Dodge D250 1990 - Out-Of-Chassis Diagnostic Procedures

Dodge D250 1990

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Base

Engine

Components

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-4

Cylinder Block

9H-5

Table of Contents

How to Use the Manual5
Generic Symbols6
Definition of Terms7
Star Pattern Torque Sequence7
General Safety Instructions9
Component and System Index13
Vehicle Identification Number15
Vehicle Identification Plate15
Vehicle Safety Certification Labels15
Engine Serial Number16
Fastener Classification16
Transmission Identification16
Metric System17
Model Line-Up and Weights18
VIN Code Charts18
Power Team Availability19
Standard Truck Body Dimensions19
Fraction, Decimal, Millimeter, Conversions20
Lubrication and Maintenance22
Table of Contents24
General Information25
- Required Maintenance for Noise Control Systems25
- Exhaust System25
- Air Cleaner Assembly25
Heavy Duty Cycle25
Noise Control Systems25
Severe Service25
A Word about Maintenance26
Parts and Lubrication Recommendations26
- Tampering with Noise Control System Prohibited26
- Classification of Lubricants26
Parts Requiring no Lubrication26
Engine Data Plate27
Fuel Pump Data Plate27
- Engine View and Parts Identification28
- Front of Engine28
- Fuel Side of Engine28
- Exhaust Side of Engine29
- Rear of Engine29
- Operating Instructions30
- Flammable Fluid Spills31
- Starting Fluids (Warning)31
- Assist (Jump) Starting32
- Maintenance Free Battery32
- With a Booster Battery32
- First Start up of the Day34
- New Engine Break-In34
- Starting the Engine34
- Anti-Lock35
- Brake Light - Diesel Powered Trucks35
- Message Center Lights35
- Waittostart35
- Waterinfuel35
- Lowfuel36
- Normal Starting Procedure36
- Cold Weather Starting37
- Engine Warm-Up37
- Hand Throttle37
- Avoid Low Coolant Temperature Operation38
- Avoid Overheating the Engine38
- Do Not Operate the Engine with Low Oil Pressure38
- Engine Idling38
- Operating the Engine38
- Stopping the Engine38
- Avoid Using Contaminated Fuel39
- Bulk Fuel Storage39
- Do Not Operate the Engine with Failed Parts39
- Fuel Requirement39
- Prevent Over-Speeding the Engine Going down Hill39
- Break-In Oils40
- Oil Performance Recommendations40
- Oil Viscosity Recommendations40
- Arctic Operation41
- Coolant41
- Maintenance Guidelines42
- DODGE Turbo Diesel43
- Maintenance Schedule43
- Maintenance Record44
- Coolant Recovery Tank Coolant Level - Check45
- Cooling System - Check45
- Daily Maintenance45
- Oil Level - Check45
- Draining Fuel/Water Separator Filter46
- Drive Belt - Inspection46
- Fan - Inspection46
- Radiator Coolant Level - Check46
  - Lubricating Oil and Filter - Change47
  - Maintenance Every 6 Months or 9,700 Km (6,000 Miles)47
- Air Cleaner Dement - Inspection50
- Antifreeze Concentration - Check 0G-1051
- Fuel Filter - Change 0C-1051
- Maintenance Every 12 Months or 19,300 Km [12,000 Miles] 0C-1051
- Coolant Drain52
- Maintenance Every 24 Months or 38,600 Km [24,000 Miles] 0C-1152
  - Cooling System - Flush53
  - Maintenance Every 48 Months or 77,200 Km [48,000 Miles]54
  - Engine Systems - Flow Diagrams56
  - Air System Diagram57
- DODGE Turbo Diesel57
- Engine Diagrams57
- Engine Systems - Flow Diagrams57
  - Fuel System Diagram57
  - Cooling System Diagram58
  - Lubricating Oil System Diagram58
- Lubrication for the Power Components59
- Lubrication for the Turbocharger59
- Lubrication for the Overhead60
  - Engine Specifications62
  - Coolant Specifications64
  - Arctic Operations65
  - Fuel Specifications65
  - Scheduled Maintenance for Vehicle Emission Control and Performance66
  - Fluid Capacities68
  - Recommended Lubricants, Fuels and Fluids70
  - Service Brakes74
  - Message Center Lights - Brake System75
- Power Steering and Vacuum Pump75
- Service Brakes DODGE Turbo Diesel75
- Reassembly79
- Specifications80
  - Clutch82
  - Clutch Pedal and Bracket83
  - Cooling System90
  - Cooling System Components and Flow91
  - Cylinder Block Diagram91
  - Cylinder Head Diagram91
  - Thermostat Diagram91
  - Cooling System Malfunctions - Diagnosis92
  - Pressure Caps94
- Water (Coolant) Pump94
- Radiator Air Flow96
- Thermostat97
- Gauges, Overfueling and Loading98
