Chrysler 1991, 1991 D&W 250, 1991 D&W 350 Service Manual Supplement

Page 1
SERVICE
MANUAL
SUPPLEMENT
DIESEL ENGINE
REAR
WHEEL
DRIVE
TRUCK
D& W 250-350
Page 2
TYSLER
MOTTOES
1991
DIESEL
SERVICE
SUPPLEMENT
1/2
To
order illustrated, inside
DODGE
the
special
please
back
cover.
ENGINE
MANUAL
TRUCKS
refer
service
to the
tools
used and
instructions
on
NO PART REPRODUCED, STORED SYSTEM, OR
BY ANY CHANICAL, OR OTHERWISE WITHOUT WRITTEN MOTORS.
Chrysler additions to or improvements in its products tions upon itself to install
Litho
OF
OR
TRANSMITTED,
PHOTOCOPYING, RECORDING,
PERMISSION
Motors
reserves the
in
U.S.A.
Copyright ©1991
THIS PUBLICATION MAY
IN A
MEANS, ELECTRONIC,
OF
right
to make changes in design or to make
them
on its products previously manufactured.
wihtout
Chrysler
BE
RETRIEVAL
IN ANY FORM
ME-
THE
PRIOR
CHRYSLER
imposing any obliga-
Motors
20M191
Page 3
FOREWORD
The information contained in this service manual has
cian
involved in daily repair operations. This manual
service training material.
Information
ing,
adjustments, removal, installation, disassembly, and assembly
To
assist the group contents section that lists major topics
Chrysler Motors
vehicle
Manual
wiring
Information
in this manual is divided into groups.
in locating a group
title
is aligned to a
reserves
at any time without prior notice or incurring obligation.
describing the operation and use of standard and optional equipment is included in the Owner's
provided
with
the vehicle.
the
title
solid
right
page,
use the Group Tab Locator on the
tab on the
within
to
change
first
the group.
testing procedures, specifications, diagnosis, repair methods, or
been
does
These
page
prepared for the professional automotive techni-
not cover theory of operation,
groups contain general information, diagnosis,
of
procedures
each
group. This
for the components.
following
first
which
page.
page
is
addressed
The
solid
of the group has a
bar after
in
test-
Page 4
C01P01E1T
Name
Group-page
Ali SYSTEi INDEX
Name
Group-page
5.9L DIESEL ENGINE ENGINE
GENERAL
AIR
CONDITIONING
COMPRESSOR
Compressor Compressor Compressor Cylinder Description Magnetic
Purging
TORQUE
BRAKES............
Diesel
Installing
Low Pump Removing
Vacuum Vacuum Vacuum Vacuum
COOLING
SPECIFICATIONS
EMISSION
EXHAUST
EXHAUST
SERVICE
Exhaust Manifold 11-1
Intake Intercooler
Turbocharger 11-3
SPECIFICATIONS
FUEL
SYSTEM
DIESEL
Air
Battery Brake
Charge
Crank Engine General Information 14-1
ENGINES. . .... 9-1
DIAGNOSIS SERVICE
INFORMATION
Head/Valve
Clutch 24-2
Compressor
SPECIFICATIONS—A/C
COMPRESSOR
Vacuum
Vacuu,—Steering
Assembly
Vacuum
Adapter
Vacuum—Steering
Assembly
Pump Pump Pump Pump
SYSTEM
CONTROL
EMISSION
SYSTEM
PROCEDURES
Manifold Cover/Air Intake Heater 11-2
14-1
FUEL
Intake Heater Relays—Engine
Output
14-4
Voltage—Engine
Switch—Engine
Air
Controller
Signal—Engine
Controller
9=3
PROCEDURES
-.9-1
24-1 OVERHAUL 24-2 Isolation Shaft Seal 24-5
24-1
5-5
Warning
5-2
7-1
AND
.11-8
INJECTION
Temperature
Input 14-2
24-1
Plate
of Air 24-1
24-9
.......5-1
Pump
Replacement
Diagnosis 5-2 Operation 5-1 Replacement Serviceability
7-1
11-9
.5-1
Switch 5-1
SYSTEMS
CONTROLS
INTAKE
(DIESEL
14-1
Controller
Controller
14-1
9-12
(SD-709)
24-8
Pump
25-1
MANIFOLD.
Controller
Sensor—Engine
........ 24-1
5-4
Pump
5-4
5-1
25-1
.... 11-1
ENGINES) . .
Controller
Input .. . 14-2
Input .... 14-2
Input 14-2
. 11-1
Ignition KSB Solenoid 14-5 Overdrive Override
Overdrive Solenoid—Engine
Park/Neutral Switch —Engine
SCI Receive and SCI Transmit—Engine
Speed Speed System System Throttle
Vehicle
Wait-To-Start
Water-ln-Fuel
Water-ln-Fuel Sensor—Engine
GENERAL
Air KSB Solenoid 14-11 On Throttle Visual
SERVICE
Fuel
Injection KSB Solenoid 14-22 Throttle
INSTRUMENT SPEED
SERVICE TEST
Checking for Distance
Inoperative
Road Speed Speed Speed Speed Stop Vacuum
Sense—Engine
Controller
Output
Input 14-2
Controller
Controller
Controller
Output
Output
Input 14-3
Intake Heater 14-11
Board
Injection
CONTROL
PROCEDURES
Lamp
Input 14-2
14-5'
Output Control—Engine Control—Engine
Diagnosis 14-1 Operation 14-5
Position
Input 14-3
Distance (Speed) Sensor—Engine
Input 14-3
Lamp—Engine
14-5
Lamp—Engine
. 14-5
DIAGNOSIS-DIESEL
Diagnostics 14-11
Position
Inspection 14-8
PROCEDURES
Timing
Position
PANEL
SYSTEM
PROCEDURES
Fault
(Speed) Sensor Test 8H-4
System
Test 8H-4
Control Cable
Control Cable Control Switch Test 8H-5 Control
Speed
Supply
Controller
Switchitch
14-5
Controller Controller
Sensor (TPS)—Engine
Sensor Test 14-10
14-21
Pump
14-22
14-26
Sensor 14-21 AND
GAUGES
8H-1
8H-8
8H-4
Code
8H-4
8H-4
Attachment—Engine Attachment—Servo
System
Electrical
Control Switch Test .... 8H-5
Test 8H-6
Input 14-2
—Engine
Controller
Controller
Input .... 14-3
Output
Controller
Controller
Controller
. 14-8
8E-1
Tests 8H-4
... 14-5
.. 8H-7
... 8H-7
Page 5
STEERING
GENERAL INFORMATION 19-1
TRANSMISSION 21-1
19-1
Fluid
Temperature Thermo-Switches General General Governor Planetary
(information Specifications—Diesel
Weight
Gears
21-1
Assembly
— 21-1
21-1
21-2
A518
......
21-3
Service
Servicing Torque Transmission
Transmission Transmission
Procedure
Changes
Clutch
Low-Reverse
21-2
The New
Converter
Packs
And
21-1
And
Overdrive
21-2 Case Overrunning
Drum
Specification
Overrunning
21-1
21-1
Clutch
Compounder
Clutch
And
....
21-2
Page 6
GROUP
Brakes
Cooling System
TAB LOCATOR
8E
8H
8W
d| i| Exhaust System and
Instrument Gauges
Speed
Wiring
Engines
Manifold
Panel and
Control
Diagrams
System
14 Fuel System
19
21
Steering
Transmission
Intake
iH:;&"*»-.i
24
25
Air
Conditioning
Emission
Control
Systems
Page 7
Page 8

BRAKES

CONTENTS
BRAKES
5 - 1
page
DIESEL INSTALLING
LOW PUMP REMOVING
DIESEL
on sel engine. However, the new vacuum pump combined
VACUUM
ASSEMBLY
VACUUM
ADAPTER
ASSEMBLY
VACUUM
A
new design power brake vacuum pump
1991-1/2 AD models
with
PUMP
VACUUM-STEERING
WARNING
REPLACEMENT
VACUUM-STEERING
PUMP
SWITCH
with
the Cummins turbo die-
PUMP
PUMP
the power steering pump into a single
is
is
used
still
assembly (Fig. 1).
The new vacuum pump is a constant displacement,
vane-type pump. Vacuum is generated by four mounted in the pump rotor. The rotor the pump housing
and is
pressed
is
onto
vanes
located in
the
pump
shaft.
The vacuum and steering pumps are both operated by a single drive shaft. The drive
gear gear
pressed
is
onto the vacuum pump
operated by . the camshaft
gear.
The vacuum and power steering pump shafts connected by a coupling. Each pump shaft adapter
with
drive lugs that
engage
in the coupling.
The vacuum pump rotating components are cated by engine pump through
oil.
Lubricating
an
oil
oil is supplied to the
line
at' the underside of the
are
has an
lubri-
pump housing.
VACUUM
PUMP
SERVICEABILITY
The vacuum pump is not a serviceable component. If
diagnosis indicates a pump malfunction, the pump
must
be
not
disassemble
removed and replaced
or attempt to repair the pump.
as an
assembly. Do
The combined vacuum and steering pump assembly must be removed for the vacuum pump can be removed disassemble
If
the power steering pump requires service, simply remove Refer
to the
dures
LOW
VACUUM
A
vacuum switch
the power steering pump.
the
assembly and
pump removal and installation proce-
in this section.
vacuum pump. brake warning
access
WARNING
is
used to monitor output of the
The
switch
light.
to either pump. However,
separate
SWITCH
is in
without
the two pumps.
circuit
having to
with
the
VACUUM
1
VACUUM
5
VACUUM
1
VACUUM
4
GEAR
A brake booster. A the brake warning
The switch
PUMP PUMP PUMP PUMP
ADAPTER
Fig. 1 Vacuum
vacuum
DIAGNOSIS OPERATION REPLACEMENT SERVICEABILITY
VACUUM
And
Steering
hose
connects the switch
wire
harness
...
..
Pump
connects the switch to
light.
is
mounted
on the
Assembly
to
driver side inner
fender panel just below the hood hinge (Fig. 2).
VACUUM
Vacuum
brake booster through a supply
PUMP
OPERATION
pump output
is
transmitted to the power
hose.
The
hose nected to an outlet port on the pump housing and to the check valve in the power brake booster.
Pump output
ranges
from a minimum
of 8.5 to
inches vacuum.
The pump rotor and
drive
gear.
The drive
shaft
gear.
Booster vacuum
switch
(Fig. chamber that circuit
with
2). measures
the brake warning
vanes
level
are rotated by the pump
gear
is
operated by the cam-
is
monitored by a warning
The switch consists
vacuum
level
and a sensor
light.
of a
page
..
2
..
1
..
4
..
1
J9105-94
the power
is con-
25
vacuum
in
Page 9
5 - 2 BRAKES
Fig. 2 Vacuum Switch Location
The vacuum chamber is connected to the booster check valve by a vacuum supply ness
connects
light.
If booster vacuum falls below 8.5 inches for
8-10
seconds
the
circuit
the switch
sensor
or more, the switch
to the warning
light
hose.
A wire
har-
to the brake warning
sensor
causing it to
completes
illumi-
nate.
(3)
Check booster operation as described in the di­agnosis hoses, eration is correct but the warning
section.
or booster
Replace
if
necessary.
the check valve, vacuum
However,
light
if
booster op-
is
continue testing.
(4)
Disconnect the vacuum switch,
plug the
hose
hose
from
the warning
and connect a hand vacuum
pump to the switch.
(5)
Start and run the engine.
(6)
Apply switch goes
out, the switch vacuum leaking. running
(7)
Apply observe goes
out, the switch is at fault and should be re-
placed. If the
(8)
Reconnect the vacuum original Run
the engine and
If
the
light
remains on, the problem is in the
tween the switch and warning
8.5 to 9 inches of vacuum to the warning
and
observe
If the
the warning
light
remains on, leave the engine
light.
If the
hose
is either loose or
and continue testing.
20-25 inches vacuum to the switch and
warning
warning switch
light
light
operation. If the
light
remains on, continue testing.
with
observe
hoses
warning
and replace the
a known good switch.
light
is now off, the old switch is
faulty.
light.
light
operation.
wiring
still
light
If the
on,
now
be-
VACUUM
Vacuum output ing
switch can
PUMP
DIAGNOSIS
pump diagnosis involves checking pump
with
a vacuum
also
gauge.
be checked
The low vacuum warn-
with
a vacuum
gauge.
Refer to the diagnosis procedure in this section.
A
standard vacuum pump output when pump supply
hose the outlet port for testing hold
steady
in a
inches at various engine
DIAGNOSING CONDITION
A
low booster vacuum condition or a
LOW
vacuum warning switch ing
light
to
illuminate.
dicates
the existence of a low vacuum condition,
gauge
necessary.
can be
used
Simply disconnect the
and connect a vacuum
range
purposes.
of approximately 8.5 to 25
Vacuum should
speeds.
VACUUM
If
OUTPUT
will
cause
the
light
the brake warn-
does
to check
gauge
faulty
to
low
go on and in-
check the vacuum pump, booster and warning switch as
follows: (1)
Check vacuum pump oil feed
line
connections are
secure
and not leaking. If leak-
line.
Verify
that
age is noted and pump is noisy, replace pump.
(2)
Check vacuum pump output vacuum booster.
gauge.
Disconnect the supply
Connect the
gauge
to this
with
a standard
hose
hose
and run the
to the
engine at various throttle openings. Output should range
from
8.5 to 25 inches vacuum. If vacuum is consistently below 8.5 inches, the problem is vacuum put is
hoses
within
or a vacuum pump component. If out-
specified
limits,
continue testing.
with
the
REMOVING ASSEMBLY
(1)
Disconnect battery negative cable.
(2)
Position drain pan under power steering pump.
(3)
Disconnect vacuum and steering pump
from
respective pumps (Fig. 3).
(4)
Disconnect oil
(Fig.
4).
VACUUM-STEERING
Fig. 3 Vacuum
And
Connections
pressure
Steering
sender
PUMP
Pump
wires at
Hose
hoses
sender
Page 10
(5)
Remove oil
pressure
sender
(Fig.
4).
PUMP
LOWER
BRAKES
ASSEMBLY
MOUNTING
5 - 3
ADAPTER BRACKET
STEERING
PUMP
Fig. 4 Oil
(6)
Disconnect
ENGINE
Pressure Sender Location
lubricating
BLOCK
oil feed
at underside of vacuum pump (Fig.
line
5).
J9119-74
from
fitting
VACUUM
PUMP
BOTTOM-INBOARD
ADAPTER
Fig. 6 Adapter
(9)
Remove upper
bly
to
engine block (Fig.
(10)
Remove pump assembly
BRACKET
And
NUT
Pump Mounting Fastener
Location
bolt
that
attaches
pump
J9105-97
assem-
7). from
vehicle
(Fig.
8).
VACUUM
PUMP
OIL
LINE J9105-96
Fig. S Oil
(7)
Remove lower
to
engine block (Fig.
(8)
Remove bottom, inboard adapter small
to
bracket
Feed
Line Connection
bolt
that
6).
steering pump
to
engine
attaches
(Fig.
block.
nut
6). This nut
Nut and bracket must be removed before pump assembly from
block.
FEED
At
Pump
pump assembly
that
attaches secures
can
be
removed
a
J9119-76
Fig. 7 Removing Pump Assembly Upper Mounting
Bolt
VACUUM
(1)
adapter
PUMP
REPLACEMENT
Remove nuts attaching vacuum pump
(Fig.
8).
to
Page 11
5 - 4
BRAKES
J9105-98
ROTATE
GEAR
TO
DRIVE
ALIGN
Fig, 8 Pump Assembly
(2)
Remove vacuum pump
Turn
pump
shaft
from
(3)
Inspect adapter
if
cut or
gear
coupling if
torn.
back and
necessary.
O-ring
COUPLING
Removal
from
adapter (Fig.
forth
to
(Fig. 9). Replace
O-RING
PUMP
ADAPTER
disengage pump
O-ring
J9105-99
Fig, 9 Vacuum Pump Removed From Adapter
(4)
Lubricate adapter
(5)
Note position of tate drive with
(6)
gear
coupling
Verify
that pump
to
(Fig.
drive
align
10).
O-ring
slots in
tangs
is
seated
with
engine oil.
coupling.
Then ro-
on vacuum pump shaft
in adapter and cou-
pling.
(7)
Install
and
tighten pump attaching nuts
washers.
PUMP
ADAPTER
(1)
Remove coupling
(2)
Remove remaining adapter attaching nuts and remove adapter
(3) If
steering pump
from
each inboard mounting stud on pump (Fig. 12).
(4)
Clean and lubricate pump shaft
REPLACEMENT
from
adapter (Fig. 11).
from
steering pump (Fig. 12).
will
be serviced, remove
with
spacer
engine
9).
and
oil.
Fig.
10
Aligning
Fig.
11
Removing/installing
(5)
Install
(6)
Install
(7)
Position adapter on pump studs.
(8)
Install
spacers O-ring
attaching nuts on outboard stud and on
Pump
Shaft
Pump
on steering pump
on adapter
(Fig.
the two upper pump studs. Do lower,
inboard stud
N-m
(18 ft. lbs.) torque.
(9)
pling
Install
is
coupling
securely engaged in shaft drive tangs.
at
this
time.
on
pump shaft.
TANGS
J9105-102
Drive
Tangs
Drive
Coupling
studs
(Fig.
11).
not
install
Tighten nuts
Be
sure
12).
nut
to 24
cou-
on
Page 12
Fig.
12
Steering Pump Mounting Stud Spacer
Locations
(10)
Install
gear
until
Verify
that pump is
ing
nuts.
(11)
Install
vacuum pump on
tangs
on pump shaft
seated
adapter.
engage
before
Rotate drive
in coupling.
installing
and tighten vacuum pump attaching
nuts.
INSTALLING
VACUUM-STEERING
PUMP
ASSEMBLY
(1)
Position new gasket on vacuum pump mounting
flange
(Fig.
