscosity Recommendations
40
Break-In Oils
40
Arctic Operation
41
Coolant
41
Maintenance Guidelines
42
Maintenance Schedule
43
Dodge Turbo Diesel
43
Maintenance Record
44
Daily Maintenance
45
Oil Level - Check
45
Cooling System - Check
45
Coolant Recovery Tank Coolant Level - Check
45
Radiator Coolant Level - Check
46
Draining Fuel/Water Separator Filter
46
Fan - Inspection
46
Drive Belt - Inspection
46
Maintenance Every 6 Months Or 9,700 Km (6,000 Miles)
47
Lubricating Oil And Filter - Change
47
Air Cleaner Dement - Inspection
50
Maintenance Every 12 Months Or 19,300 Km [12,000 Miles] 0C-10
51
Antifreeze Concentration - Check 0G-10
51
Fuel Filter - Change 0C-10
51
Coolant Drain
52
Maintenance Every 24 Months Or 38,600 Km [24,000 Miles] 0C-11
52
Cooling System - Flush
53
Maintenance Every 48 Months Or 77,200 Km [48,000 Miles]
54
Engine Systems - Flow Diagrams
56
Fuel System Diagram
57
Air System Diagram
57
Engine Diagrams
57
Cooling System Diagram
58
Lubricating Oil System Diagram
58
Lubrication For The Turbocharger
59
Lubrication For The Power Components
59
Lubrication For The Overhead
60
Engine Specifications
62
Coolant Specifications
64
Arctic Operations
65
Fuel Specifications
65
Scheduled Maintenance For Vehicle Emission Control And Performance
66
Fluid Capacities
68
Recommended Lubricants, Fuels And Fluids
70
Service Brakes
74
Power Steering And Vacuum Pump
75
Message Center Lights - Brake System
75
Service Brakes Dodge Turbo Diesel
75
Reassembly
79
Specifications
80
Clutch
82
Clutch Pedal And Bracket
83
Cooling System
90
Cooling System Components And Flow
91
Cylinder Block Diagram
91
Cylinder Head Diagram
91
Thermostat Diagram
91
Cooling System Malfunctions - Diagnosis
92
Pressure Caps
94
Water (Coolant) Pump
94
Radiator Air Flow
96
Thermostat
97
Gauges, Overfueling And Loading
98
Cooling System Replacement Procedures
99
Drive Belt - Replacement
99
Belt Tensioner - Replacement
99
Fan Pulley - Replacement
100
Coolant - Draining
100
Water Pump - Replacement
101
Thermostat Replacement
102
Cup Plugs Replacement
104
Fan Hub - Replacement
104
Fan Hub Inspection
105
Fan Hub Disassembly
105
Fan Hub Assembly
106
Thermostat - Inspection
107
Thermatic Fan - Check
107
Thermatic Fan - Remove
108
Thermatic Fan Installation
108
Flush The Coding System
109
Cooling System Specifications
111
Cooling System Capacity
111
Component Capacrew Torque Values
111
Electrical System
112
Electrical System Description/Operation
113
Starting Motor
113
Alternator
114
Intake Manifold Heater System
115
Message Center And Run Circuit
116
Electrical System Specifications
117
Diagnosing Electrical Malfunctions
117
Engine Does Not Crank
117
Starting Motor Troubleshooting
117
Engine Cranking Speed Too Slow
119
Abnormal Ammeter Operation
120
Switch On, Negative (-) On Ammeter, Engine Running
120
Abnormal Charging System Operation
120
Fuel Shut Off Valve - Check
121
Oil Pressure Switch And Temperature Sensor
121
Coolant Heater - Check
122
Oil Pressure Switch/Sending Unit - Check
122
Coolant Temperature Sensor - Check
122
Engine Electrical System Replacement Procedures
123
Starting Motor Replacement
123
Alternator - Replacement
123
Electric Fuel Shut Off Valve - Replacement
125
Oil Pressure Switch - Replacement
125
Temperature Sensor - Replacement
126
Oil Pressure Switch/Sending Unit Socket
126
Thermistor - Replacement
127