- Belt Tensioner - Replacement99
- Cooling System Replacement Procedures99
- Drive Belt - Replacement99
- Coolant - Draining100
- Fan Pulley - Replacement100
- Water Pump - Replacement101
  - Thermostat Replacement102
  - Cup Plugs Replacement104
- Fan Hub - Replacement104
  - Fan Hub Disassembly105
  - Fan Hub Inspection105
  - Fan Hub Assembly106
- Thermatic Fan - Check107
- Thermostat - Inspection107
  - Thermatic Fan - Remove108
  - Thermatic Fan Installation108
- Flush the Coding System109
- Component Capacrew Torque Values111
- Cooling System Capacity111
  - Cooling System Specifications111
  - Electrical System112
  - Electrical System Description/Operation113
- Starting Motor113
- Alternator114
- Intake Manifold Heater System115
- Message Center and Run Circuit116
- Diagnosing Electrical Malfunctions117
- Electrical System Specifications117
- Engine Does Not Crank117
- Starting Motor Troubleshooting117
- Engine Cranking Speed too Slow119
- Abnormal Ammeter Operation120
- Abnormal Charging System Operation120
- Switch On, Negative (-) on Ammeter, Engine Running120
  - Fuel Shut off Valve - Check121
  - Oil Pressure Switch and Temperature Sensor121
- Coolant Heater - Check122
- Coolant Temperature Sensor - Check122
- Oil Pressure Switch/Sending Unit - Check122
- Alternator - Replacement123
- Engine Electrical System Replacement Procedures123
- Starting Motor Replacement123
- Electric Fuel Shut off Valve - Replacement125
- Oil Pressure Switch - Replacement125
- Oil Pressure Switch/Sending Unit Socket126
- Temperature Sensor - Replacement126
- Thermistor - Replacement127
- Fuel Heater - Replacement128
  - Screwdriver Adapter129
  - Engine Block Water Heater Replacement130
- Intake Manifold Heater - Replacement131
- Remove131
- Battery Voltage - Check132
- Install132
- Intake Manifold Heater Controls - Check132
- Operating Temperature132
- Thermistor - Check133
- Preheat/Postheat Cycle - Check134
- Intake Manifold Heater Check135
- Temperature/Cycle Time Chart of Normal Operation135
- Specifications136
  - Base Engine Components138
  - Troubleshooting Logic140
  - Engine Diagrams141
  - Problem Isolation and Correction141
  - Engine will Not Crank or Cranks Slowly143
  - Engine Cranks but will Not Start - no Smoke from Exhaust144
  - Engine Hard to Start or will Not Start - Smoke from Exhaust146
  - Engine Starts but will Not Keep Running148
  - Surging (Speed Change)149
  - Rough Idle (Irregularly Firing or Engine Shaking)150
  - Engine Runs Rough or Misfiring151
  - Engine RPM will Not Reach Rated Speed153
  - Low Power154
  - Excessive Exhaust Smoke157
  - Coolant Temperature above Normal159
  - Coolant Temperature below Normal162
  - Coolant Loss163
  - Lubricating Oil Pressure Low165
  - Lubricating Oil Pressure too High167
  - Lubricating Oil Loss168
  - Contaminated Coolant170
  - Contaminated Lubricating Oil171
  - Fuel or Oil Leaking from Exhaust Manifold172
  - Compression Knocks173
  - Excessive Fuel Consumption174
  - Engine will Not Shut off175
  - Excessive Vibration176
  - Excessive Engine Noises178
  - Alternator Not Charging or Insufficient Charging179
  - Engine Lubricating System180
  - Lubricating Oil Pump181
  - Lubricating System Flow181
- Pressure Regulating Valve181
- Lubrication for the Turbocharger182
  - Oil Coolers182
  - Oil Filter Bypass Valve182
  - Oil Filters182
  - General Description of Oil Flow183
- Lubrication for the Power Components183
- Lubrication for the Overhead184
  - Diagnosing Lubricating System Malfunctions185
  - Bearings and Oil Pump186
  - Oil Filter186
  - Oil Gauge186
  - Oil Suction Tube186
  - Coolant Diluted Oil187
  - Oil Dilution187
  - Fuel Diluted Oil188
  - Injection Pump Shaft Seal189
- Fuel Leakage by the Rings190
  - Cylinder Head Leakage191
  - Lift Pump Leakage191
  - Oil Leaks191
  - Lubricating Oil Level - Check192
- Lubricating Oil and Filter - Change193
  - Lubricating System Replacement Procedures195
  - Oil Pressure Regulator Spring196
  - Replacement of the Filter Bypass Valve196
- Oil Cooler Element And/Or Gasket - Replacement197
  - Oil Pan, Suction Tube And/Or Gaskets - Replacement199
  - Oil Pump - Replacement201