13). Use Mopar perfect seal, or silicone
adhesive/sealer to
Fig.
13
Positioning Gasket
hold
gasket in place.
On
Flange
Pump Mounting
attach-
_
(2)
Insert pump assembly upper attaching mounting hold
(3)
upper
to
hold
(4)
flange and gasket. Use
bolt
in place if
Position pump assembly on engine and
bolt
(Fig. 14). Tighten upper
assembly in place at this
Fig.
14
installing
Working sembly lower attaching lower
bolt
to 77 N-m (57 ft. lbs.) torque.
(5)
Position bracket on steering pump inboard stud. Then
install
stud.
Tighten nut to 24 N»m (18 ft. lbs.) torque.
(6)
Connect oil feed tor.
Tighten
(7)
Install
BRAKES
sealer
or
necessary.
bolt
only
time.
Pump
from
under vehicle,
Assembly
On
Engine
install
bolt.
Then tighten upper and
pump as-
remaining adapter attaching nut on
line
to vacuum pump connec-
line
oil
fitting
pressure
securely.
sender
and connect
wires.
(8)
Connect steering pump lines
to pump. Tighten
N-m
(22 ft. lbs.) torque.
(9)
Connect vacuum
(10)
Connect battery cables, if removed. (11) Fill (12)
gine circulate
(13)
voir
(14)
eration. vacuum Then before
power steering pump reservoir.
Purge air
and
slowly fluid
and purge air
Stop engine and top off power steering
fluid
level.
Start engine and check brake and steering op-
Verify
assist
verify
moving
that power brake booster is
and
that steering action is correct. Do this
vehicle.
hose
from
steering pump lines. Start en-
turn
steering wheel
firm
pressure
pressure
line
fitting
and return
to vacuum pump.
left
and
from
system.
brake pedal is obtained.
5 - 5
bolt
in
grease
to
install
enough
sender
to 30
right
to
reser-
providing
Page 13
Page 14
COOLING

COOLING SYSTEM

GENERAL
This cooling main diator. as a result of the new radiator.
RADIATOR
A year. The radiator cools the engine and automatic transmission
REMOVAL
(1)
INFORMATION
group contains
changes
made
to the diesel
system during the mid-1991 model year. The
change
The cooling system capacities
cross-flow radiator is used in the
Disconnect battery negative cable
is a new higher capacity cross-flow ra-
have
changed
mid-1991
(if
equipped).
from
battery.
model
SYSTEM
7 - 1
WARNING: BLOCK DRAINCOCK PRESSURE COOLANT
(2)
Drain
Cooling
DO NOT
DRAIN
PLUGS OR LOOSEN THE
WITH
BECAUSE SERIOUS
CAN OCCUR,
REMOVE
THE SYSTEM HOT AND
the cooling system. Refer to
System in the 1991
Rear
THE CYLINDER
RADIATOR
UNDER
BURNS
FROM
Draining
Wheel
Drive
Service Manual.
(3)
Remove
Remove coolant
hose
reserve
clamps and
tank
hose
hoses
from
from
radiator.
radiator
neck nipple.
(4)
Remove fan shroud retaining clips. The shroud has two radiator.
tabs
that fit into clips in the bottom of the
Lift
the shroud up and position it back onto
the engine (Fig. 1).
(5)
Remove radiator top mounting brackets. The brackets fit over support dowels on the radiator tank (Fig. 1).
(6)
The bottom of the radiator has two dowels that fit
into
holes in the lower support panel. Taking
not
to
damage
radiator cooling fins or tubes,
lift
Truck
filler
inlet
care
ra-
Fig. 1 Radiator
diator
straight up out of engine compartment.
INSTALLATION
(1)
Position shroud rearward on engine.
(2)
Lower radiator into bottom lower
ing
retaining
ing Truck
of the radiator fit into alignment holes in the
support panel.
(3)
Install
top mounting brackets. Tighten mount-
screws to 23 N»m (17 in. lbs.) torque.
(4)
Connect radiator
(5)
Position fan shroud on radiator flange.
clips.
(6)
Open
(7) Fill
heater
cooling system
Cooling System in the 1991
Service Manual.
(8)
Operate engine
hoses.
valve.
until
and Fan
position.
Install
with
coolant. Refer to
Rear
it
reaches
Shroud
The dowels on the
ature. Check cooling system.
hose
clamps.
Install
Fill-
Wheel
Drive
normal temper-
IMINI
Diesel
Diesel
MOML
All
All
SPECIFICATIONS
COOLING
RADIATOR
m
WIDTH INCHES
A
26
26
IHKK-
NISS
2.25 3
2.25
SYSTEM
ROWS
OF
TUBES
3
CAPACITIES
HNS
DIAMETBR
MR
INCH
INCHES
13 22.0
13 22.0
NO.
OP
BLADES
7
7
FAN
PITCH
INCH
•NOAOIMINT
T1MMRATURI
2.20
2.20
CLWTCH
140°F
140
°F
CAPACITY
QUARTS
17.0
16.0 15.1
units
39107
16.1
881
Page 15
Page 16
OWERDRIWE
REMOVAL
(1)
Locate bracket
mittent
(2)
Remove 2 nuts
panel support.
(3)
Remove ground
(4)
Depress
the instrument panel.
LOCKOUT
holding
wipe module (Fig.
lock
tabs
INSTRUMENT
PANEL
AND
INSTRUMENT PANEL AND GAUGES
of
INSTALLATION
(1) Hold wiring
(2)
Push
switch
(3)
Continue
(4)
Install
straps
are
installed.
connector
on
to
push
bracket
to
wiring
until
with
in
switch
modules.
SWITCH
chime module and inter-
2).
holding
straps
and bracket.
on
switch
bracket
and
to
instrument
push
it
out
GAUGES
switch
opening.
connector.
snaps
Be
sure
GROUND
8E - 1
into
place.
ground
Fig. 1 Overdrive
Lockout
J918E-37
Switch Location
COMBINATION
BUZZER
INTERMITTENT
WIPER
MODULE
BRACKET
INTERMITTENT
CONTROL
Fig. 2 Intermittent Wiper Module Bracket
WIPER
MODULE
J918E-36
Page 17
Page 18
SPEED
CONTROL

SPEED CONTROL SYSTEM

CONTENTS
SYSTEM 8H -
1
SERVICE
GENERAL
The tuated and vacuum is integrated into the
PROCEDURES
INFORMATION
speed
control
8
system operated.
(Fig. 1) is electrically ac-
The electronic control
engine
controller, located next to the battery. The controls are located on the ing
wheel and
CEL
and designed km/h)
and 85 mph (142 km/h).
WARNING; RECOMMENDED NOT
PERMIT
SUCH
AS
ARE
WINDING,
PERY.
TO
ACTIVATE:
to the
depressed
trol
function is now
TO
DEACTIVATE: or normal gaged
will memory. Pushing latched position or turning off the
consist
of the ON/OFF, RESUME/AC-
SET/DECEL buttons.
to
operate
THE USE
MAINTAINING A CONSTANT
IN
HEAVY
at
WHEN
ICY,
speeds
OF
SPEED
DRIVING
TRAFFIC
SNOW
between
OR
COVERED,
By pushing the ON/OFF button
latched position, ON, the
ready
for use.
A soft tap of the
brake
application while the
disengage
speed
the
ON/OFF button
control without
The
CONTROL
CONDITIONS
ON
system
35
mph (50
SPEED,
ROADS
OR
speed
brake
system
to the un-
ignition
erases
memory.
TO
SET SPEED: When the vehicle the desired gage the desired
TO gaged, lows the vehicle to
TO system SUME/ACCEL ously
TO gaged, and
release
speed
system
push
which
the SET/DECEL button to en-
will
then automatically maintain
speed.
DECELERATE: When
holding the SET/DECEL button
coast
to a lower
RESUME:
by
After
tapping
disengaging the
the
brake
button to return vehicle to the previ-
set
speed.
ACCELERATE: While
hold the RESUME/ACCEL button
at a
new desired
speed
pedal
speed
speed.
has
control
depressed
speed
speed
push
control
This
setting.
the
depressed
will
page
steer-
is
IS
NOT
DO
THAT SLIP-
con-
pedal, is
en-
erasing
the
reached
is en-
al-
control
RE-
is en-
allow
TEST
PROCEDURES
the vehicle higher
TAP-UP: gaged, crease system
TO
ACCELERATE accelerator is
released
ting
in memory.
SERVO
to
speed
When
tapping the RESUME/ACCEL button
the
speed
will
respond
as the vehicle
CONNECTOR
Fig, 1 Speed
page
4
continuously
accelerate
and
set at a
setting.
the
speed
setting
by 2
to multiple
for
control
PASSING:
system
mph
(3
tap-ups.
is en-
will
km/h).
Depress
in-
The
the
you would normally. When the pedal
will
return
Control
to
the
speed
J918H-20
System
set-
Page 19
8H
- 2
SPEED
CONTROL
SYSTEM
WARNING: THE USE
IS
NOT
CONDITIONS
TRAFFIC
RECOMMENDED WHEN DRIVING
DO NOT
A CONSTANT SPEED, SUCH
OR ON
ICY, SNOW COVERED
Of
ROADS THAT ARE WINDING,
SPEED
WITHOUT PUSHING THE
"SET/DECEL"
FAULTY
DEFECTIVE
THE SPEED CONTROL
PERMIT MAINTAINING
CONTROL ENGAGES
ELECTRICAL
AS
HEAVY
OR
SLIPPERY.
BUTTON
CIRCUIT*
j
:
SERVO
START
ENGINE
ACCELERATE
TO
DESIRED
VEHICLE
SPEED
PUSH ON/OFF BUTTON
TO
"ON"
POSITION.
PUSH AND RELEASE
"SET/DECEL"
REMOVE
ACCELERATOR.
FOOT
BUTTON
FROM
SPEED
SHOULD BE CONTROLLED
SPEED
CONTROL
ENGAGES
ENGINE
IS
FAULTY
ELECTRICAL
DEFECTIVE
WHEN
STARTED
CIRCUIT*
SERVO
NO SPEED CONTROL WHEN
SET/DECEL
PRESSED
FUSE BLOWN
NO
BUTTON
AND
VACUUM
IS
RELEASED
AT
SERVO
SPEED
CONTROL
THROTTLE
CABLE
DISCONNECTED
IMPROPER
AND SWITCH
FAULTY
STOP LAMP
SPEED
CONTROL
ADJUSTMENT
ELECTRICAL
CIRCUIT*
DEFECTIVE
SERVO
HUNTING SURGE
SPEED
VARIATIONS
AT LOW SPEEDS
LOCK-UP
TORQUE
CONVERTER
ROUGHNESS
AMPLIFICATION
OF
ENGINE
SURGE
DEFECTIVE
SERVO
DEFECTIVE
CABLE
DEFECTIVE
ENGINE
*TESTS
AND
IN APPROPRIATE SECTION
CONTROLLER
ADJUSTMENTS ARE DESCRIBED
MANUAL.
OR
OF
SERVICE
EXCESSIVE
ON HILLS
IN TRAILER TOWING
SAG
OR
ENGINE
PERFORAAANCE
VACUUM
LEAK
EXCESSIVE
REQUIRE
ASSISTANCE
LOAD
MAY
MANUAL
ON
HILLS
DEFECTIVE
VACUUM
PUMP
REFER
FOR
TO
VACUUM
SPEED
LOCK-IN,
DEFECTIVE
GROUP 5 -
PUMP
DIAGNOSIS.
SETTING AFTER
TOO
OR TOO LOW
VACUUM
HIGH
LEAK
SERVO
DEFECTIVE
CABLE
DEFECTIVE
VACUUM
PUMP
BRAKES
DEFECTIVE
VACUUM
PUMP
J918H-27X
Page 20
UNIT DISENGAGES ON ROUGH ROAD
ZZZ3
DRIVE VEHICLE OVER
ROUGH ROAD
<E
BRAI
PEDAL
,
SPEED
.
SHOULD
GAGE
TAP
LIGHTLY
CONTROI
DISEN
SPEED
C01T10L SYSTEi SH - 3
IMPROPER
ADJUSTMENT OF STOP
LAMP
AND SPEED
CONTROL
NOT
SWITCH*
FAULTY
ELECTRICAL
CIRCUIT
EfMGSNE
DOES
RETURN
*
TO
NORMAL IDLE
SPEED CONTROL THROTTLE
KINKED OR DAMAGED
STANDARD
LINKAGE FAULTS
CABLE
THROTTLE
r
SPEED
CONTROL
DISENGAGES
PUSH
RESUME/ACCEL
SWITCH VEHICLE
SHOULD RESUME
PREVIOUSLY
MEMORIZED SPEED
VEHICLE
SHOULD DISENGAGE
RESUMES
SPEED
DEPRESS BRAKE
PEDAL,
SPEED
CONTROL
NO SYSTEM
DISENGAGEMENT
WHEN
BRAKE PEDAL
IS DEPRESSED
DEFECTIVE
OR
IMPROPERLY ADJUSTED
STOP
LAMP
SPEED
AND
CONTROL
SWITCH
SPEED
CONTROL
THROTTLE
CABLE
KINKED OR DAMAGED
FAULTY
ELECTRICAL
'
CIRCUIT*
DEFECTIVE
SERVO
NO RESUME
WHEN
BUTTON IS PRESSED
DEFECTIVE
FAULTY
SWITCH
ELECTRICAL
CIRCUIT'
SPEED
CONTROL
DISENGAGES
SPEED
CONTROL
SYSTEM OK
NO SYSTEM
DISENGAGE
WHEN
BRAKE PEDAL IS
DEPRESSED
DEFECTIVE
CONTROLLER
FAULTY
CIRCUIT*
ENGINE
ELECTRICAL
RESUME SPEED
IS POSSIBLE
BELOW
20
DEFECTIVE
SENSOR
DEFECTIVE
ENGINE
CONTROLLER
M.P.H.
DISTANCE
J918H-28X
Page 21
8H
- 4
SPEEI
CONTROL SYSTEM
f
TEST
PROCEDURES
INDEX
page
Speed
Checking for Fault Code 4 Distance
(Speed)
Sensor
Test . 4 Inoperative System 4 Road Test 4 Speed
Control Cable Attachment—Engine 7
ROAD TEST
Road
test
vehicle to system malfunction. The road tention
to the
speedometer.
should be smooth and without flutter at all
Flutter which tem.
might
The
in the
cause
cause
verify
reports of
speedometer
surging in the
of any
speedometer
speed
control
test
should include at-
Speedometer
operation
speeds.
indicates a problem
speed
control
sys-
deficiencies
should be corrected before proceeding.
INOPERATIVE SYSTEM
If
road
test
verifies that system is inoperative and
speedometer
operation is satisfactory, inspect for
loose electrical and vacuum connections at the servo.
Corrosion nals
and a
Grease,
Inspection should ends
of the
should be removed
light
coating of Mopar Multi-Purpose
or equivalent, applied.
also
be
made
speed
control cable are securely attached.
from
to
electrical
verify
that both
termi-
CHECKING FOR FAULT CODE
(1)
When electronic malfunction use a DRB cause
trying
to
verify a speed
control system
II
to determine the
(refer to Powertrain Diagnostic
Procedures
Control
Speed
Control
Speed
Control
Stop
Lamp
Vacuum
these
components
complete
ELECTRICAL
(1)
Turn
the
speed voltmeter negative lead to a good
(2)
Disconnect the 4-way connector going to the servo (Fig. 2). The blue wire the main proximately connections, brake switch adjustment or, repair the main
harness
(3)
Connect a jumper wire between the male and female terminals of the blue wire The other should show battery voltage.
(4)
Using an ohmmeter, connect one lead to a good body ground. Touch other lead to the black terminal The meter should show continuity. If not, repair the ground
circuit
Cable
Attachment—Servo Switch System
Speed
Supply
system
TESTS
ignition
Test
5
Electrical
Control
Test
failure
Switch
6
are
damaged,
may
occur.
AT SERVO
switch to the ON position.
control switch in the ON position, set up a
to read battery voltage and connect the
chassis
with
harness
4-way connector should read ap-
battery voltage. If not, check for loose
as
necessary.
three
male terminals
If
in the 4-way connector of the main
as
necessary.
manual).
(2)
Correct any problems found and recheck for
Fault Code if
DISTANCE
For testing of the distance ponents dures
manual.
SPEED
CONTROL SYSTEM ELECTRICAL TESTS
Electronic ing
two different methods. One involves use of a
DRBII.
If this
the Powertrain Diagnostic Test
The other meter method is described in the
If
any information is
fer
to Group 8W -
CAUTION: nuity
at
not
to
damage
changes
(SPEED) SENSOR
were
made.
TEST
sensor
and related com-
refer to the Powertrain Diagnostic Proce-
speed
test
When
electrical
control
test
method is desired,
method
systems
uses
needed
Wiring
test
connectors,
connector,
Diagrams. .
probing
may be
please
Procedures
a voltmeter. The
following
concerning
for
voltage
care
terminals,
wiring,
must
or
tested
refer to
manual.
tests.
or
be
seals.
us-
volt-
re-
conti-
taken
If
ELECTRICAL CONTROLLER
(1)
troller,
(2)
body ground
(3) be in the ON position. Refer to Fig. 4 for controller terminal voltmeter the
speed voltmeter switch battery voltage. If not, repair the main necessary.
(4) terminal voltmeter OFF position and battery voltage the ON position.
TESTS
AT ENGINE
Unplug 60-way connector
located on the
left
fender (Fig. 3).
Connect negative lead of voltmeter to a good
near
the module.
For the
following
tests,
the
locations. Touch the positive lead of the
to the terminal in cavity number 33.
control switch in the OFF position, the
should read 0 volts.
With
in the ON position, the voltmeter should read
Touch the positive lead of the voltmeter to the
in cavity number 53. As in
should read 0 volts
with
7
Tests
4
Test
5
intermittent
ground.
the red tracer of
with
red tracer.
from
the servo
not,
replace the servo.