Fuel Heater - Replacement
128
Screwdriver Adapter
129
Engine Block Water Heater Replacement
130
Intake Manifold Heater - Replacement
131
Remove
131
Intake Manifold Heater Controls - Check
132
Battery Voltage - Check
132
Install
132
Operating Temperature
132
Thermistor - Check
133
Preheat/Postheat Cycle - Check
134
Intake Manifold Heater Check
135
Temperature/Cycle Time Chart Of Normal Operation
135
Base Engine Components
138
Troubleshooting Logic
140
Problem Isolation And Correction
141
Engine Will Not Crank Or Cranks Slowly
143
Engine Cranks But Will Not Start - No Smoke From Exhaust
144
Engine Hard To Start Or Will Not Start - Smoke From Exhaust
146
Engine Starts But Will Not Keep Running
148
Surging (Speed Change)
149
Rough Idle (Irregularly Firing Or Engine Shaking)
150
Engine Runs Rough Or Misfiring
151
Engine Rpm Will Not Reach Rated Speed
153
Low Power
154
Excessive Exhaust Smoke
157
Coolant Temperature Above Normal
159
Coolant Temperature Below Normal
162
Coolant Loss
163
Lubricating Oil Pressure Low
165
Lubricating Oil Pressure Too High
167
Lubricating Oil Loss
168
Contaminated Coolant
170
Contaminated Lubricating Oil
171
Fuel Or Oil Leaking From Exhaust Manifold
172
Compression Knocks
173
Excessive Fuel Consumption
174
Engine Will Not Shut Off
175
Excessive Vibration
176
Excessive Engine Noises
178
Alternator Not Charging Or Insufficient Charging
179
Engine Lubricating System
180
Lubricating System Flow
181
Lubricating Oil Pump
181
Pressure Regulating Valve
181
Oil Coolers
182
Oil Filters
182
Oil Filter Bypass Valve
182
General Description Of Oil Flow
183
Diagnosing Lubricating System Malfunctions
185
Oil Filter
186
Oil Gauge
186
Oil Suction Tube
186
Bearings And Oil Pump
186
Oil Dilution
187
Coolant Diluted Oil
187
Fuel Diluted Oil
188
Injection Pump Shaft Seal
189
Fuel Leakage By The Rings
190
Lift Pump Leakage
191
Cylinder Head Leakage
191
Oil Leaks
191
Lubricating Oil Level - Check
192
Lubricating System Replacement Procedures
195
Oil Pressure Regulator Spring
196
Replacement Of The Filter Bypass Valve
196
Oil Cooler Element And/Or Gasket - Replacement
197
Oil Pan, Suction Tube And/Or Gaskets - Replacement
199
Oil Pump - Replacement
201
Remove The Lubricating Oil Pump
202
Installing The Lubricating Oil Pump
205
Gear Cover - Installation
206
Lubricating Oil Viscosity Recommendations
211
Lubricating Oil, Arctic Operation
211
Lubrication System Specifications
211
In And Out-Of-Chassis Repairs
212
Base Engine Components Description
213
Cylinder Head And Valve Train In-Chassis Repair
213
Front Gear Housing And Gear Train
214
Front Crankshaft Seal In-Chassis Repair
214
Flywheel Housing And Flywheel In-Chassis Repair
215
Piston And Connecting Rod Assemblies Out-Of-Chassis Repair
216
Crankshaft And Main Bearings Out-Of-Chassis Repair
217
In-Chassis Repairs - General
220
In-Chassis Diagnostic Procedures
222
Air And Fuel Systems - Check
223
Valve Train And Head Assembly
223
Valve Adjustment Check
224
Valve Seal Wear
224
Injector Protrusion
225
Rocker Lever, Valve Stem, Push Rod, Tappet And Camshaft
226
Front Gear Housing Cover And Gear Train
227
Flywheel Housing And Flywheel
227
Rear Crankshaft Seal
228
Rear Gear
228
In-Chassis Repairs
230
Rocker Levers And Push Rods - Replacement
231
Rocker Levers - Disassembly
232
Rocker Levers Assembly
234
Rocker Lever Assembly Installation
236