  - Remove the Lubricating Oil Pump202
  - Installing the Lubricating Oil Pump205
  - Gear Cover - Installation206
  - Lubricating Oil Viscosity Recommendations211
  - Lubricating Oil, Arctic Operation211
  - Lubrication System Specifications211
  - In and Out-Of-Chassis Repairs212
  - Base Engine Components Description213
  - Cylinder Head and Valve Train In-Chassis Repair213
  - Front Crankshaft Seal In-Chassis Repair214
  - Front Gear Housing and Gear Train214
  - Flywheel Housing and Flywheel In-Chassis Repair215
  - Piston and Connecting Rod Assemblies Out-Of-Chassis Repair216
  - Crankshaft and Main Bearings Out-Of-Chassis Repair217
  - In-Chassis Repairs - General220
  - In-Chassis Diagnostic Procedures222
  - Air and Fuel Systems - Check223
  - Valve Train and Head Assembly223
  - Valve Adjustment Check224
  - Valve Seal Wear224
  - Injector Protrusion225
  - Rocker Lever, Valve Stem, Push Rod, Tappet and Camshaft226
  - Flywheel Housing and Flywheel227
  - Front Gear Housing Cover and Gear Train227
  - Rear Crankshaft Seal228
  - Rear Gear228
  - In-Chassis Repairs230
  - Rocker Levers and Push Rods - Replacement231
  - Rocker Levers - Disassembly232
  - Rocker Levers Assembly234
  - Rocker Lever Assembly Installation236
  - Valve Clearance Adjustment237
  - Cylinder Head Removal238
  - Cylinder Head Overhaul240
  - Grinding the Valves (Cylinder Head)244
  - Grinding the Seats (Cylinder Head)245
  - Assembly of the Cylinder Head249
  - Inspect the Valve Springs249
  - Measure Valve Spring Force249
  - Plastic Hammer250
  - Valve Spring Compressor250
  - Cylinder Head and Gasket - Installation251
  - Front Crankshaft Seal - Replacement253
  - Replacing the Timing Pin255
  - Timing Pin Assembly or Gasket - Replacement255
  - Timing Pin Housing Assembly - Installation (with Head On)256
  - Gear Cover - Removal260
  - Camshaft, Gear and Tappet - Replacement264
  - Camshaft Inspection265
  - Camshaft Gear - Replacement266
  - Camshaft Bushing - Inspection268
  - Tappet - Removal269
  - Tappet Inspection271
  - Tappet Stem Specifications271
  - Tappet Installation272
  - Camshaft Installation274
  - Flywheel Ring Gear - Replacement276
  - Flywheel - Installation277
  - Rear Seal - Replacement278
  - Out-Of-Chassis Repairs - General280
  - Out-Of-Chassis Diagnostic Procedures282
- Base Engine Components DODGE Engine Components283
- Piston and Rod Assembly283
- Crankshaft and Main Bearings285
- Cylinder Block286
- Out-Of-Chassis Diagnostic Procedures287
  - Out-Of-Chassis Repairs288
  - Oil Pan, Suction Tube And/Or Gasket Replacement289
- Base Engine Components Out-Of-Chassis Repairs290
- DODGE Turbo Diesei290
- Piston and Rod Assembly - Removal290
- Piston and Rod - Disassembly292
- Piston, Pin and Connecting Rod - Clean292
- Piston, Pin and Rod - Inspection293
- Piston and Rod - Assembling295
- Piston Ring Gap - Check296
- Piston Rings Installation297
- Cylinder Block - Inspection299
- Straight Edge, Feeler Gauge299
- Cylinder Bores - De-Glaze300
- Connecting Rod Bearings - Install303
  - Piston and Rod Assembly Installation303
  - Crankshaft Removal307
- Crankshaft - Cleaning and Inspection308
  - Determine Main Bearing Clearance309
  - Determine Rod Bearing Clearance309
  - Crankshaft Gear - Replacement310
  - Crankshaft - Installation311
  - Rear Crankshaft Seal Housing and Seal Replacement315
  - Rear Crankshaft Installation316
  - Gear Housing and Gasket Replacement317
- Timing Pin - Installation (Cylinder Head Off)318
  - Engine Removal, Replacement and Testing322
  - Engine Replacement - Procedure325
  - Engine Testing327
  - Blowby Limits328
  - Blowby Measurement328
  - Blowby Conversion Chart329
  - Engine Rating330
  - Engine Run-In330
  - Engine Test Check List330
  - Alternative Repair Procedures332
  - Cylinder Block Repair Procedures334
  - Combustion Deck335
  - Cam Bore(S)336
  - Cylinder Bore(S) Repair - General336
  - Repair Sleeve Installation338
  - Crankshaft Grinding - General342
  - Crankshaft Main Journal Regrind Specifications342
  - Crankshaft Repair Tools342
  - Thrust Journal/Thrust Surface Width Regrinding343
  - Crankshaft Main Journal Radius - Regrind344
  - Crankshaft Rod Journal Radius - Regrind345