(BK)
from
the engine con-
ignition
switch must
the
speed
harness
step
the switch in the
with
the switch in
page
or
With
wire
harness.
With
control
as
(3), the
Page 22
A VACUUM
y-
HOSE
SPEED
CONTROL
SYSTEM 8H -
5
Fig. 2 Servo
And
Harness Connector
J918H-25
0 ooooooooo
1 10,
oooooooooo
x
3
\2L
IE
Fig. 4 Engine Controller 60-Way Connector Shown
(6)
Touch the positive lead of the voltmeter to the
utar
terminal in cavity read 0 volts
with
°50|
from
Terminal
number
the
speed the OFF or ON position. SUME battery switch the main
terminal in cavity read 0 volts With should tinue to RESUME switch is control switch check
or
SET position,
voltage.
test.
harness
(7)
Touch the positive lead of the voltmeter to the
If
not, perform
If the switch
and
repair
number
with
the
switch
the switch in the ON position, the voltmeter
read
read
battery
battery
voltage. The voltmeter
voltage when
pressed.
test.
If the switch is not
the main
(8)
Using an
harness
ohmmeter, body ground and touch the in
cavity the depressed,
meter
number
should
the
meter
29.
With
show
continuity. When the
should
OOOOOOOOOO
11
20
oooooooooo^
,C1 31
AO/
)OOOOOOOOO
umr
End
u
RR8HC7
50. The voltmeter should control switch in
With
switch in
the
voltmeter should
the
is
not
at
fault, then
as
necessary.
speed
either
either
control
check
49. The voltmeter should
in the
OFF position.
will
either
If not, perform the
and
repair
connect
other
the
one lead to a good
lead to the terminal
brake
at
as
necessary
pedal
the SET or
speed
fault, then
released,
pedal
show
open
circuit.
RE-
read
con-
.
is
SINGLE
ENGINE
CONTROLLER
SPEED
CONTROL
SERVO
Fig. 3 Engine Controller
(5)
Touch the positive lead of the voltmeter to the
terminal in cavity
switch
in the
read
0 volts.
voltmeter should
OFF position,
With
read SET button should from
battery
switch
is
switch
test.
the main
voltage
held.
If
If the switch
harness
and
Connector Location
number
48.
With
the
speed
the
voltmeter should
the switch in the ON position, the
battery
cause
to 0
not, perform
and
repair
voltage.
the
volts for
is
not
as
Pressing
voltmeter
the
at
to
as
long
speed
fault, then
necessary.
BOARD
J918H-29
control
the change as the
control
check
SPEED
mounting position. Use an Switch Continuity correct. switch positions,
STOP
switch. Using checked (Fig.
To
check
CONTROL
the
SWITCH
switch,
remove
ohmmeter
If
there
LAMP SPEED
(1)
Disconnect
at the switch
Chart is replace
the
an
to
no continuity
the switch.
CONTROL
connector
ohmmeter,
side
of the
5):
(a)
With
the
be no
brake
resistance
pedal
between:
the black (BK) and white
TEST
the
determine
SWITCH
at the
continuity
connector
released,
with
red
wires
the yellow
dark blue
pink (PK) and white (WT) wires.
with
with
red
red
tracer
tracer
(YL/RD)
(DB/RD) wires
switch
from
and refer to the
if continuity is
at
any one of the
TEST
stop
may be
as follows
there
tracer
(WT/PK)
its
lamp
should
Page 23
8H - 6
SPEED
SPEED
CONTROL
CONTROL
SWITCH
CHART
SYSTEM
CONTINUITY
— —— — — 4
CONNECTOR
SPEED
SWITCH
POSITION
OFF
ON
ON AND
ON AND RESUME
SET
TERMINAL
SWITCH
CONTROL
CONTINUITY
SWITCH
CONTINUITY
END
PIN 1 AND
PIN 1 AND PIN 1 AND PIN 2 AND
PIN 1 AND PIN 1 AND
BETWEEN
PIN
4
PIN
4
PIN
2
PIN
4
PIN
2
PIN
3
18PK
Fig. 5 Stop
STOP LAMP
CONTROL
SPEED
Lamp
AND
SWITCH
CONTROL
Switch
18WT
SPEED
WITH
Connector
J908H-8
(b)
With
brake pedal continuity wires. (BK) There should with tracer
(2)
If the above results
lamp
switch
Stop lamp
-
Brakes.
VACUUM
(1)
Disconnect vacuum
a vacuum gauge
(2)
Start engine and observe gauge
gauge should read
(3)
If
between
There should be no
and
white
with'
be no
red
tracer
(YL/RD)
(DB/RD)
is
defective
wires.
switch
-
SUPPLY
TEST
in
at
vacuum
does
check for vacuum leaks
depressed,
pink
red tracer
continuity
are not
or
adjustment
hose
the
hose
least
not
or
918H-14
there should
(PK)
continuity
and
between black
(WT/PK)
between
and
dark blue
obtained,
out
of adjustment.
is
detailed in Group
at
the servo and
(Fig.
6). at
idle.
ten
inches of mercury.
white
the
with
be
(WT)
wires.
yellow
red
the
stop
install
Vacuum
meet this requirement,
poor engine performance.
5
Fig. 6 Vacuum
Gauge
Test
Page 24
SPEED
C0IT10L
SYSTEi
8H - 7
SPEED
to
CONTROL CABLE ATTACHMENT—ENGINE
(1)
The clevis of the
the bellcrank by a washer and
(2)
Visual
inspection
speed
will
control
verify
cable is retained
hairpin
that the cable is
clip.
securely attached. If the cable is not attached, the speed
control
SPEED
CONTROL
The
speed with a wire verify-
that the
the
speed
system
control
clip
clip
control
will
be inoperative.
CABLE
ATTACHMENT-SERVO
cable is attached to the servo
(Fig.
7). A check should be made to
is in place. If the
system
will
be inoperative.
clip
is missing
Fig. 7 Speed Control Cable Attachment
at
Servo
Page 25
8H - 8 SPEEI
CONTROL
SYSTEi
SERVICE
SERVO
UNIT
REMOVAL
,
(1) Disconnect vacuum
(2)
Disconnect
(3)
Remove 2 nuts
(4)
Pull
servo away
(5)
Remove and discard push nuts on servo studs.
(6)
Pull
speed
pose
cable retaining
(7)
Remove
INSTALLATION
(1)
With
in
cable sleeve
taining
mounting N*m
clip.
(2)
Insert servo
(3)
Install
(4)
Insert servo
bracket. One stud mounts reservoir,
(5)
Install
(50 in.
(6)
Connect vacuum
(7)
Connect the
electrical
control
clip
attaching cable to servo.
bellcrank
with
studs
new push nuts on the servo studs.
the 2 attaching nuts and lbs.).
electrical
hose
at
servo.
connector
from
servo
from
mounting
cable away
at
servo.
mounting
bracket.
from
bracket.
servo
clip.
pivoted
full
rearward
hole in servo pin and
through holes in the cable.
studs
through holes
tighten
hose
to servo.
connector to servo
align install
in
nals.
PROCEDURES
(7)
Install
(8)
Install
crank
rod.
SPEED
REMOVAL
(1)
Disconnect battery negative cable.
(2)
to
ex-
hole
re-
servo
to 6
termi-
Remove 2 screws
wheel
(3)
Rock
switch
(4)
Disconnect 4-way
clockspring.
cable end on bellcrank rod.
washer and
CONTROL
hairpin
SWITCH
from
(Fig.
1).
switch
away
from
out of steering wheel.
electrical
COVER
STEERING
clip
on end of
back side
horn
pad
while
connector
HORN
of
steering
bell-
lifting
from
SERVO
REMOVAL
THROTTLE
(1)
Remove
CABLE
hairpin
ASSEMBLY
clip
and washer retaining bles on bellcrank. Remove servo bellcrank.
(2)
Disconnect cable
at
servo and remove cable
sembly.
INSTALLATION
(1)
Locate cable through servo
(2)
Connect cable sleeve to servo stud,
and
install
(3)
Insert servo
(4)
Install
(5)
Insert servo
stall
nut
(6)
Route cable
hairpin
clip.
studs
through holes in cable.
new push nuts on servo studs.
studs
through holes in bracket. In-
washers
and torque to 6 N*m
from
servo,
bracket.
throttle
cable
mounting
align
(50 in.
to
cable support
ca-
from
as-
bracket.
holes,
lbs.).
HARNESS
Fig. 1 Speed Control
INSTALLATION
(1)
Connect 4-way
spring
to
switch.
(2) ward pins
(3) with
Place on
Attach
switch
edge
of
switch
switch
switch
the screw
with
at
VACUUM PUMP
Refer
to
Group
lation
of the vacuum pump.
WIRE
RETAINING
SCREW
Switch
electrical
connector
in steering wheel,
under
horn
pad.
J9119-8
Removal
from
sliding
Line
up
holes in steering wheel frame.
to
wheel
the
left
5 -
Brakes for removal and
with 2 screws starting
end of the
switch.
clock-
the
for-
locating
instal-
Page 26
WIRING
DIAGRAMS
8W - 1
WIRING
DIAGRAMS
INDEl
Wiring
Diagram
.2
.7
.9
Name
Left
Headlamp
Left
Park
Left
Side Marker
Right
Headlamp
Right
Headlamp
Right
Park
Right
Side Marker
Front
End Daytime Running Left
Headlamp
Left
Headlamp
Left
Park
Left
Side Marker
Right
Headlamp
Right
Park
Right
Side Marker
Fuel
Tank
Fuse
32
Sending Headlamp Headlamp Headlamp
A/C
Heater Ash Receiver Ground Headlamp
Ignition
Switch Message Message Oil
Pressure Coolant Oil
Pressure Sending
Overdrive
Coolant Control Engine
Lockout Lockout
Transmission
Rear
Lighting
Seat
Belt Combined Fuse
32
Seat
Belt
Speed
Control Clockspring Engine Fuse
• • Resistor Servo
15 Speed Stop
Lamp
Starter
System
Ground
and
Turn
and
Lighting
• 19 Ground
and
Turn
and
System
Unit
. 32
High
Beam Switch Switch
Switch
Lamp 22
• Switch
,
Center
» 25
Center
Splice
and
Temperature Sending
Lockout
Thermal
Module
Controller
Solenoid Switch
Thermal
System
Warning
Buzzer
Switch
System
16
Controller
16
Control
Switch
3, 4
.' 17
Signal
Lamp .17
Lamp 17 18 Ground
Turn
. -20
Turn
. . . Controlled
Temperature Warning
6
.
System
Switch
18
Signal
Lamp 18
(Canada)
Light
Module
.19 y-
Signal
Lamp .19 tp^
Lamp 19 £
Signal
Lamp • 20
Switch
Interior
Lamp 22
Ground
System
Switch
.6 6
32
22
26
Unit
Switch A518 6 .6
Switch
29,
.32
15
, .16
16
Name
A/C and
Anti-Lock
Heater
System
Blower Motor Blower Motor Clutch Compressor
Fuse
-. Heater Low Pressure
Vacuum Zener Diode
Brake Warning Controller Diagnostic Dual
Solenoid
Electric
Fuse
13
Ground
Park Brake Resistor R.W.A.L. Stop
Lamp Bulkhead Connector 33, Charging
Alternator Battery Fusible I.O.D. Voltage
Engine
Controller
Engine
Wiring
Air
Heater
Air
Heater Relay Battery Diagnostic Distance Engine Fuel
Heater
Fuel
Pump Fusible Ground
K.S.B.
Resistor Thermo Throttle Temperature Sensor
Water-in-Fuel
Four
Wheel
Fuse
31
Lamp .31
Transfer
Front
End
Left
Headlamp
.27 Resistor
Cycling
Blower
Switch
28
. .
27
Switch Switch
Switch
.28
Brake
System
Switch
13
Connector
Hydraulic
Vacuum
.14
Switch
14
Sensor
Switch
System
1,2
.2 1 Links
.............................
Connector
Regulator
.7,
7
• Connector
Sensor . •
Controller
.11
- 11
Link
7
11
Motor
11 Switch Position
Sensor
Drive
Case
Lighting
27
.................. .
27
.28
.27
.13,
14
.13
Valve
.14
Sensor
Connector
.11
.11
Indicator
Switch
.17
14
13
.14
14
1
2
. 35
7
10
8, 9, 10
Transducer
8
10
8
System
. 31
Sheet Number
.28
14
34
8, 9,
10,
11
Wiring
Diagram
Sheet Number
Lamp 18
20
Lamp 20
Lighting
Unit
12
6
22
System
12
12
• 16
.21 .21
.22
-5
.6
30
Page 27
8W
- 2
WIRING
Name Sheet Number
Back-Up Clutch Neutral Relay Starter
Stop/Turn
Fuse
Hazard Switch . . Turn
Lamp
Switch . . .
Start
Switch
3
Motor
3
and
Hazard
...........
Warning
24
Signal
Flasher
DIAGRAMS
Wiring
Diagram
Switch
.3
4
3
Flasher
Flasher
24
System
.24
24
Wiring
Diagram
Name \ ^ Sheet Number
Windshield
Fuse Ground Motor Switch Washer
Wiper
System
23
23
23
23
Motor
23
Page 28
Page 29
8W - 4
TO
(SEE
TO
ENGINE WIRING
(SEE
TO
<J2> 2 I SPLICE
(SEE
SH 7)
WIRING DIAGRAMS
IGNITION SWITCH
LEFT
SH
r
SH 5)
11)
f
Y-
•J2
J2
14DB
J2
14DB
14DB
(REAR
OF
BATTERY)
J2
14DB-
J2
14DB-
DJ2
14DB
TO
DIAGNOSTIC
CONNECTOR
(SEE
SH
10)
BODY
GROUND
(LEFT
YOKE
FRONT
OF
BATTERY)
AD
ENGINE GROUND
(LEFT
OF ENGINE)
Al
2/0
RD
TO
STARTER MOTOR
(SEE
SH 3)
1
FRONT
Al
2/0 RD-
S5
14BR
(REAR
OF
BATTERY)
CHARGING
TO
HAZARD
FLASHER
(SEE
-BLACK
SH
Y
48)
f
A3
16PK
S5
14BR
SYSTEM
5.9L
ENGINE
#23 [nj
«
A3 16PK
TO
STARTER
RELAY
(SEE
SH 3)
WITH
I.O.D.
CONNECTOR
NATURAL
(FRONT
SIDE
A3
22WT
LEFT
SHIELD)
FUSIBLE
(HYPALON
DIESEL
LINK
WIRE)
J918W-13
Page 30
R9 6BK*
WIRING
DIAGRAMS
GROUND
(ON ENGINE)
8W - 5
CHARGING
J918W-13 5.9L ENGINE
SYSTEM
WITH
DIESEL
(SEE
SH 21)
AD 2
Page 31
8W - i
WIRING
DIAGRAMS
#
AUTOMATIC
NEUTRALSTARTAND
(ON
TRANSMISSION
BACK-UPSWITCH
TRANSMISSION)/
S4
B1 B2
18BR
18WT 18VT
YL*
! BK*
Bl
18WT
S4
18BR/YL*
B2 1SVT/BKX
'
/
/
/
STARTER
RELAY
(LEFTSIDE
SHIELD)
\
MANUAL
\BACK-UPLAMPSWITCH
\
(ON TRANSMISSION)
TRANSMISSION
S2
16YL
S4
18BR/YL*
54
18BR/YL*
55
14BR
S5
18BR
A1
12RD
BOARD (AUTO/TRANS)
S4
20BR
YL
*
TO
SINGLE
ENGINE
CONTROLLER
CAVITY
(SEE
30
SH 11)
TO CHARGING
SYSTEM
(SEE
SH 1)
DARK
GRAY
DARK GRAY
(REAR
ENGINE)
AD 3
OF
FUSE
#13
(20
AMP)
>—J2 - 14DB
T0<flj72lGRPJA
SPLICE
#25
(SEE
<f
B2 18VT/BKX-Y
—J
IGNITION
}
SWITCH
(SEE
STARTER SYSTEM
SH
11)
TO
SH 5)
TO BACK-UP
N
LAMPS
(SEE
SH 29)
DIESEL
BLACK
(REAR
OF
ENGINE)
MANUAL TRANS
STARTER
(LEFT
REAR
OF
MOTOR
LOWER
ENGINE)
J918W-13
Page 32
S2
16YL—
S21
14YL*-
S2
14YL
•S2
14YL
WIRING
DIAGRAMS
TO
IGNITION SWITCH
(SEE
SH 5)
8W - 7
S5
18BR
TO ENGINE
CONTROLLER
(CAVITY (SEE
8)
SH 8)
*30
TRANSMISSION
MANUAL
BLACK
18BK
CLUTCH SWITCH
(ON CLUTCH ROD)
SWITCH
CLUTCH IS DEPRESSED
CLOSES
18BK
WHEN
BLACK-
(NEAR CLUTCH ROD)
\
BLACK-
S2 14YL
BYPASS
(TAPED
TO WIRE
AUTOMATIC
TRANSMISSION
JUMPER
HARNESS)
J918W-13
DIESEL
STARTER SYSTEM
AD 4
Page 33
8W
(SEE
IjeiJ
8
TO
CHARGING
SYSTEM
(SEE
#49
TO
STARTER
SYSTEM
SH
J10
#50
12PK*
WIRING
SH 2)
T
Jl
12RD
C
>
4)'
-S2
J10
GROUND
(THRU
STEERING
COLUMN
ATTACHMENT)
DIAGRAMS
(ON
-
Jl
12RD
14YL
12PKX
IGNITION
STEERING
SWITCH
COLUMN)
»-J2
14DB
Q20 12BK/RDX-
Q2 (30
14BK*
CIRCUIT
FUSE
(20
FUSE
#2
AMP
BREAKER)
#13
AMP)
FUSE*
(30
AMP)
TO
LAMP
Bl
18WT
G5 20DB*—^
TO <J2
SPLICE
(SEE
SH 1)
AIR
ANDHEATERFEED
-CI
(SEESH
12BR
1
>-Wl 12TN/BKX—{
BACK-UP
SWITCH
(SEE
SH 3)
T
T0
<G5>
SPLICE
(SEE
SH
TO
CONDITIONING
58,59,61)
POWER
WINDOWS
(SEE
50)
TO
SH
63)
i
TO
CHARGING
SYSTEM
(SEE
SH 2)
TO CIGAR
(SEE
S2
14YL
-J2
14DB
P51
20BK/GY*
P51
20BK/GYX
J10
12PK*
Q20 12BK/RD*
14BK*
Q2
12RD
J1
LIGHTER
SH
44)
TORADIO
(SEESH
53,
55,
57)
TO
TURN
SYSTEM
(SEE
SIGNAL
SH
48)
FUSE
#9
(20
AMP)
FUSE
#10
(20
AMP)
V6 18DB—^
V6
18DB~5
Dl
14RD/YL*-
P51
20BK/GYX-
P51
20BK/GYX-
TO WIPER
SYSTEMS
(SEE
TO
R.W.A.L.