Valve Clearance Adjustment
237
Cylinder Head Removal
238
Cylinder Head Overhaul
240
Grinding The Valves (Cylinder Head)
244
Grinding The Seats (Cylinder Head)
245
Inspect The Valve Springs
249
Measure Valve Spring Force
249
Assembly Of The Cylinder Head
249
Valve Spring Compressor
250
Plastic Hammer
250
Cylinder Head And Gasket - Installation
251
Front Crankshaft Seal - Replacement
253
Replacing The Timing Pin
255
Timing Pin Assembly Or Gasket - Replacement
255
Timing Pin Housing Assembly - Installation (With Head On)
256
Gear Cover - Removal
260
Camshaft, Gear And Tappet - Replacement
264
Camshaft Inspection
265
Camshaft Gear - Replacement
266
Camshaft Bushing - Inspection
268
Tappet - Removal
269
Tappet Inspection
271
Tappet Stem Specifications
271
Tappet Installation
272
Camshaft Installation
274
Flywheel Ring Gear - Replacement
276
Flywheel - Installation
277
Rear Seal - Replacement
278
Out-Of-Chassis Repairs - General
280
Out-Of-Chassis Diagnostic Procedures
282
Piston And Rod Assembly
283
Base Engine Components Dodge Engine Components
283
Crankshaft And Main Bearings
285
Cylinder Block
286
Out-Of-Chassis Repairs
288
Oil Pan, Suction Tube And/Or Gasket Replacement
289
Piston And Rod Assembly - Removal
290
Base Engine Components Out-Of-Chassis Repairs
290
Dodge Turbo Diesei
290
Piston And Rod - Disassembly
292
Piston, Pin And Connecting Rod - Clean
292
Piston, Pin And Rod - Inspection
293
Piston And Rod - Assembling
295
Piston Ring Gap - Check
296
Piston Rings Installation
297
Cylinder Block - Inspection
299
Straight Edge, Feeler Gauge
299
Cylinder Bores - De-Glaze
300
Connecting Rod Bearings - Install
303
Piston And Rod Assembly Installation
303
Crankshaft Removal
307
Crankshaft - Cleaning And Inspection
308
Determine Rod Bearing Clearance
309
Determine Main Bearing Clearance
309
Crankshaft Gear - Replacement
310
Crankshaft - Installation
311
Rear Crankshaft Seal Housing And Seal Replacement
315
Rear Crankshaft Installation
316
Gear Housing And Gasket Replacement
317
Timing Pin - Installation (Cylinder Head Off)
318
Engine Removal, Replacement And Testing
322
Engine Replacement - Procedure
325
Engine Testing
327
Blowby Limits
328
Blowby Measurement
328
Blowby Conversion Chart
329
Engine Rating
330
Engine Test Check List
330
Engine Run-In
330
Alternative Repair Procedures
332
Cylinder Block Repair Procedures
334
Combustion Deck
335
Cam Bore(S)
336
Cylinder Bore(S) Repair - General
336
Repair Sleeve Installation
338
Crankshaft Repair Tools
342
Crankshaft Grinding - General
342
Crankshaft Main Journal Regrind Specifications
342
Thrust Journal/Thrust Surface Width Regrinding
343
Crankshaft Main Journal Radius - Regrind
344
Crankshaft Rod Journal Regrind Specifications
345
Crankshaft Rod Journal Radius - Regrind
345
Cylinder Head Repair Tools
347
Cylinder Head Combustion Deck Inspection And Refacing
348
Valve Guides: Inspection And Installation
348
Valve Seats - General
350
Calculating The Grinding Depth
351
Grinding The Valve Seats
351
Installing Service Valve Seats
354
Replacing Service Seats
357
Tools Required
363
Capscrew Markings And Torque Values - Metric
364
Metric Capscrew Nomenclature
364
Pipe Plugs, Fittings, And Adapters
365
Engine Component Torque Value
365
Engine Sealants
368
Engine Lubricants
369
Base Engine Components Specifications
372
Valve Train
372
Valve Spring
373