  - Crankshaft Rod Journal Regrind Specifications345
  - Cylinder Head Repair Tools347
  - Cylinder Head Combustion Deck Inspection and Refacing348
  - Valve Guides: Inspection and Installation348
  - Valve Seats - General350
  - Calculating the Grinding Depth351
  - Grinding the Valve Seats351
  - Installing Service Valve Seats354
  - Replacing Service Seats357
  - Specifications362
- Tools Required363
  - Capscrew Markings and Torque Values - Metric364
  - Metric Capscrew Nomenclature364
  - Engine Component Torque Value365
- Pipe Plugs, Fittings, and Adapters365
- Engine Sealants368
- Engine Lubricants369
- Coolant Specifications371
- Fuel Specifications371
  - Base Engine Components Specifications372
  - Valve Train372
  - Valve Rim Thickness373
  - Valve Seat Width373
  - Valve Seating Angle of Face373
  - Valve Spring373
  - Camshaft Data374
  - Gear Train Data374
  - Tappets Data374
  - Pin Bore Diameter375
  - Piston Pin Diameter375
  - Pistons Data375
  - Ring Groove Data375
  - Connecting Rod Data376
  - Crankshaft Data376
  - Cylinder Block Data377
  - Cylinder Bores Data378
  - Oil Pump Specifications379
  - Rocker Lever Specifications380
  - Exhaust System and Intake Manifold382
  - Air System Flow383
- Air Flow Restriction Results in Excess Smoke and Low Power384
- Diagnosing Air System Malfunctions384
- Exhaust Leaks385
- Malfunctioning Turbocharger386
- Oil Consumption and Leaks386
- Turbocharger Noise387
  - Rotor Assembly Clearance Measure388
  - Normal Operation of the Intake Manifold Heater System389
- White Smoke389
- Check Battery Voltage390
- Check Thermistor390
- Intake Manifold Heater - Check390
- Check Preheat Cycle391
- Air Crossover - Replacement393
- Air System Replacement Procedures393
- Start the Engine393
- Intake Manifold Cover and Gasket - Replacement394
- Turbocharger - Replacement396
- Exhaust Manifold And/Or Gasket - Replacement399
- Air Cleaner Element Replacement400
- Intake Manifold Heater - Replacement400
- Remove400
- Install401
- Description402
- Identification402
- Turbocharger - Rebuilding402
- Exploded View of the Turbocharger404
- Disassembly of the Turbocharger405
- Cleaning of the Turbocharger409
- Inspection of the Turbocharger410
- Assembly of the Turbocharger411
  - Exhaust System and Intake Manifold Specifications418
  - Fuel System420
  - Fuel System Components and Flow421
- Fuel System Specification Dodge Ram 5.9 Liter Diesel421
- Fuel System Malfunction - Diagnosis422
- Lift Pump422
- Air in the Fuel System423
- Fuel Water Separator/Filter Unit424
- Injection Pump Identification424
- Fuel Control Lever Travel and Adjustment425
- Governor Malfunctions425
- Injection Pump425
- Manual Shut down Lever426
- Advance Timing Mechanism427
- Electrical Shut off Valve427
- Injection Pump Timing428
- High Pressure Fuel Lines430
- Injectors431
- Fuel Drain Manifold433
  - Fuel System Replacement Procedures433
  - Fuel System - Bleeding434
  - Fuel Filter - Replacement435
  - High Pressure Lines - Venting435
  - Injection Pumps - Venting435
  - Low Pressure Fuel Line - Replacement436
  - Lift Pump - Replacement437
  - High Pressure Lines - Replacement439
  - Fuel Drain Manifold Replacement440
  - Injection Pump Supply Line Replacement442
  - Air Fuel Control Tube - Replacement443
  - Injector - Replacement443
  - Injection Pump - Replacement446
- Fuel System Replacement Procedures447
  - Bosch VE Pump Timing Check454
  - Timing Indicator454
  - Shaft Seal - Replacement455
- Accelerator Pedal and Throttle Controls456
- General Information456
- Service Procedures456
  - Throttle Controls457
  - Throttle Linkage Adjustments457
  - Low Idle Stop Speed459
  - Fuel System Specifications460
  - Steering462
  - Transmission464
  - Manual Transmission Removal and Replacement465
  - Manual Transmission Specifications465
  - Automatic Transmission Road Test466
  - Throttle Linkage466
  - Adjustment Procedure467
  - Throttle Cable Adjustment467
  - Heating and Air Conditioning468
  - Refrigerant Compressor - Remove469
  - Refrigerant Compressor - Install470
  - Emission Control System472
  - Index474
Identifying Your Engine28

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