MODULE
(SEE
SH 13)
SH
23)
BRAKE
LAMP
P51
20BK
GYX
Li
MESSAGE '
CENTER
(SEE
TO
WARNING
SWITCH
(SEE
SH
TO
SH
13)
25)
AD 5
IGNITION
SWITCH
J918W-13
Page 34
TO
IGNITION SWITCH
(SEE
SH 5)
-J2
14DB
G5 20DB>
(SEE
SH
25)
G5 20DBX-
<G5
G5
20DBX
U4
20OR/WTX
U5 20YL/BK*
H4 20BK-
WIRING
BLACK-
DIAGRAMS
U50 20YL/DB t
E10
200R/YLX
8W - S
I
U50 20YL/DB *
I
I
U5 20YL/BK t
SINGLE
BOARD
ENGINE
CONTROLLER
(SBEC)
CONNECTOR
(SEE
SH 34)
G5 20DBX
NATURAL
E1 0
20OR/YLX 1
TRANSMISSION
THERMAL
SWITCH
•U6 20
I
\
I I
RD/WT
U4Q 20OR/LGX-
OPENS ABOVE
278°F
20BK
U6
U5
20OR/BK
T
H4
20RD/WT*
(
LEFT
Of
ENGINE)
OVERDRIVE
(RIGHT
SUPPORT
-H4 20BK-
=
OPENS
BELOW
60°F
REAR
MODULE
SIDE
ON
BRACKET)
U4
20OR/WT*
COOLANT
SWITCH
T0<H4>1 J SPLICE
(SEE
SH 22)
THERMAL
=
U40 20OR/LG-*
lilij
DARK
(REAR
ENGINE)
U4
20OR
WT*
GRAY
OF
J918W-13
TO<J2^jJ
(SEE
SPLICE
SH 11)
OVERDRIVE
(A518
}-
LOCKOUT
-J2
14DB-
SYSTEM
(DIESEL)
AUTO/TRANSMISSION)
OVERDRIVE
(ON
TRANSMISSION)
LOCKOUT
SOLENOID
AD 6
Page 35
8W - 10
WIRING
DIAGRAMS
A5
6BK
-A5
6BK-
FENDER
SHIELD)
-A5
(LEFT
SIDE
12BK
O)
TO
BATTERY
POSITIVE
A4
6BK
(LEFT
FENDER
SIDE
SHIELD)
(SEE
SPLICE
TO SH 1)
A6
6BK
A6
6BK-
AIR
INTAKE
HEATER
TO
MESSAGE
CENTER
(SEE
(ON
UNDER
(DIESEL)
SH
25)
INTAKE
INLET
PIPE)
20
E5
DG
WT*
#11
TO STARTER
RELAY
(SEE
-S21
y
SH 7)
18YL/BKX-
E5
20DG
WT*
,
L
S21
18YL/BK % -
-J2
14DB-
-S22
180R/BKX-
S5
18BR
-E5
20DG/WTX-
AD 7
DIESEL
ENGINE
WIRING
J918W-13
Page 36
•N5 18BK/LB•
•K32
20TN/BKX-
WIRING
DIAGRAMS
TO
GROUND
(SEE
K5
1
6BK
X
8W - 11
EYELET
SH
11)
TO
DISTANCE
SENSOR
(SEESH
12)
WATER-1N-FUEL
(IN
18BK
FUEL
TO
20TN
#AAA#
FILTER)
MESSAGE
CENTER
(DIESEL)
(SEE
SH
SENSOR
/Q)
r
W
25)
W
TEMPERATURE
SENSOR
K31 20BK/PKX
DARK GRAY
(REAR
S20
18LBX-
-K31 20BK/PK
#38
OF
X-
ENGINE
K32
BKX
20TN
BKX
K32
20TN
BKX
L
N
)
S20
18LB
TL=5L
9
9°°O
JJ
K5
18BK*
DARK GRAY
TO
VACUUM
SENSOR
(SEE
SH
14)
r
K5
18BK*
\
J918W-13
$21
18YL/BKX•
-J2
14DB-
-
522 180R/BKX-
S5
18BR
-E5
20DG/WTX•
TO DIAGNOSTIC
(SEE
SH
DIESEL
CONNECTOR
J
10)
16
9
15
8
56
ENGINE
CONTROLLER
FOR CONNECTOR (SEE
SH
ENGINE
C.
1
54-»
5h»
21
35)
WIRING
DK5 16BK*
-»-
K32
K31
-»-S20
20TN/BKX-
20BK/PKX-
-K5 18BKX
18LB/BKX
AD
8
Page 37
8W - 12
WIRING
DIAGRAMS
SINGLE
BOARD
ENGINE CONTROLLER
(DIESEL)
CONNECTOR
(SEE
SH
35)
J11
16RD
UK
TO
FUSIBLE
LINK
(SEE
SH 2)
-G7
20WT/OR*
DARK GRAY
(REAR
OF
ENGINE)
T
D40
18WT
PK*
TO STOP
SWITCH
(SEE
SH
29
LAMP
14,
16)
-N5
20BK/LB*
T
S4
20BR
YL*
TO STARTER
RELAY
(SEE
SH 3)
G7
20WT/OR*-
30
<8>-
47
T
G7
20WT
OR*
G7
20WT
OR*
TO DAYTIME
RUNNING
MODULE
(CANADA
(SEE
SH
T
G7
20WT
OR*
I
-N5
LAMP ONLY)
20)
20BK/LB
*-
AD
m
9
DISTANCE
TRANSMISSION)
(ON
SENSOR
REAR
OF
^1
^1
^1
TO
LEFT
PRINTED
BOARD CONNECTOR
(SEE
CIRCUIT
SH
DIESEL ENGINE WIRING
m
go]
G7
20WT
OR*
52)
J918W-13
Page 38
11
12
SINGLE
BOARD
25
45 4
ENGINE
CONNECTOR
(SEE
SH
35)
CONTROLLER
WIRING
6
DIAGRAMS
22
23
8W 13
THROTTLE (AUTO/TRANS ONLY)
POSITION
TRANSDUCER
(REAR
BLACK
OF
ENGINE)
J918W-13
DIESEL
ENGINE WIRING
AD
10
Page 39
8W
- 14
WIRING
DIAGRAMS
14DB
COLD
ADVANCE
(K.S.B.
J2
RD*
START
MOTOR)
HARNESS NEAR
THERMO
-BLACK
RESISTOR
TAPED
IN
SWITCH
J
2
-14DB-
BLACK
THERMO
SWITCH
SPLICE
(SEE
J2
14DB
SH 1)
4x4
|
TO TRANS/CASE
SWITCH
(SEE
r-
SH
31)
-K5 16BKX
-JTO
(FRONT
ENGINE)
ONLY I
18BK
1
f
<^>T1
(SEE
OF
X9
1
J9
i
14BK
TO STARTER
(SEE
1
(REAR
OF
ENGINE)
SPLICE
SH 8)
J9
14BK
\
\
S4
18BR
YL*
MANUAL
TRANSMISSION
RELAY
SH 3)
FUEL
HEATER
(REAR
OF
ENGINE)
TO
OVERDRIVE
LOCKOUT
SOLENOID
(SEE
SH 6)
(AUTO/TRANS)
BLACK
FUEL
(CENTER
ENGINE)
J2
14DB
PUMP
OF
AD 11
DIESEL
ENGINE WIRING
J918W-13
Page 40
TO
LEFT
PRINTED
BOARD CONNECTOR
/OOuuO
GRAY
(SEE
CIRCUIT
SH 56)
G20 20VT/YLX
*17[jO
«—
-G20 20VT/YLX-
WIRING
DIAGRAMS
8W - 15
BLACK
TO RIGHT
PRINTED
BOARD.CONNECTOR
(SEE
CIRCUIT
SH
56)
G6 20GY
G60 20GY/YLX
19
00
«—
G60 20GY/YLX-
-G6 20GY-
•G60 20GY/YL*
G6 20GY-
G60
2QGY
YL*
BLACK (REAR
G6
20GY
G20
20VT
YL*
OF
ENGINE
J918W-13
OIL
PRESSURE
SENDING UNIT
AND
SWITCH
G60 20GY/YLX-
G6 20GY
G20
20VT
YL*
(LEFT
SIDE
OF
BLOCK
CENTER)
TEMPERATURE
SENDING UNIT
(LEFTREAR
OF CYLINDER
HEAD)
-
OIL
PRESSURE AND TEMPERATURE
SYSTEM FOR
DIESEL
ENGINE
AD 12
Page 41
8W - 16 WIRING
DIAGRAMS
TURN
(SEE
REAR
WHEEL
ANTI-LOCK
CONTROL
MODULE
(R.W.A.L.)
TO
SIGNAL
FLASHER
SH
48)
3
8
II
14
13
f
I
4
h
•Dl
-01
14RD/YLX
-IS1
16LGX-
•DS1
14WT/BRX-
-VS1
18LB —
-X4
20LG/BR X ~
-B01
18RD/VTX-
-B02
18WT/VTX-
ROLLS
TEST
(IN-PLANT
18RD/YLX
TWISTED
CONNECTOR
USE ONLY)
PAIR
FUSE#9 (20
AMP)
(SEE
TO
SWITCH
SH
31)
B01
18RD/VT X
B02
18WT/VTX
4WD INDICATOR
r
~i
LAMP
)—02
14BK*-
TO
<
IGNITION
>
SWITCH
(SEE
SH 5)
-DS1
-IS1
16LGX-
14WT/BRX-
VS1
18LB
10
12
D4 P2 P5 X4 Dl
IS1
1
H40 18BK/LG X-
18WT/TNX­20BK/GYX­20GY/BKX­20LG/BRX-
14RD/YLX-
AT1 180R
16LGX-
-
•04
18WT/TNX-
•03
20PK/DBX-
•P2
20BK/GYX-
ATI 1 SOR.-
INTERMITTENT
WIPER
<d
E
PS 20GY/BK X
TO
MODULE
(SEE
SH 46)
-GRAY
-101
-B02
-DK 18BKX
-VS1 H40 18BK/LGX
-03
-DS1
DK 18BKX
18RD/VTX
18WT/VTX
18LB
20PK/DBX
14WT/BRX
BLACK
SERVICE
DIAGNOSTIC
CONNECTOR
(LOWER RIGHT
SIDE
COWL)
D4
18WT/TNX-
D3 20PK/DBX-
MESSAGE CENTER
TO
(DIESEL)
(SEE
SH 25)
P2
20BK/GYX-
TO
IGNITION
SWITCH
(SEE
SH 5)
AD 13
REAR
WHEEL
ANT
I-LOCK
(DIESEL
BRAKE SYSTEM
ENGINE)
PARK
SWITCH
BRAKE
J918W-13
Page 42
WIRING
DIAGRAMS
8W - 17
B01
18RD/VT*
B02
18WT/VT*
B09
18GY/WTX-
i
B09 18GY/BK*
PANEL
GROUND
(LEFT
SIDE
TWISTED
-04
18WT/TN*-
-03
20PK/DBX-
SEE
-cnQ)—|
UNDER
PAIR
TO
BUZZER
SH 32)
(LEFTREAR
FRAME
^
INSTRUMENT PANEL)
03
20PK
DB*
03
18PK/DB*-
H4 18BK •
RAIL)
BLACK-
-BOl
•B02
it
D4
18WT
TN*
•04
20WT/TNX-
BRAKE
WARNING
LAMP
SWITCH
(LEFT
FRONT
FRAME
18RD/VTX•
18WT/VTX-
04
16WT ? FLASHER
(TAPED
HARNESS
CONNECTOR)
RAIL)
x
I
-ft
HAZARD
(SEE
IN
NEAR
TO
SWITCH
SH 24)
RESET
SWITCH
#OTP
ISO
SOL
DUAL
SOLENOID
HYDRAULIC VALVE
31
BOl
B02
18RD 18RD
VT*
VT*
TWISTED
PAIR
(LEFT
SIDE
SHIELD)
J918W-13
TO DIAGNOSTIC CONNECTOR (SEE
SH 10)
FENDER
REAR
^EEL ANT I -LOCK BRAKE SYSTEM
(DIESEL
18PK
STOP
H4 20BK
L
-D40
18WT/PKX-
18WT
o
LAMP
SWITCH
ENGINE)
RESISTOR
#41
D40
18WT/PK*
X
TO ENGINE
CONTROLLER
(SEE
SH 9)
BOl
20PK
R.W.A.L.
IN
REAR
BLACK
802
20LG
OR*
SENSOR
DIFFERENTIAL)
AD
14
Page 43
8W
18
WIRING
SINGLE
ENGINE
CONTROLLER (SBEC)
CONNECTOR (SEE
DIAGRAMS
BOARD
ON/OFF 49
SET
48
RESUME
50
BRAKE
QQ
SENSE
^
VACUUM
33
VENT
53
SH
35)
-»—
^>—
-»—
-»—
-»—
-»—
X32
20YL/RDX-
•X31
20BR/RD*
•X33
20WT/LG*
•D40 18WT/PK*-
•X36
20TN/RD*
-X35
20LG/RD*
-
-
-
X9B 20BK
TO\C9>
(SEE
SH
SPLICE
23)
X9B
20BK
20DB
DIRECT
CONNECTION-
TO SERVO
X30
RD*
X35
20LG
RD*
k
1
X36
20TN
RD*
TO
R.W.A.L.
(SEE
SH
D40
18WT
TO SEAT
BELT
WARNING
SYSTEM
(SEE
FUSED BATTERY
X30
14)
D3 20PK/DB*
D3
18PK
DB*
SH
22)
FEED
20DB/RD *-
AD
15
ELECTRONIC
SPEEDCONTROLSERVO
(UNDER
BATTERYTRAY)
DIESEL
SPEED
CONTROL
SYSTEM
J918W-13
Page 44
D3 20PK/DBX
D3 18PK/DB X
D40
TO
IGNITION switch
(SEE
SH 5)
-X32
20YL/RDX-
•X31
20BR/RDX-
-X33
20WT/LGX-
-X30
20DB/RDX-
TO
<H4T|
GROUND
(SEE
18WT/PKX-»-D40
SPLICE
SH
5—
22)
20BK
mil
#41
,
y
#10
# 8
M
—»-
# 9
E)
—»-
M^
»
H4
18WT/PKX
7
J2
14DB
-X32
20YL/RD*-
X32
20YL
RDX
X30
20DB
RDX
FUSE
2
AMP
-X31
20BR/RD*-
X33
20WT/LGX
•D4
20WT/TN
#11
D4
18WT/TNX-
•D4 16WT-
H4
20B"
TO
R.W.A.L.
MODULE
(SEE
J
TO
FLASHER
(SEE
X-
RESISTOR
^HARNESS
nCONNECTOR)
SH 14)
X32 X31
X34 X33
HAZARD
SWITCH
SH 48)
(TAPED
IN
NEAR
WIRING
20YL/RD*
20BR/RD*
20RD/LB* 20WT/LG*
DIAGRAMS
X34
20RD/LB f'
--fl
8W - 11
J918W-13
18BK
WITH
18DB
STOP
CONTROL SPEED
18PK
SPEED
ELECTRONIC
18WT
PKX
RDX
18YL
RDX
o
o
LAMP
AND
SWITCH
CONTROL
DIESEL
SPEED
18WT
18BK
18PK
STOP
WITHOUT
CONTROL
O
LAMP
SPEED
18WT
PKX
18WT
SWITCH
CONTROL
SYSTEM
SPEEDCONTROL
SWITCH
(IN
STEERING
AD 16
WHEEL)
Page 45
8W - 21 WIRING
DIAGRAMS
LEFT SIDE
MARKER
LEFT
AND
SIGNAL
LAMP
PARK
TURN
LAMP
(LEFT
REAR RADIATOR
YOKE PANEL)
AD
17
FRONT
END
LIGHTING
J918W-13
Page 46
WIRING
DIAGRAMS 8W - 21
05
18TN
05
18TN
1*22
L3
14RD/0R*—i
L7
18BK.