Valve Rim Thickness
373
Valve Seating Angle Of Face
373
Valve Seat Width
373
Gear Train Data
374
Camshaft Data
374
Tappets Data
374
Pistons Data
375
Pin Bore Diameter
375
Ring Groove Data
375
Piston Pin Diameter
375
Connecting Rod Data
376
Crankshaft Data
376
Cylinder Block Data
377
Cylinder Bores Data
378
Oil Pump Specifications
379
Rocker Lever Specifications
380
Exhaust System And Intake Manifold
382
Air System Flow
383
Diagnosing Air System Malfunctions
384
Air Flow Restriction Results In Excess Smoke And Low Power
384
Exhaust Leaks
385
Malfunctioning Turbocharger
386
Oil Consumption And Leaks
386
Turbocharger Noise
387
Rotor Assembly Clearance Measure
388
White Smoke
389
Normal Operation Of The Intake Manifold Heater System
389
Intake Manifold Heater - Check
390
Check Battery Voltage
390
Check Thermistor
390
Check Preheat Cycle
391
Start The Engine
393
Air System Replacement Procedures
393
Air Crossover - Replacement
393
Intake Manifold Cover And Gasket - Replacement
394
Turbocharger - Replacement
396
Exhaust Manifold And/Or Gasket - Replacement
399
Air Cleaner Element Replacement
400
Turbocharger - Rebuilding
402
Description
402
Identification
402
Exploded View Of The Turbocharger
404
Disassembly Of The Turbocharger
405
Cleaning Of The Turbocharger
409
Inspection Of The Turbocharger
410
Assembly Of The Turbocharger
411
Exhaust System And Intake Manifold Specifications
418
Fuel System
420
Fuel System Components And Flow
421
Fuel System Specification Dodge Ram 5.9 Liter Diesel
421
Fuel System Malfunction - Diagnosis
422
Lift Pump
422
Air In The Fuel System
423
Fuel Water Separator/Filter Unit
424
Injection Pump Identification
424
Injection Pump
425
Governor Malfunctions
425
Fuel Control Lever Travel And Adjustment
425
Manual Shut Down Lever
426
Advance Timing Mechanism
427
Electrical Shut Off Valve
427
Injection Pump Timing
428
High Pressure Fuel Lines
430
Injectors
431
Fuel Drain Manifold
433
Fuel System Replacement Procedures
433
Fuel System - Bleeding
434
Injection Pumps - Venting
435
High Pressure Lines - Venting
435
Fuel Filter - Replacement
435
Low Pressure Fuel Line - Replacement
436
Lift Pump - Replacement
437
High Pressure Lines - Replacement
439
Fuel Drain Manifold Replacement
440
Injection Pump Supply Line Replacement
442
Air Fuel Control Tube - Replacement
443
Injector - Replacement
443
Injection Pump - Replacement
446
Timing Indicator
454
Bosch Ve Pump Timing Check
454
Shaft Seal - Replacement
455
Accelerator Pedal And Throttle Controls
456
Service Procedures
456
Throttle Controls
457
Throttle Linkage Adjustments
457
Low Idle Stop Speed
459
Fuel System Specifications
460
Steering
462
Transmission
464
Manual Transmission Removal And Replacement
465
Manual Transmission Specifications
465
Automatic Transmission Road Test
466
Throttle Linkage
466
Throttle Cable Adjustment
467
Adjustment Procedure
467
Heating And Air Conditioning
468
Refrigerant Compressor - Remove
469
Refrigerant Compressor - Install
470
Emission Control System
472
Index
474
Previous
Page
1
...
482
483
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Table of Contents
Troubleshooting
Electrical System Specifications
117
Troubleshooting Logic
140
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This manual is also suitable for:
D350 1990
W250 1990
W350 1990
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