YL*
C9
14BK-
L9
20BK-
L4
16VT*-
L3
14RD/OR*-
RIGHTHEADLAMP
GROUND
(CENTER
DASH
PANEL)
C9
14BK-
AO
TO <C9>
(SEE
SH 23)
SPLICE
RIGHT
HEADLAMP
C9
14BK
D5 18TN
L9
18BK
L7
183K
YL*
C9
14BK-
(RIGHT
RADIATOR
L7
18BK/YL*•
-05
in
REAR
YOKE)
TO
BLOWER
(SEE
18TN
MOTOR
SH 27)
•18BK/YL*-
18TN-
18BK-
H)
RIGHT
SIDE
MARKER
LAMP
RIGHT
PARK
ANO TURN
SIGNAL
LAMP
J918W-13
FRONT END
LIGHTING
AD 18
Page 47
8W - 22 WIRING
BLACK
TO
RIGHT
PRINTED
BOARDCONNECTOR
CIRCUIT
(SEE
SH
HEADLAMP
52)
LEFT
^
y\ & 26
TO
<L7>7]
(SEE
SH 21)
DIAGRAMS
L33
16RD/BKX
TO
DIMMER
(SEE
TO TURN
SIGNAL
(SEE
SPLICE
5 L7
SWITCH
SH
39)
SYSTEM
SH 24
18BK/YLX
L33
16RD/BK*-
LEFT
PARK
AND TURN
SIGNAL
LAMP
AD 19
(LEFT
REAR RADIATOR
YOKE
PANEL)
FRONT
END
LIGHTING
(CANADA)
J918W-13
Page 48
TO
HEADLAMP
SWITCH
(SEE
SH 21)
L33
16RD/BKX-
05
18TN
05
18TN
_
y
a|#22
L4
16VTX-
L3
14RD/0RX-
# 12
•L20
18LG/BK %-
-<f
Mi
L33
16RD/BKX-
<3>
SPLICE
(SEE
I—J9
TO
SH 10)
16BK-
L20
14LG/BKX-
L3
14RD
OR*
L4
16VT*
C
I
J2
14DB
WIRING
(DIRECT
CONNECTION
TO
MODULE)
20WT
TO ENGINE WIRING
A
> (SEE
(DIESEL
DIAGRAMS
G7
(ENGINE
SH 2) ENGINE)
8W - 23
DAYTIME
RUNNING
LIGHT
MODULE
COMPARTMENT
LEFT SIDE)
T0<^>SPLICE
(SEE
SH 9)
L9
22BK
L4
16VTX-
L3
14RD/0R*-
-L4
16VTX
L7
-D5 18TN
C9 14BK-
—no
18BK/YL %
TO
BLOWER
(SEE
SH 26)
-
MOTOR
RIGHT
HEADLAMP
RIGHT
SIDE
MARKER
LAMP
18
BK/YL*-, SIGNAL
RIGHT
AND
PARK
TURN
LAMP
HEADLAMP
GROUND (CENTER
DASH
J918W-13
RIGHT
PANEL)
(Q
FRONT
END LIGHTING
(RIGHT
RADIATOR
REAR
YOKE)
(CANADA)
AD 20
Page 49
8W
- 24
WIRING DIAGRAMS
TO
HORN
RELAY
(SEE
SH
20)
TO
LEFT
DOOR
SWITCH
(SEE
SH 22)
TO <M2>
(SEE
TO <H4>
(SEE
M16 20BK/LBX M16 20BK/LBX M26 M26
L8
M2
L2
El
Ll
-LI
Ll
12RD*
M16 20BK/LB M16
20BK/LB*
SPLICE
SH
41)
11
SPLICE
SH
22)
2 H4
^
20LB 22LB
18PK/RD
20YL 14LG
18TN
*
12RD* 12RD*
M2
20YL
SNOW
PROVISION
(SEE
» ,
TO
SH
T
H4
18BK
L
M16
BlLH—
GO*
FUSE#4 (20
PLOW
22)
"==
18BK-
20BK/LBX-
L20
14LG/BKX
Ll
12RDX
L7
18BK/YL*
Ll
12RDMT™
AMP)
BLACK
LE
(SEE
SH 2)
•El
18TN
GRAY
HEADLAMP
SWITCH
(INSTRUMENT
PANEL)
L7
M16
-
20BK
LB*
CONNECTOR
(SEE
FUSE
(3
18BK/YLX
L2
14LG
L20
14LG/BK*-
M26_
20LB
TO
COMBINED
(SEE
TO
KEY-IN
SWITCH
(SEE
SH
1
FOR
SH
79,
80)
#14
AMP)
1
4~
NATURAL-
BUZZER
SH 32)
41)
E2
200R
L7
L7 18BK/YLX-
L7
18BK/YLX-H&
PROVISIONS
FOR
SNOW
LIGHTING
ONLY
BLACK
(UPPER
LEFT
COWL)
18BK/YL
ROOFCLEARANCEAND
IDENTIFICATION
t
PROVISION
(SEE
SH
32,
LAMP
33)
[nj#26
1
L7
18BK
YL
*
TO
FRONT
END
LIGHTING
(SEE
SH
17,
19)
TO REAR
LIGHTING
(SEE
SH 29)
TO DAYTIME
RUNNING
MODULE
(SEE
SH 20)
(CANADA
PLOW
. .
)H
LAMP
ONLY)
AD
21
BLACK
(NEAR
BULKHEAD
CONNECTOR)
HEADLAMP
SWITCH
L40
16VTX
<f-L4
<f-L3
14RD/OR*—$
nj
#5
16VT
P3
#6
X—£
TO
FRONT
END
LIGHTING
(SEE
SH
17,
19) J918W-13
Page 50
H4
18BK
TO
ELECTRONIC
CONTROL
MODULE
SEE
DIESEL
SH 29
E2
ASH
RECEIVER
LAMP
200R-
E2
200R
H4 20BK-
TO RIGHT
PRINTED
CIRCUIT
CONNECTOR
(SEE
BOARD
SH
52)
E2
200R
•E2
-H4
-E2 200R-
E2
200R-
WIRING
18BK-
200R
TO
RADIO
(SEE
SH
53, 55,
DIAGRAMS
57)
SW
PROVISION
SNOW (NEAR
^
BLOCK)
BLACK
SIGNAL
(SEE
- 25
FOR
PLOW
CONTROLS
FUSE
TO
TURN
FLASHER
SH
24)
TO
HEADLAMP
SWITCH
GROUND
(SEE
SH
COMBINED
(SEE
SH
TO
MAP LAMP
AND
READING
(SEE
21)
BUZZER
32)
SH
41)
TO OVERDRIVE
A
SWITCH
(SEE
SH 6)
TO
CHASSIS
X2 16BK—} WIRING
H4
18BK
{
(SEE
—(
TO
}
(SEE
i
TO
KEY-IN
n
(SEE
OVERDRIVE
(SEE
SH 6)
H4
12BK
TO BRAKE SWITCH
(SEE
TO
POWER
TO
POWER
TO
POWER
SEAT
MODULE
(SEE (SEE (SEE
SH
SH
29)
SH
14,
DOOR
SH
SH SH
BLACK
•H4 22BK
BELT
SWITCH
SH
32)
LAMP
41)
16)
LOCKS
65)
MIRRORS
67)
WINDOWS
63)
TO
MESSAGE
CENTER
(DIESEL)
(SEE
SH
(RIGHTOF STEERING
COLUMN)
H4 18BK/LG —}
RED
22)
H4 20BK
H4
H4 20BK-
H4
H4 20BK-
A/C HEATER SWITCH
LAMP
,
18BK-
18BK-
E
V 7
V
—'
TO
INTERMITTENT
WIPER
(SEE
MODULE
SH
18BK
45)
TOCIGAR
<
-J
LIGHTER
(SEE
SH
44)
<
TOCARGOLAMP
>
SWITCH
(SEE
SH
J
TO A/C &
>
HEATER WIRING
(SEE
SH
4
TO
GLOVE
BOX
LAMP
(SEE
SH
44)
H4
20BK
41)
27)
J918W-13
HEADLAMP
INTERIOR
SWITCH
LIGHTING
CONTROLLED
AD 22
Page 51
8W - 21
TQ<Qjll
(SEE
WIRING
SPLICE
SH
18)
L9
18BK
DIAGRAMS
TO
CHASSIS
WIRING
(SEE
SH
32)
•X2
SPEED
SERVO
(SEE
16GY-
TO
CONTROL
SH
15)
X9B
20BK-
WINDSHIELD WIPER SWITCH
(CONNECTOR - SEE
LO
PARK PARK
HI
P2
#46
Q
LO
IS
O
HI
SH 80)
P1
V6
V10
18DB 20BR
|
0
V6
V10
18DB 20BR
W
L/.Lc..'J
(LEFT
#29
C9
14BK
GROUND
SIDE
TO
IGNITION
SWITCH
(SEE
FUSE
#10
(20
AMP)
SH 5)
C9
14BK
Q2
14BKX
TO
BLOWER
(SEE
A/C
MOTOR
SH
26)
SPLICE
FOR
DIESEL
ONLY
AD
2
SPEED WINDSHIELD
WIPER
(CENTER
MOTOR
OF
PLENUM)
23
TO
A/C
D
A
Dl/
SWITCH
annul
(DIESEL
(SEE
SYSTEM
ONLY)
SH 28)
KM KM
WINDSHIELD
V3
18BR
V6
V5
% 18DB 18DG
V4 18RD/YLX
WIPER
•V10
•V9 20BK
SYSTEM
WINDSHIELD
PUMP
(UNDER
WINDSHIELD
WASHER
RESERVOIR)
20BR
WASHER
MOTOR
J918W-13
Page 52
0
MOUNTED
FUSE
(SEE
ON
BLOCK
SH 77)
1
3 h
Q2 14BKX-
FUSE (20
AMP)
Dl
14RD/YL*
•Dl
18RD/YLX-
-D32
18PKX—
#9
TO
IGNITION
4
SWITCH
(SEE
SH 5)
TO
R.W.A.L.
MODULE
(SEE
SH 13)
TO
SNOW PROVISION
(SEE
SH 22)
PLOW
A3
16PK
A3
16PK
WTX
WIRING DUG
TO
CHARGING
4 SYSTEM
(SEE
#23
FUSE
#3
(20
AMP)
SH 1)
MOUNTED
FUSE
BLOCK
(SEE
SH 77)
•D31
•D32 18PKX-
RAPS
ON
18BKX
8W - 27
HAZARD WARNING FLASHER
r
LFb
TURN
SIGNAL
FLASHER
D2
18RD
BKX
D2
18RD
BKX
D32
1SPK
HAZARD
SWITCH
FLASHER
-D4
18WT/TNX
(SEE
FOR
CONNECTOR
SH
77,
78)
D4
18WT/TNX
D7
18BR
YLX
D4
18WT/TN
TO
BRAKE
f
i
(SEE
D7 18BR/YLX
SH
X
SWITCH
14,
16)
4 TO
R.W.A.L.
^
(SEE
4 LIGHTING
PRINTED
CONNECTOR
(SEE
06
18LG-
06
18LG-
END LIGHTING
(SEE
MODULE
SH 14)
TO
REAR
r
(SEE
SH 29)
TO
LEFT
CIRCUIT
BOARD
SH 52)
TO
FRONT
END LIGHTING
(SEE
SH
17,
TO
FRONT
SH
17,
19)
IT'
19)
jgisw-is
TO REAR
LIGHTING
(SEE
SH 29)
D8
18DG/YLX
STOP/TURN
TURN
(ON STEERING
^
AND
SIGNAL
SWITCH
COLUMN)
HAZARD
D8
18DG
YLX
FLASHER
SYSTEMS
TO RIGHT PRINTED CIRCUIT
BOARD
CONNECTOR
(SEE
SH 52)
BLACK
AD 24
Page 53
8W - 21 . WIRING
DIAGRAMS
#
AD
P5
20GY/BK*
P51
20BK/GY*
P2
20BK/GY* BRAKE
25
K31
20BK/PK* WATER-IN-FUEL
P5
20GY/BK*
PARK
IGNITION
P2
20BK/GY*
BRAKE
R.W.A.L.
WARNING
WARNING
R.W.A.L.
(SEE
(SEE
SWITCH
(BULB TEST)
(SEE
SWITCH
VACUUM
(SEE
(SEE
MESSAGE CENTER
SH 8)
MODULE
SWITCH
SH
13)
GROUND
SH 5)
&
SWITCH
SH
13)
MODULE
SH 13)
E5 20DG* WAIT-TO-START SWITCH (SEE
SH 7)
AT1 180R ANTI-LOCK
(SEE
SH
13)
G5 20DB* (SEE
H422BKGROUND­(SEE
G40 20DB/RD* LOW (SEE
SH
SH
FUEL
SH
26)
32)
IGNITION-
22)
SWITCH
(DIESEL)
MODULE
12V
H4>1 I SPLICE
FUEL
TANK
J918W-13
FEED
Page 54
WIRING
DIAGRAMS
8W - 29
OVERDRIVE SWITCH
-G5 20DB*
TO
AND MODULE
(SEE
SH 6)
T
G5
20DB
X
TO MESSAGE
CENTER
(SEE
s
TO4WD
<
INDICATOR
(SEE
SH
LAMP
31)
SH
G5 20DB
24)
*•
RED
G5 20DB
*
G5 20DB*
TO
RIGHT
PRINTED
BOARD CONNECTOR
(SEE
CIRCUIT
SH
52)
BLACK
G5
20DBX
a,
TO
COMBINED
BUZZER
(SEE
SH
32)
G5
20DBX
GRAY—\
-G5 20DBX-
FUSE # 12
(5
TO
PRINTED
BOARD CONNECTOR
(SEE
2(0 0)1
J2
14DB
AMP)
LEFT
CIRCUIT
SH
52)
TO
IGNITION
SWITCH
(SEE
SH 5)
J918W-13
MESSAGE
CENTER
SPLICE (DIESEL)
AD
26
Page 55
8W
- 30
NATURAL
C6
MLB
C7
12DG-
WIRING
[T] [T]— C3
-to
DIAGRAMS
C5
I6LG
12WT/DG*
-C4
12TN
TO
IGNITION
SWITCH
(SEE
SH 5)
N
7-
•Q20
12BK/RD
X—(•
FUSE
(30
#1
AMP)
CI
12BR
C3
12WT
DGX
BLOWER
MOTOR
RESISTOR (UPPER SIDEPLENUM)
f7
RIGHT
12DG
ipr)G
C7
0FF
//
O
Hi—@
L0
"MED
•#
HEATER BLOWER SWITCH
(INSTRUMENT
PANEL)
C7
12DG
NATURAL
C6 14LB­C5
16LG-~-^t-c=]
C4
10TN
C7
12DG-
1
,V»
HI
C4
10TN
k
C4
10TN —<(
BLACK--.
C2
18DB/0RX-
&"
L
t
r.
AIR
VACUUM
12WT/DG
10BR
10TN
CONDITIONER
AND
HEATER
SWITCH
(INSTRUMENT
PANEL)
CI
10BR
X
BLACK
CI
12BR
H4
18BK
C2
18DB
ORX
BLOWER
MOTOR
(RIGHT
DASH
AD
C7
1
—C9
SIDE
PANEL)
27
12DG-
12BK-
V9
20BK
TO
WASHER
MOTOR
(SEE
SH
BLACK
C9
14BK
JO
SPLICE
(SEE
SH
23)
A/C
C7
12DG
18)
&
HEATER-DIESEL ENGINE
•C3
12WT/DGX-<(
NATURAL
C7
12DG
(LEFT
CENTER
OF
INSTRUMENT
PANEL)
nj#2
-C7
12DG
CI
10BR
H4
18BK
C2 18DB/0RX
-H4 18BK—^
TO <H4>2|SPLICE
(SEE
SH
22)
J918W-13
CI
12BR
Page 56
A/C COMPRESSOR
CLUTCH
(FRONT
OF
ENGINE
WIRING
DIAGRAMS
8W - 31
WIPER
(SEE
TO
MOTOR
SH 23)
\
A/C LOW
\
SWITCH
\
(RIGHT
\
SIDE
\
\
C20
PRESSURE
FENDER
SHIELD)
PROBE
«
E3=
(RIGHT
SIDE
SHIELD)
18DB/0RX
, ,
ELECTRONIC
CLUTCH
CYCLING
SWITCH
J918W-13
C20
18DB/0R*
A/C &
HEATER-DIESEL ENGINE
J2
C20
14DB-
18BR-
AD
28
Page 57
8W - 32
WIRING
DIAGRAMS
TO
TRANSMISSION
5
WIRING
SEE
SH 3)
TO <L7>1
(SEE
SH
TO
TURN
SIGNAL
SWITCH
(SEE
SH
SPLICE
21)
24)
CAB
I
CHASSIS
SWEPT-
LINE
BOX
AD
LEFT
TAIL.
STOP
TURN
SIGNAL
LAMP
LEFT
BACK-UP
LAMP
LEFT
TAIL,
STOP
t
TURN
SIGNAL
LAMP
LEFT
BACK-UP
LAMP
29
t
B2
18VT/BK*-
REAR
LIGHTING
TO
<X25T|SPLICE
SEE
SH
32)
J918W-13
Page 58
(LEFT
FRAME
BLACK
REAR
/
RAIL)/
X2
18GY
L7
18BK/YL*
BLACK
(CENTER
H4
18BK-
BLACK-
OF
L7
18BK
REAR
BUMPER)
WIRING
H4
18BK
L7
18BK/YL*
H4
18BK
L7
18BK/YL*
DIAGRAMS
LICENSE WITHOUT
BUMPER
LICENSE
sftjU
LAMP
LICENSE
LAMP
^
STANDARD
8W - 33
LAMP
STEP
BUMPER
LICENSE
LAMP
BUMPER
L7
18BK
YLX
X2
18GY
X2
18GY-1
B2 18VT/BK*
•L7
18BK/YLX
07
18BR/YLX
X2
18GY
BLACK
RIGHT TAIL,
STOP
1
TURN
SIGNAL
LAMP
RIGHT
BACK-UP
LAMP
RIGHT TAIL.
STOP
I
TURN
RIGHT
BACK-UP
LAMP
CAB
I
CHASSIS
SWEPT-
LINE
BOX
J918W-13-
REAR
LIGHTING
AD 30
Page 59
8W
- 34
TO
WIRING DIAGRAMS
J2
14DB
IGNITION
SWITCH
(SEE
SH 5)
FUSE
(5
AMP)
#12
G5 20DB*
FOUR WHEEL
DRIVE
INDICATOR
LAMP
G5
20DB*
SPLICE
(SEE
SH 26)
MODULE
TRANSFER
CASE
SWITCH
(DIESEL
ENGINE)
REAR
WHEEL
ANTI-LOCK
(SEE
r
^—
205
TRANSFER
C_
>
SH
13)
CASE
s
-X4 20LG/BRX —X9 18BK—
BLACK
(ON TRANSFER
CASE)
X4 20LG/BRX-
J
T0<J9>2|
(SEE
DIESEL
SPLICE
SH 11)
~
X4 20LG/BR
DARK GRAY
(REAR
OF
ENGINE)
X4
20LG
BRX
nl#40
%
AD
31
4
WHEEL
DRIVE INDICATOR
LAMP
J918W-13
Page 60
TO IGNITION
SWITCH
(SEE
SH 5)
WIRING
DIAGRAMS
SW - 31
SPLICE
(SEE
SH 29)
J918W-13
5 X2
16GY
AND
DIESEL
SEAT
FUEL
BELT
H4
(SEE
SH 22)
FUEL
TANK
UNIT
WITH
LAMP
TANK
GAUGE
WARNING SYSTEM
SEAT
BELT
SWITCH
JH
SEAT
BELT
BUCKLE)
,
18BK —4 LAMP
GROUND
LOW
SWITCH
TO CARGO
SPLICE
SENDING
FUEL
(SEE
SH 42)
AD 32
Page 61
8W
- 36 WIRING
DIAGRAMS
SMALL
INDEX
49
48
14
47
41
40
39
©
©
©
13
12
11
4
5
LARGE
INDEX
50
44
43
42
34
33
32
27
28
26
22
21
20
16
15
6
TERMINAL
OF DISCONNECT
38
10
3
END
46 1 45 37
36
35
31
30
29
24
25
23
17
19
18
7
9
8
2
1
CAVITY
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
ENGINE
COMPARTMENT
HEADLAMP A/C & HEATER
HEADLAMP HEADLAMP SPEED SPEED SPEED SPEED WAIT
HIGH
WATER
OIL OIL
_
LEFT RIGHT BATTERY-HAZARD
BACK-UP PARKING BACK-UP
_
STARTER HORN UNDERHOOD
WINDSHIELD WIPER
AIR WATER
4
WHEEL
BRAKE SENSOR
SPEED OVERDRIVE WINDSHIELD WIPER
SPLICE-IGNITION
IGNITION IGNITION IGNITION
L1
12RD*
C7
12DG
L4
16VT/WT
L3
14RD/0R* X30 X31 20BR/RD* X33 X32
E5
20DG/WT L33 L20
G20 G620GY G60
-
D618LG D5 18TN A3 16PK
B2
18VT/BK* L7
18BK/YL* B1 18WT
V10
-
S2
16YL* H2
18DG/RD L22 P51 V5 18DG V6 18DB WINDSHIELD WIPER C20 K31 20BK/PK*
X4
20LG/BR D40
G7
20WT/OR U4
200R/WT* V3
18BR/WT* V4 18RD/YL* WINDSHIELD WIPER J2
14DB C13 J1
12RD J10
*
20DB/RD*
20WT/LG 20YL/LG*
16RD/BK* HIGH
*
14LG/BK
-
20VT/YL*
20GY/YL*
20BR WINDSHIELD
18BK/RD 20GY/BK* BRAKE
12PK*
*
*
*
18DB/0R*
*
18WT/PK*
*
12BK/RD*
SWITCH
BLOWER
LOW
HIGH CONTROL CONTROL CONTROL CONTROL
TO START BEAM BEAM
PRESSURE SWITCH PRESSURE SENDING UNIT
TURN
TURN
CONDITIONING
LAMP INDICATOR FEED
TEMPERATURE SENDING UNIT
SIGNAL
SIGNAL
LAMPS
LAMPS
LAMP
SWITCH
WASHER
RELAY-IGNITION
LAMP
WARNING
IN
FUEL
LAMP
DRIVE
SWITCH
SENSOR
LOCKOUT
OFF
DRAW SWITCH SWITCH
MOTOR
BEAM
(2
BEAM
(2
LAMP
(DR.L.
LAMP
LAMP
FLASHER
(2
WIRES)
MOTOR
LAMP
MOTOR
MOTOR
DAMPED
MOTOR MOTOR
RUN
CIRCUIT
CIRCUITS
WIRES)
WIRES)
MODULE)
(DIESEL)
(2
WIRES)
(2
WIRES)
SWITCH
PRESSURE SWITCH
AD
33
50-WAY
BULKHEAD
DISCONNECT
J918W-13
Page 62
WIRING
DIAGRAMS
8W • 37
CAVITY
1 2 C7 3 4 5 L40 6
7 8 X31 9
10 X32
11 E5 12 13 14 15 16 17 18 19 20 21
22
23 24 25 26 L7 27 28 29 30 31 32 33 L22 34 P51 35 36 37 38 39 40
41 42 43 44 45 46 47
48 49 J1 50
INSTRUMENT PANEL
L1
12RD* 12DG A/C & HEATER
16VT/WT*
L30
14RD/0R*
X30
20DB/RD*
20BR/RD
X33
20WT/LG 20YL/AD*
X32
20YL/RD
20DG/BK*
L33
16LG/BK*
L20
20LG/BK*
G20 G620GY G60
-
D6
18LG
D6
18LG
D5
18TN D5 18TN A3
16PK/WT
B2
18VT/BK* 18BK/YL*
B1 18WT
V10
20BR
_ -
S2 14YL
H2
18DG/RD*
18BK/RD*
20BK/GY V5 18DG V6 18DE
C2
18DB/0R* A/C CLUTCH
K31
20BK/PK*
X4
20LG/BR*
X4
20LG/BR*
D40
G7
20WT/0R*
U4
200R/WT* V3 18BR* WINDSHIELD WIPER V4
18RD/YL*
J2
14DB
J2
14DB
C13
12BK/RD*
12RD
J10
12PK*
*
*
*
20VT/YL*
20GY/YL*
*
18WT/PK*
BATTERY
HEADLAMP - LOW HEADLAMP-HIGH SPEED SPEED SPEED
SPEED WAIT HIGH HIGH
TEMPERATURE-SEND/UNIT OR SWITCH OIL OIL
-
LEFT
RIGHT HAZARD
BACK-UP PARKING BACK-UP
WINDSHIELD
IGNITION HORNS UNDERHOOD BRAKE WINDSHIELD WIPER SWITCH WINDSHIELD WIPER SWITCH
WATER
4 BRAKE SENSOR
SPEED OVERDRIVE
WINDSHIELD WIPER HIGH
BATTERY
FEED
BLOWER
CONTROL CONTROL CONTROL
CONTROL TO START BEAM BEAM
PRESSURE PRESSURE
FRONT
FRONT
WHEEL
IGNITION-RUN & START
IGNITION IGNITION
INDICATOR FEED
TURN
TURN
FLASHER
LAMPS
LAMPS
LAMP
WASHER
START
LAMP
WARNING
IN
FUEL
DRIVE
SENSOR
LOCKOUT
FEED
SWITCH SWITCH
LAMP
(DRL
LAMP GAUGE-SEND
FEED
LAMP
LAMP
SWITCH
(2
CIRCUITS
MOTOR
BEAM
BEAM
LAMP
MODULE)
SIGNAL
SIGNAL
MOTOR
SWITCH
(DIESEL
WIRES)
SWITCH
LOW
(B1) (B3)
UNIT
LAMP
LAMP
SPEED
SPEED
ONLY)
TERMINAL
OF
DISCONNECT
r.
.
45 I 46
35
37
36
29
30 31 24
23
25
17 18 19
7
8
9 2
I
47
39 40 41 42
38
(O)
(O)
(O)
12
11
10
3
LARGE
END
48 | 49
32 33 26 27 28 20 21 22
14
13
4
5
INDEX
43
15
50
44 34
16
6
J918W-13
50-WAY
BULKHEAD DISCONNECT
AD
34
Page 63
8W
- 38
WIRING
DIAGRAMS
VIEWED
END OF
SHORT
I
i i I i I i i I i 1/
LONG
FROM
WIRE
CONNECTOR
TAB
TAB
CAV
1
K32
2
J11
3 4 5 6
7 8
9 10 11 12 13 14 15 16 17 18
19 20 21 22 23 24 25 26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44 45 46 47 48 49 50 51 52 53 54 55
56 57 58 59 60
16RD
N5
18BK/L8*
K5
16BK*
K8
20VT/WT
S518BR J2
14DB
U4
20RD/WT* J918LB/RD* J918LB/RD*
_
S22 S21
- -
_
S2018LB* K7180R/DB* K718
DK21
-
D40 S4
20BR/YL*
_
X36
-
_ _
-
_
DK20
_ _
G7
20WT/OR
X31
X32
X33
X35 K31 V40 E5
20DG*
-
-
_
20TN/BK *
*
180R/BK* 18YL*
0R/DB*
-20PK
18WT/PK*
20TN/RD *
20LG
20BR/RD*
20YL/RD 20WT/LG *
20LG/RD * 20BK/PK 20OR/LG*
*
*
IGNITION
SYSTEM
CIRCUITS
WATER-IN-FUEL
DIRECT
SENSOR RETURN
SIGNAL
5
VOLT
START IGNITION OVERDRIVE POWER POWER
- -
_
HEATER HEATER
_
INTAKE THROTTLE THROTTLE
SCI
TRANSMIT
-
BRAKE PARK/NEUTRAL SWITCH
SPEED
- -
-
_
- -
SCI
RECEIVE
SPEED SPEED SPEED SPEED
SPEED WATER-IN-FUEL
OVERDRIVE
WAIT-TO-START
_
- -
SENSOR
BATTERY
GROUND
SUPPLY
SIGNAL
FEED
LOCKOUT
CONTROL
GROUND
GROUND
#2
RELAY
#1
RELAY
AIR
TEMPERATURE
POSITION
SENSOR
POSITION
SENSOR
SENS!
CONTROL-VACUUM
SENSOR
PICKUP
CONTROL-SET
CONTROL-ON/OFF
CONTROL-RESUME
CONTROL-VENT
LAMP
LOCKOUT SOLENOID
LAMP
-
SHEET
8
9
10
8
10
8 8
6 10 10
_
8
8
-
8 10 10
10
-
9,15
9
_
15
_
_
10
_
9
15
15
15
15
8 6 8
-
_
AD
35
ENGINE
SINGLE
BOARD
CONTROLLER CONNECTOR (DIESEL)
J918W-13
Page 64
5JL
(DIESEL)
ENGINES
9 -
1
5JL DIESEL
ENGINE ENGINE
tercooled six-cylinder diesel engine valve-in head
The 5.9
are
DIAGNOSIS SERVICE
Liter
head
type (Fig. 1). The cylinder block and
cast
iron.
......................
PROCEDURES
(359 CID) Cummins Turbocharged/In-
..........
CONTENTS
GENERAL
is an
In-line
ENGINES
page page
3 GENERAL INFORMATION 1
12
INFORMATION
This
engine is designed for No, 2 Diesel Fuel. Only use No. 1 Diesel Fuel where extended arctic condi­tions exist (below
The cylinders
2, 3,
4, 5 and 6). The
2).
• "
-23°C
are
or
~10°F).
numbered
firing
order is
1
53^-2—4
from
front to
1-5-3-6-2-4
.
rear
(1,
(Fig.
00000O
Fig. 2 Engine Firing Order
Engine lubrication system type oil pump and a full valve.
flow
consists oil
filter
J898D-10
of a
gerotor
with a bypass
Fig. 1 Six-Cylinder
In-line Engine
Page 65
9 • 2
5.9L (DIESEL)
ENGINES
ENGINE
Type
In-line Bore and Stroke 102 x 120 mm (4.02 x 4.72 Inch) Displacement 5.9 Liters (359 cubic inches) Compression Engine Firing Order Lubrication Pressure feed-Full Flow
Engine Cooling
Cooling
Coolant Recovery Tank 0.95 Liter (1.0 Cylinder Block
Crankshaft
Cylinder Combustion
Camshaft Chilled
Pistons
Connecting
Ratio
17.5:1
Torque 542
1-5-3-6-2-4
Oil Capacity 11.4 Liters (12 Quarts)
System
Liquid
Capacity
Head
Cast
(Auto
Trans)
16.2
(Manual
Cast
Induction
Cast
Chambers
Rods
Forged Steel
Trans) 15.2
High
DESCRIPTION
5,9L
with
DIESEL
6
N»m
Bypass
Cooled-Forced Circulation Liters Liters
Iron
Iron
Swirl
Aluminum
ENGINES
(400 ft. lbs.) @ 1750 rpm
Filtration
Filter
• (16 Quarts)
Hardened-Forged Steel
Combustion Bowl
Cast
Iron
(17 Quarts!
Quart)
J9109-255
Page 66
5.9L
(DIESEL)
ENGINES 9 - 3
GENERAL
Engine
causes
of
routine
chanical engine
tune-ups.
These
idles
CONDITION
LUBRICATING PRESSURE
INFORMATION
diagnosis
malfunctions
malfunctions
(e.g.,
rough
OIL
LOW
is
a strange
and
helpful
in
determining
not detected and
may be
classified
noise),
or
performance
stalls).
SERVICE
POSSIBLE
Low
oil level.
Oil viscosity thin, wrong specification.
Improperly switch/gauge.
Relief valve stuck open.
CAUSES
diluted
operating pressure
ENGINE
the
remedied
as
either
by
me-
(e.g.,
DIAGNOSIS
or
DIAGNOSIS
Refer and
the possible to
Group
to the
causes and
Service
Service
14,
Fuel
Diagnosis-—Mechanical
Diagnosis—Performance
corrections
System
of
for the
malfunctions.
fuel
system
Chart
sis.
-
(a) Check and
(b) Check for a severe external oil leak
Verify to Contaminated Lube Oil (Engine Diagnosis—Mechanical).
Verify
replace switch/gouge.
Check/replace
MECHANICAL
CORRECTION
fill
with
clean engine oil.
that
could reduce the
pressure.
the correct oil is being
the pressure switch is functioning correctly. If not.
valve.
used.
Check for oil dilution. Refer
Chart
for
Refer
diagno-
Plugged oil
If cooler was replaced, shipping plugs
If
pump
oil
pump
cylinder engine.
Loose
Worn
Suction leaking.
Loose
Worn bearings installed.
filter.
left
in cooler.
replaced,
installed in a six
or missing cup plugs.
oil pump.
tube
main bearing cap.
bearings or wrong
four
cylinder
loose or seal
Change oil
revised.
Check/remove shipping plugs.
Verify pump
Check
Check
Check
Check
Inspect and replace connecting rod or main bearings. Check and replace piston cooling nozzles.
filter.
Oil
filter
change interval may need to be
that
the correct
for a six cylinder engine.
and replace cup plugs.
and replace oil pump.
and replace
and install new bearings and
pump
seal.
is installed. If not, install an oil
tighten
cap to proper torque.
J9109-237
Page 67
9
- 4 5.9L
(DIESEL)
ENGINES
CONDITION
LUBRICATING PRESSURE
LUBRICATING
TOO
OIL
HIGH
OIL
LOSS
SERVICE
Pressure operating
Engine running too cold.
Oil viscosity too thick.
Oil
pressure regulator valve
stuck
closed or binding.
External leaks.
Crankcase
Incorrect oil specification or
viscosity.
Oil cooler leak.
DIAGNOSIS
POSSIBLE
CAUSES
switch/gauge
properly.
being overfilled.
not
• MECHANICAL
Verify
the pressure switch is functioning correctly.
replace switch/gauge.
Refer to Coolant Temperature Below Performance)
Make
sure the correct oil is being
Lubrication and Maintenance.
Check
and replace valve, and/or
Visually inspect
Verify
that
(a)
Make
sure the correct oil is being
(b) Look for reduced viscosity
(c) Review/reduce the oil change intervals.
Check
and replace the oil cooler.
(CONT.J
CORRECTION
oil
for
oil leaks. Repair as required.
the correct dipstick is being
from
Normal
used.
cooler cover.
dilution
(Engine Diagnosis—
Refer to Group O,
used.
used.
with
If
fuel.
not,
COMPRESSION
KNOCKS
High
blow-by
the breather.
Turbocharger leaking oil to the air intake.
Worn
valve
Piston rings not sealing (oil being consumed by the engine).
Air in the
Poor
quality
Engine
Incorrect injection
Improperly
forcing oil out
seals.
fuel
system.
fuel.
overloaded.
pump
operating injectors.
timing.
Check
the breather
required repairs.
Inspect the air ducts for evidence of oil transfer. Repair as required.
Inspect and replace the valve
Perform
blow-by
Bleed
the
fuel
Verify
by operating and flush the filter.
Verify
that
engine load
Check
and
time
Check
and replace inoperative injectors.
tube
area for
check. Repair as required.
system
fuel
(refer
from a temporary
supply tanks. Replace
rating
injection
pump
signs
seals.
to Group 14, Fuel System).
is not being exceeded.
(refer
of oil
loss.
tank
with
fuel/water
to Group 14, Fuel System).
Perform the
good fuel. Clean
separator
J9109-266
Page 68
5.9L
(DIESEL)
ENGINES
9 - 5
CONDITION
EXCESSIVE
EXCESSIVE NOISES
VIBRATION
ENGINE
SERVICE
Loose
or broken engine mounts.
Damaged
operating
Improperly operating
DIAGNOSIS
POSSIBLE
fan
accessories.
CAUSES
or
improperly
vibration
damper.
Improperly operating fan hub.
Worn
or damaged alternator
bearing.
Flywheel housing misaligned.
Loose
or broken power
component.
Worn
or unbalanced driveline
components.
Drive
belt tension or abnormally high loading.
squeal, insufficient
• MECHANICAL
Replace
Check
Inspect/replace the
Inspect/replace the fan hub.
Check/replace
Check/correct
Inspect the crankshaft and rods for damage unbalance. Repair/replace as required.
Check/repair
Check
pump, tensioner pulley, fan hub and alternator
engine mounts.
and replace the
the tensioner and inspect the drive
(CONT.)
CORRECTION
vibrating
vibration
the
alternator.
flywheel alignment.
driveline components.
components.
damper.
that
belt.
causes
Make
turn
an
sure water
freely.
ALTERNATOR CHARGING OR IN- SUFFICIENT
NOT
CHARGING
Intake
air or exhaust leaks. Refer to
Excessive
Turbocharger noise.
Gear
Power function knock.
Loose
connections.
Alternator
Alternator pulley loose on shaft.
Improperly alternator.
valve lash
train
noise.
or corroded
belt
operating
battery
slipping.
Excessive
Performance).
Adjust valves. levers
or adjusting
or severely
Check
turbocharger impeller and
contact. Repair/replace as required.
Visually inspect and measure gear backlash. Replace gears as required.
Check/replace
Clean/tighten
Check/replace
Tighten pulley.
Check/replace
Exhaust Smoke (Engine Diagnosis—
Make
sure the push rods are not
worn
screws
pads.
rod and main bearings.
battery
belt
tensioner. Check/replace
alternator.
are not severely worn. Replace
turbine
connection.
bent
and rocker
wheel for housing
belt.
bent
J9109-253
Page 69
9
- 6 5.9L
(DIESEL)
ENGINES
CONDITION
ENGINE CRANK SLOWLY
ENGINE BUT START—NO FROM
WILL NOT
OR
CRANKS,
WILL NOT
EXHAUST
CRANKS
SMOKE
SERVICE
POSSlBLi
Starting motor operating, but not cranking the engine.
Crankshaft
Starting circuit connections loose
Neutral safety switch or starter relay inoperative.
Battery charge low.
No voltage to starter solenoid.
Solenoid
inoperative.
No fuel in supply tank.
Electrical open.
Air
intake or exhaust plugged.
rotation restricted.
or corroded.
or starting motor
fuel shutdown not
DIAGFdQSIS
CAUSES
- PERFORMANCE
CORRECTION
Remove a
Rotate the engine to
Clean
Check neutral safety. Replace defective parts.
Check held.
Check
Replace
Fill
Check Check
Remove
the starter motor.
broken starting motor spring.
and tighten connections.
starter relay for supply voltage and proper operation of
battery voltage. Replace battery if a charge cannot be
voltage to solenoid. If
starter motor.
fuel supply.
for loose wires and verify to be
sure
manual shutoff lever is in the run position.
the obstruction.
check
Check
for broken flywheel teeth or
for rotational
necessary,
that
resistance.
replace the solenoid.
the valve is functioning.
ENGINE START, NOT FROM
HARD TO
OR WILL
START—SMOKE
EXHAUST
Fuel
filter
plugged.
Injection pump not getting fuel or fuel is aerated.
Worn or inoperative injection
pump.
Internal pump timing incorrect.
Camshaft
Incorrect
Cranking
Cold or are needed.
Intake heater system not working.
out of time.
starting procedure.
speed too slow.
starting aids not working
Drain fuel/water separator and replace fuel
Check
fuel flow/bleed fuel
Visually injector to one of the pump outlets. Replace the pump if fuel is
Time the pump (refer to Group 14, Fuel
Check/correct
The
(a) Verify
(b) corroded
(c)
Verify the aids are operating. Repair/replace inoperative parts.
Verify system is working. Repair/replace inoperative parts.
check
fuel delivery
not being delivered.
gear train timing alignment.
manual fuel shutoff control must be in the run position.
that
the transmission is not engaged.
Check
the battery, starting motor and look for loose or
wiring connections.
Rotate the engine
MTE No. 3377462, or equivalent) to
rotational
resistance.
system.
with
an externally connected
with
a barring tool (Snap-On Tool SP371,
System).
check
filter.
for internal
Insufficient intake air.
Air
in the fuel system or the
fuel supply is inadequate.
Inspect
or replace
supply
tube.
Check
the flow through the
and eliminate the air
filter
and
filter
source.
check
for obstructions to the air
and bleed the
system.
Locate
J9109-232
Page 70
5.9L
(DIESEL) ENGINES
9 - 7
ENGINE START, NOT FROM (Cont'd)
ENGINE BUT KEEP
HARD
OR WILL
START—SMOKE
EXHAUST
STARTS,
WILL
NOT
RUNNING
TO
SERVICE
Fuel
pump inoperative.
Injection pump loose
or damaged.
Contaminated
Worn
or
pump.
Injection pump out of time.
Valves
One
or
not operating
Idle speed accessories.
Intake restricted.
DIAGNOSIS
POSSIBLE
CAUSES
throttle
linkage
fuel.
inoperative injection
incorrectly
more
air or
adjusted.
injectors
properly.
too low
exhaust system
for
worn
the,
-
or
PERFORMANCE
Disconnect pump.
Visually
Verify temporary tank.
flush
Visually
injector
not being delivered.
Check/time
Adjust
Check/replace
Adjust
Visually Repair/replace
check
by
fuel supply tanks. Replace fuel/water separator
check
to
valves.
the
check
(CONT.)
C01RECTION
fuel line and verify fuel delivery.
the
linkage. Tighten/replace linkage.
operating
one
the
idle
the
engine
with
Check
for
presence
fuel delivery
of the
pump (refer
bad improperly operating injectors.
speed.
for
exhaust restriction and inspect
restricting parts.
with
pump outlets. Replace
to
clean fuel
of
gasoline. Drain
an
externally connected
Group
14,
If
needed replace
from
the
pump
Fuel
System).
the air
a
and
filter.
if
fuel
is
intake.
SURGING
(SPEED
CHANGE)
ROUGH (IRREGULARLY OR
IDLE
FIRING
ENGINE SHAKING)
Air
in the
fuel
fuel
supply
Fuel
waxing due to extremely
cold
weather.
Contaminated fuel.
If
the
condition the idle speed the
accessories.
High
pressure
One
or
not operating properly.
Improperly operating injection pump.
Cold
engine.
Idle speed accessories.
system or the
is
inadequate.
occurs
at
is
set
fuel leak.
more injectors worn
too low for the
idle,
too low for
or
Check
the
flow through
and eliminate
Verify
by climatized fuel. Replace fuel/water separator heater
Verify
by supply separator
Adjust
Inspect/correct
delivery valve sealing
Check/replace
Replace
Refer
to
(see
Group 11,
Adjust
idle
the air
inspecting
for
proper operation.
operating
tank.
Check
filter.
the
idle.
leaks
the
the
injection pump.
troubleshooting logic
Exhaust
speed.
the
filter
and bleed
source.
the
fuel
filter.
Clean
the
engine
with
for
presence
in the
high
washers.
inoperative injectors.
System & Intake
clean fuel
of
gasoline. Replace fuel/water
pressure
for
intake manifold heater system
the
lines.
Manifold)
the
system.
system and use
filter.
from a temporary
Fittings
Locate
Check
and
fuel
Engine
mounts damaged
loose.
or
Repair
or
replace mounts.
J9109-233
Page 71
SERVICE DIAGNOSIS
-
PERFORMANCE (GGNT.)
CONDITION
ROUGH
IDLE (IRREGULARLY OR
ENGINE
(Cont'd)
ENGINE
OR
RUNS ROUGH
MISFIRING
FIRING
SHAKING)
POSSIBLE
High
pressure
Air in the fuel Sticking
needle
fuel leaks.
system.
valve
injector. Fuel
injection lines
Air in
the
supply Contaminated
Incorrect
Injection Improperly Defective
fuel or the fuel
is
inadequate.
fuel.
valve
adjustment.
pump
timing
operating
injection
(delivery valves).
CAUSES
in
an
leaking.
incorrect.
injectors.
pump
Correct
leaks
in
the
high
valves.
Bleed
the
fuel
system and eliminate the source
Check
and
replace
Correct
leaks
washers
Check and eliminate the
Verify supply
separator
Check
if
Check/time
Replace Replace
or
the
flow
by
operating
tank. Check
filter.
for a bent push rod and adjust
necessary.
inoperative injection
the
injector
in
the high pressure
delivery
pump
valves.
through the
air
source.
the engine
for
(refer
injectors.
pump.
COKKBCTSON
pressure
presence
to
lines,
fittings or
with the
filter
with
Group 14, Fuel System).
sticking
lines,
fittings, injector sealing
and bleed the
clean fuel
of
gasoline. Replace fuel/water
valves.
delivery
of
the air.
needle
valve.
system.
from a temporal,
Replace push rod,
Locate
ENGINE
REACH
LOW
POWER
RPM
RATED
WILL
SPEED
Camshaft Damaged
NOT
Engine
Improperly tachometer.
Throttle incorrectly
Partially shutdown
Inadequate
Improperly pump.
Fuel
control
full
throttle.
Mechanical/shutdown partially
High
oil
out of
time.
camshaft
overloaded.
operating
linkage
worn or
adjusted.
engaged
mechanical
lever.
fuel
supply.
operating
lever not
engaged.
level.
or
tappets.
injection
moving
lever
to
Check/correct
Inspect
Verify
high
sure
correct gear is being
Verify
engine speed
Adjust
linkage
Adjust
Check
the
inadequate Replace
Check/correct
Check
to
Check/correct
gear train
camshaft
linkage
if
and place shutdown lever
injection
see
valve
idle
speed
for
necessary.
fuel
flow through the system
fuel
supply—correct
pump.
for
stop-to-stop travel.
if
the shutdown lever is
oil
level.
timing
alignment.
lift.
Replace camshaft and tappets.
without
with
stop-to-stop fuel control lever travel. Replace
load. Investigate operation
used.
hand tachometer-—correct as required.
in
the run position.
to
as
locate the reason
required.
in
run position.
to be
for
Engine
overloaded.
Check
for
dragging needed.
added
and
other
loading
changes
from
in
accessories
vehicle
boding.
or
driven units, brakes
Repair/replace
as
J9109-264
Page 72
—•———————
SERVICE
DIAGNOSIS • PERFORMANCE (CON7.)
5.9L (DIESEL) ENGINES
9 - 9
CONDITION
LOW
POWER
(Cont'd)
POSSIBLE
Slow
throttle
air
fuel
control
improperly operating control
in
the
pump.
Incorrect
pump
external
timing. Inadequate High
pressure
Inadequate
High
fuel
temperature.
Poor
quality
contaminated
Air
leak
between
response,
tube
intake
fuel
fuel
supply.
fuel
or
with
caysss
leaking
or
injection
air
flow.
leak.
fuel
gasoline.
the turbo­charger and the intake manifold.
Intercooler
blocked.
CORRECTION
Tighten
the
fittings.
Replace the
pump
if
the
controls
are not
functioning.
:
Verify
that
14, Fuel
System). Inspect/replace Inspect/correct
sealing
washers
Check
the flow
injection
pump
timing
marks
are
aligned
(see
Group
' |
air
cleaner
leaks
or
through
element.
in
the high pressure
delivery
the
valve* filter
Look
seals.
to
locate
for
other
restrictions.
lines,
fittings
injector
the source of the
restriction.
Verify
that
fuel
heater
is off
during
warm
restricted
Verify Check filter.
fuel
by
operating
for
presence of
• '
Check/correct and
around
mounting
drain
manifold.
Repair/replace
from a temporary
gasoline.
- •
leaks
in
the
air
tubes,
capscrews or
tank with
Replace
*
intercooler,
through
weather.
fuel/water
holes
as
needed.
good
hoses,
in
the manifold
Check
for
fuel.
separator
gaskets,
a
cover. Check
pressure
drop
across
intercooler
(4" of Hg. max. @ rated
power).
EXCESSIVE SMOKE
EXHAUST
Exhaust
leak
at the manifold
or turbocharger. Improperly operating turbo-
charger. Valve
clearance
Injection
pump
incorrect.
improperly
operating. Worn
or improperly operating
injectors.
Improperly operating
injection
pump. Excessive
Engine running too
exhaust
restriction.
cold
(white
smoke).
Inadequate
Air
leak
and
Intercooler
Exhaust
between
intake
leak
intake
air.
turbocharger
manifold. blocked.
at the manifold
or turbocharger. Improperly operating
turbocharger.
Check/correct If
manifold
is
Inspect/replace
Check/adjust Check/time
valves.
pump
Check/replace
Replace
injection
Check/correct Refer
to normal manifold
troubleshooting
(refer
heater/KSB Inspect/change Check/correct
mounting Check
capscrews or
pressure
power). Check/correct
If
cracked
replace
Inspect/replace
leaks
in
cracked,
the manifold or turbocharger gaskets.
replace
turbocharger.
(refer
to
injectors.
pump.
the
restriction
logic
to
Group
14,
valve
air
cleaner.
leaks
in
the
through
drop
across
leaks
in
the manifold or turbocharger gaskets.
manifold.
turbocharger.
manifold.
Group
14, Fuel System).
in
the exhaust system.
for
coolant temperature
Cooling
for
air
System).
proper operation.
Look
for
other
tubes,
intercooler,
holes
in
the manifold cover.
intercooler
(4" of Hg. max. @ rated
Inspect
intake
restriction.
hoses,
below
gaskets,
J9109-265
Page 73
9
- 10 5.9L
(DIESEL)
ENGINES
SERVICE
DIAGNOSIS
PERFORMANCE
(CONT.)
CONDITION
EXCESSIVE
SMOKE
(Cont'd)
ENGINE
SHUT-OFF
COOLANT TURE
ABOVE
EXHAUST
WILL NOT
TEMPERA-
NORMAL
POSSIBLE
More
than one sealing washer
under an injector.
Improperly operating injectors.
Improperly operating or over­fueled injection pump.
Piston
rings not sealing
(blue smoke).
Fuel
shutoff valve inoperative.
Engine
running on fumes drawn
into
the air intake.
Low
coolant level.
Incorrect/improperly operating pressure
cap.
CAUSES
CORRECTION
Check
and remove extra washer.
Check
and replace inoperative injectors.
Replace
Perform blow-by check. Correct as required.
Stop the engine mechanically Check/replace
Check
TO OTHER EXTINGUISHER LOCATED BEHIND THE BUMPER.
(a) Check coolant level. Add coolant, if
(b) Locate and correct the source of the coolant leak. Refer to
Replace
injection pump.
with
sealing washer, piston and spring.
the air intake ducts for the source of the fumes.
STOP
AN ENGINE THAT IS RUNNING ON
THAN THE
BELOW
troubleshooting logic for coolant
cap
DIESEL
INTO
THE RIGHT HEAD LIGHT
with
the correct rating for the
FUEL
THE AIR INTAKE
lever on the fuel pump.
INJECTION
loss.
FUEL
SYSTEM,
SYSTEM.
(PASSENGER
necessary.
system.
THE AIR PICKUP IS
SOURCES
SPRAY A FIRE
SIDE)
High
lube oil level.
Loose
drive
belt
flow
radiator
on water
to the
hose.
system.
pump/fan.
Inadequate air radiator.
Radiator fins plugged.
Collapsed
Improperly operating tempera­ture
sensor/gauge.
Improperly operating, incorrect or no thermostat.
Air in the cooling
Inoperative water pump.
Incorrect injection pump timing.
Check/drain
Check/replace
Check/repair required.
Blow
Replace
Verify Replace
Check
(a)
Make
vented thermostat is installed.
(b) Check for loose hose clamps. Tighten if loose.
(c)
If aeration continued, check for a compression leak through the head gasket.
Check
Verify pump pump (refer to Group 7, Cooling System).
oil to correct level.
belt
or
belt
tensioner.
radiator core, fan shroud and fan clutch as
debris
from
fins.
the
hose.
that
the gauge and temperature
gauge/sensor, if bad.
and replace the thermostat.
sure the
and replace the water pump.
fill
rate is not being exceeded and the correct
timing
marks are aligned. Check/time the injector
sensor
are accurate.
J9109-236
Page 74
5.9L
(DIESEL)
ENGINES
9 - 11
SERVICE
CONDITION
COOLANT
TURE
(Cont'd)
COOLANT TURE
INSPECTION
If
an oil leak source is not readily
following
(1)
regulator
(2)
at
the
TEMPERA-
ABOVE
BELOW
NORMAL
TEMPERA-
NORMAL
(ENGINE
steps
should be
Attach
an
air
to the dipstick tube.
Disconnect the breather cap to air cleaner
breather cap end. Cap
Overfueled
Plugged radiator,
block.
Engine
Too
much
radiator.
Incorrect thermostat
contamination
Temperature
inoperative.
Coolant temperature
OIL
LEAKS)
followed:
hose
with
DIAGNOSIS
POSSIBLE
cooling
head,
overloaded.
air
thermostat,
not
infection
flow
jiggle
in
sensor
flowing
sensor.
CAUSES
passages head
pin
thermostat.
identifiable,
pressure
or
plug
pump.
across
or
by
breather
nipple.
(3)
Remove the PCV valve
cover. Cap or
(4)
After
regulator
(5)
Using a liquid
plug
the engine
NO
HIGHER
the PCV valve grommet.
is
soap stethoscope, inspect all suspected oil
leak
area
is detected, repair per the service man-
ual
instructions.
(6)
If no leaks are detected, and remove PCV
valve and breather cap check for higher mal
engine operation.
(7)
Clean the oil off the a suitable solvent. speeds engine for signs
the
air
pressure
approximately
of
an
hose
Drive
24
oil
from
the cylinder head
sealed,
set
the air
than 27 kPa (4 psi).
solution
turn
or
preferable
oil
leak
off the air supply
and all plugs.
hose.
See
leaks occurring during nor-
suspect
the
km (15
leak.
If
oil
vehicle
miles).
an
oil
leak
at
leak is
repair per the service manual instructions.
-
in
gasket
broken
or
or
the
gauge
the
gauge
and
hose
cap
pressure
a
areas.
Install
If
the
an
step 7 and
area
using
various
Check
the
found,
PERFORMANCE
Replace
Flush
Verify
Check/repair
Check and
Verify gauge/sensor.
Check and
the
the
that
that
(8)
(CONT.)
CORRECTION
injection
system
the
viscous
replace
the
clean
pump.
and
fill
engine
load
fan
thermostat.
gauge
and sensor
coolant
with
clean
rating
as
required.
passages.
If the leakage occurs
coolant.
is not
being
exceeded.
are
accurate.
at
the crankshaft rear oil
seal:
(a)
Raise the vehicle.
(b)
Remove torque converter
or cover and inspect rear of block for evidence of A
circular spray pattern generally indicates seal leakage. Where leakage down,
possible
causes rear cam and galley plugs. (Rear
Main
Bearing Oil Seals), for the proper seal
(and
retainer) installation.
(c)
If
no
leaks are detected
pressurized
27 kPa (4
tends
to
are a porous block and
See
Group
while
the crankcase is
psi), very
slowly crankshaft and watch for leakage. If a leak tected
while the crankshaft seal surface area,
minor nicks
with
emery
ENGINE
OIL
(1)
Remove oil
(2)
Install
turning
or
cloth.
PRESSURE
pressure
Oil
Pressure
the
crankshaft,
is
scratches
sending
Line
damaged in the seal
can be polished out
unit.
and
C-3292.
(3)
Start engine and record
Pressure
in Engine Specifications for the proper pres-
pressure
sures).
If
not,
clutch
run
its
Gauge
(refer
replace
J9109-254
housing
straight
9,
Engines
turn
is
possible
Tool
to
oil.
the
the
de-
Oil
Page 75
9 - 12 5.9L
(DIESEL)
ENGINES
ENGINE SERVICE PROCEDURES
INDEX
page
Piston
Cylinder Engine Assembly . . 12
Oil Cooler Element/Gasket 19
Oil Pressure
Oil
ENGINE
REMOVAL
hood.
Head
Pump
17
Regulator
19
Valve/Spring
19
ASSEMBLY
(1)
Disconnect the electrical connection
Scribe the hood hinge
bolt
locations and re-
into
the
Cooling Piston/Connecting Rod Assembly 19 Rocker Levers/Push Rods 15 Specifications—5.9L Diesel Engines 20
Nozzles
move the hood (Fig. 1).
page
19
Fig. 1 Scribe Hood Hinge
(2)
Disconnect the battery
cables
and remove the
battery.
(3)
Drain
to
Group 7, Cooling System for the proper proce­dures). Do not is
clean, drain the coolant
the coolant
waste
reusable
from
the cooling system (refer
coolant. If the solution
into
a clean container for
reuse.
(4)
Disconnect the radiator
hoses.
Remove the fan shroud, fan/fan clutch assembly and radiator (refer to Group 7, Cooling
(5)
Disconnect the
Systems
heater
for the proper procedures).
hoses
at the
dash
panel
and at the water valve (Fig. 2).
(6)
Disconnect the air
inlet
tube
from
the turbo­charger (Fig. 3) and the air intake housing. Remove the tube.
Fig.
3 Air
Intel
Tube
and
Exhaust Pipe Connection
(8)
Disconnect the intercooler turbocharger and the intercooler inlet
duct.
(9)
Disconnect the intercooler outlet duct air
inlet
housing and the intercooler
inlet (Fig.
the outlet duct.
duct
from
the
4). Remove the
from
the
(Fig.
4). Remove
Page 76
5.9L
(DIESEL)
ENGINES
I - 13
Fig. 4 Intercooler Ducts
(10)
Remove the drive belt. Disconnect the alterna-
tor
ground
(Fig,
5).
(11)
A/C
compressor is located below the alternator.
(12)
control
wire.
Remove the alternator and set
Fig, 5 Alternator
Removal
Remove the A/C compressor and set aside. The
Disconnect the accelerator linkage, the
linkage and the throttle valve linkage (Fig.
6). (13)
Raise
(14)
Drain
oil
according to all applicable regulations.
(15)
Disconnect the exhaust pipe
and support the vehicle on a hoist. the engine
lubricating
oil.
Dispose of the
steady
rest
and remove.
(16)
Disconnect the starter connections (Fig. 7).
(17)
Disconnect the transmission cooler lines.
aside
speed
clamp
Fig. 8 Accelerator/Speed
Fig. 7 Starter Connections
(18)
MANUAL
TRANSMISSION-See Group 21,
Control/Throttle
Linkage
Valve
J91
09-1
13
Transmissions for the G360 Manual Transmission
Removal
(19)
sembly alignment (Fig. 8). Note that
procedure.
AUTOMATIC
TRANSMISSION (a) Remove torque converter (b)
Mark
torque converter and drive plate for as-
bolt
access
bolt
cover.
holes in crankshaft flange, drive plate and torque converter all
have
one offset hole.
(c)
Rotate crankshaft in clockwise direction
until converter bolts are accessible. Then remove bolts one at a time. Rotate crankshaft wrench
on damper pulley
(d)
Support the transmission.
(e) Remove
bell
housing bolts and inspection
bolt.
with
socket
plate. (20)
Lower the vehicle.
(21)
Disconnect the power steering lines.
(22)
Disconnect the vacuum pump lines.
Page 77
I
- 14 5.9L
(DIESEL)
ENGINES
Fig. 8 Marking Converter
Alignment Reference
(23)
Disconnect all electrical connections
engine. Put
tags
on the connections to
and
locations.
(24)
Disconnect the
fuel
return. Use
tags
fuel
lines to the
to
identify
Drive
Plate
for
from
the
identify
lift
their
pump and
the lines (Fig. 9).
CAUTION: to
damage
mounted
Fig.
(28) Lift
When
on the dash
10
the
removing
wiper
Vifiper
Motor/Voltage
motor
panel
the
engine,
and
voltage
(Fig. 10).
Regulator
take
care
regulator
the engine out of the vehicle (Fig. 11).
ENGINE
not
(25)
Put a cover or
(26)
Make mounted and
with
install
Fig. 9 Lift
in the proper
Pump
and
Fuel Lines
tape
over all engine openings.
sure
that the
lifting
brackets are
the eye up. If not, remove the bracket
position.
Tighten the
bracket bolts to 77 N-m (57 ft. lbs.) torque.
(27)
Use the
lifting
brackets to apply tension to the engine. Remove the engine mount through-bolts the cylinder block mounting bracket.
lifting
from
Fig.
(29)
Install
(30)
Remove all
ously
removed for use
11
Lifting
Engine
from
Vehicle
the engine on a suitable stand.
accessories
with
and brackets not
the replacement engine.
J9109-11
previ-
Page 78
5.9L
(DIESEL)
ENGINES
9 - 15
INSTALLATION
(1)
If removed,
lifting
bracket to 77 N-m (57 ft. lbs.) torque. Do not
install
and tighten the
rear
engine
exceed this torque valve.
(2)
Check the ment engine is the gine
that was removed.
(3)
Install been
removed
(4)
Use the
data
all
accessories
from
lifting
plate to
same
verify
that the replace-
model and rating as the en-
and brackets that had
the previous engine.
brackets to
lift
the engine off
of
the stand.
(5)
Position the' engine in the the through N-m
(30 ft. lbs.) torque.
(6)
Remove the covers or
bolt.
Tighten the through
chassis
and
bolt
tape
covering the engine
install
nut to 41
openings.
-
(7) Connect the
fuel
lines to the
lift
pump and
fuel
return.
(8)
Connect all electrical connections.
(9)
Connect the power steering lines.
(10)
Raise
(11)
MANUAL
and support the vehicle on a hoist.
TRANSMISSION-See
Group 21, Transmissions for the G360 Manual Transmission In­stallation
(12)
CAUTION; flashing o'clock
converter is aligned set holes in plate are next to 1/8 circle
41
torque converter, N-m
(13)
to
22 N#m (16 ft. lbs.) torque. Connect the solenoid
procedure.
AUTOMATIC
If new
from
the engine back plate at the 5 and 7
TRANSMISSION
flei
plate is installed, remove
positions.
(a)
Rotate converter
until
alignment mark on the
with
mark on drive plate.
inch
Off-
hole in inner
of drive plate (Fig. 8).
(b)
Install
bell
housing bolts. Tighten the bolts to
N-m (30 ft. lbs.) torque.
(c)
With
the torque converter plate aligned to the
install
and tighten the bolts to 31
(270 in. lbs.) torque.
(d)
Install
(e)
Remove the transmission support.
the converter housing
access
plate.
Connect the ground cable and tighten the nut
cable and tighten the nut to 5 N-m (44 in. lbs.) torque.
(14)
Connect the transmission cooler lines.
(15)
Install
(16)
Lower the vehicle.
(17)
Install
bolts
to 47 N#m (35 ft. lbs.) torque. If removed, con-
nect the
(18)
Install mounting tighten
lbs.)
torque. Connect all wires.
the exhaust pipe to the exhaust system.
the A/C compressor and tighten the
clutch
electrical
wire.
the alternator. Tighten the upper
bolts to 24 N-m (18 ft. lbs.) torque. Now
the lower mounting bolts to 43 N-m (32 ft.
(19)
Install and fan shroud (refer to Group 7, for
the proper procedures). Connect the radiator
the radiator, fan/fan
clutch
Cooling
assembly
Systems
hoses.
(20)
Position the intercooler charger and the intercooler in
position, tighten the clamp nut to 8 N-m (72 in.
lbs.)
torque.
(21)
Position the intercooler outlet duct to the air inlet
housing and the intercooler (Fig. 4).
inlet
(Fig.
duct to the turbo-
4).
With
the clamps
With
the clamps in position, tighten the clamp nut to 8 N-m (72
in. lbs.) torque.
(22)
Connect the air intake tube to the turbo­charger Tighten
Tighten
inlet
flange and the air cleaner housing.
the clamps to 8 N-m (72 in. lbs.) torque.
(23)
Install
the exhaust pipe to the turbocharger.
the
steady
rest
clamp to 8 N-m (72 in. lbs.)
torque.
(24)
Make connections are
(25) Fill
clean engine
sure
the air intake and exhaust pipe
tight
the engine
lubricating
and free of leaks.
with
the required amount of
oil
(see Group 0,
Lubrication
and Maintenance).
(26) Fill water and 50% ethylene-glycol Group
(27)
the
7,
Cooling
Install
cooling
system
with
a mixture of 50%
base
antifreeze (refer
System for the proper procedure).
the battery and connect the battery ca-
bles.
(28)
Check the
2
or 3 minutes. Oil held in the oil
sages
will
cause
(29)
Operate the engine at
oil
level
the oil
after the engine has run for
filter
and oil
level
in the pan to be lower.
idle
for 5 to 10 minutes
pas-
and check for leaks and loose parts.
ROCKER
REMOVAL
(1)
(2) adjusting
(3) tals. blies
(4)
DISASSEMBLE-ROCKER
(1) (Fig.
(2)
LEVERS/PUSH
RODS
Remove the valve covers (Fig. 1). Loosen the adjusting screw locknuts. Loosen the
screws Remove the bolts Remove the
until
they stop (Fig. 2).
from
the rocker lever
pedestals
and rocker lever
pedes-
assem-
(Fig. 2).
Remove the push rods.
LEVERS
Remove the retaining rings and thrust
washers
2). Remove the rocker levers
(Fig.
2). Do not
disas­semble the rocker lever shaft and pedestal. The ped­estal and shaft must be replaced as an assembly.
(3)
Remove the locknut and adjusting screw (Fig.
2).
(4)
Clean all parts in a strong solution of laundry
detergent in hot water.
(5)
Use compressed air to dry the parts after rins-
ing
in clean hot water. The
pedestals
are
made
from
Page 79
I
- 18
powdered
after
5.9L
Fig. 2 Location
metal and may continue
they have been cleaned and
(6)
Inspect for excessive wear in the bore and
(DIESEL)
Fig. 1 Valve
LOCKNUT
of
Rocker
ENGINES
Cowers
ADJUSTING
Lever
Components
to
dried.
contact surface for the valve stem.
(7)
Measure maximum if
out of
(8)
Inspect the pedestal and shaft.
(9)
Measure the shaft diameter. The
ameter
is
the
rocker lever bore diameter.
diameter is 19.05 mm (0.75
limits.
18.94 mm (0.746
inch).
Replace if out of
limits.
ASSEMBLE—ROCKER
(1)
Install
LEWERS
the adjusting screw and
locknut.
J9109-31
show wetness
the
The
inch).
Replace
minimum
di-
(2)
Lubricate
sure
to
assemble
vers in the correct
(3)
Position the levers on the rocker shaft.
the
shaft
the
location.
with
clean engine oil.
intake and exhaust rocker
the thrust washers.
(4)
Clean the push rods in the hot soapy water.
(5)
Inspect the push rod scoring pressed
'
ness.
valve clean
completely
INSTALLATION
installed
cylinder
or
cracks where the
into
the tube.
(6)
Check the push rods for roundness and straight-
(7)
Install
the
push rods
tappets. Lubricate
engine oil.
(8)
Make sure the rocker lever adjusting screws are
backed out.
(1)
Make sure the
into
the
dowel
(2) If
the push rod is
head, bar the engine
set on the head surface
(3)
Use clean engine oil
head
bolt
threads and under the
(4)
Install
lever
pedestals.
Step 1—Tighten the bolts, in
90
N-m
than
90 N-m (66 ft.
Step 2—Tighten the bolts, in
120 N-m (89
lower
the
long
Tighten
(66 ft. lbs.) torque. Check the torque.
ft.
lbs.) torque. Check
than
120
N-m
ball
and socket for signs of
ball
and the socket
into
the
the
push rod sockets
dowel
rings in the
bores in the
holding
without
the pedestal
until
interference.
to
lubricate
the pedestal
bolt
bolts (12 mm)
the bolts
as
sequence
lbs.),
tighten to this torque.
sequence
(89 ft.
lbs.),
tighten
sockets
pedestals
cylinder
the
heads.
into
the
follows:
(Fig. 3),
(Fig. 3),
the
torque.
Step 3—Tighten the bolts, in
additional
Cn
(5)
90°.
FRONT
Fig. 3 Rocker
Tighten
Lever
(Head
Sequence
the 8 mm bolts
sequence
Bolts)
to
24 N-m (18 ft. lbs.)
(Fig.
J9109-32
Tightening
torque.
(6)
Install
bolt
to 24 N-m (18 ft. lbs.) torque.
the valve cover.
Tighten
the valve cover
Install
of the
with
head.
off
of the
will
cylinder
rocker
If
lower
torque.
to
this
3),
Be
le-
are
are
to
to
If
an
Page 80
V
CYLINDER
The cylinder
design and can not be interchanged
HEAD
heads
on the
1991V2
engine are a new
with
earlier mod-
els.
REMOVAL
(1)
Drain
the coolant. Do not waste reusable ant. If the solution is clean, drain the coolant clean container for
(2)
Drain
the engine oil. Dispose of the used oil
reuse.
properly.
(3)
Disconnect the radiator and
to
Group 7,
(4)
Remove the turbocharger
(5)
Remove the exhaust
Cooling
System).
manifold
heater
(Fig.
(Fig. 4).
hoses
1).
cool-
into
a
(refer
5.9L
(DIESEL)
(9)
Remove the fuel/water separator
ENGINES
filter
9 - 17
(Fig. 6). Refer to Group 14, Fuel System, for the proper pro­cedures.
Fig. 4 Exhaust Minifold
(6)
Remove the
to
Group 14, Fuel System).
(7)
Remove the valve covers (Fig. 5).
fuel
lines and injector nozzles (refer
Fig. 6 Fuel/Water
(10)
If the engine is hot, remove the cylinder head
bolts
in the sequence are 3 bolt
for future installation.
(11)
Remove the cylinder head and gasket
cylinder
sequence
is not important
sizes
of head bolts. Note the position of each
block.
Separator
Filter
shown in Fig. 7. The removal
if
the engine is
cold.
There
from
the
J9109-36
Fig. 5 Valve
(8)
Remove the rocker levers and push rods.
Cover
Fig. 7 Cylinder
Sequence—Cylinder
INSPECTION
Head
Head
Bolt
Removal
Hot
Remove the cup plugs and inspect the coolant
sages.
A large
removal
build
up of rust and
lime
will
require
of the cylinder block for cleaning in a hot
tank.
Inspect the cylinder
bores
for
damage
or excessive wear. Rotate the crankshaft so the piston is at tom
Dead Center
(BDC)
to inspect the bores.
pas-
Bot-
Page 81
9 - 18 5.91.
(DIESEL)
ENGINES
Measure the cylinder
with
in-chassis repair if the
worn
beyond
pair - Cylinder
the
limits
Block).
MIN.
102.0 mm (4.0157 inch)
MAX.
102.1
Out-of-Round
16 mm (4.0203 inch)
0.038 mm (0.0015 inch)
Taper 0.76 mm (0.003 inch) Oversize pistons and rings are
available
Check
the top
cylinder
sion,
head gasket leaking between cylinders.
Inspect
the
etc.
Check the head
for bored cylinder blocks.
Fig. 8 Cylinder
surface
block and head surface for nicks, ero-
distortion the combustion deck face (0.0004 inch) Overall (0.012
inch).
Do
not proceed cylinder (within
in
any 50.8 mm (2.00 inch) diameter.
variation end to end or side to side 0.30 mm
with
the in-chassis overhaul if the
head or block surface is damaged or not
specifications).
bores
(Fig.
8). Do not proceed
bores
(refer
Bore
for
(Fig.
is
not to exceed 0.010 mm
are
damaged
to
Cylinder Bore Re-
Diameter
damage
caused
9). The
distortion
J9109-75
by the
flat
or
of
surface and maintain the surface tolerances. The combined not
exceed 1.00 mm (0.03937
total
finish
and
flatness of stock removed must inch).
The amount of stock removed each time must be steel stamped just above the right valve
Surface
ters
REFERENCE
CLEANING
Clean
a
nylon
Scrape
edge
of the combustion deck on the lower
hand corner of the rear face (Fig. 10). Check
protrusion after head surface refacing.
finish
(60-126
Fig.
the carbon or
the gasket residue
requirements
microinch).
STOCK REFERENCE
SURFACE
10
Cylinder
from
brass
brush.
are
TOTAL
mm
to
to
±0.25
3.2
FINISH
128
(MAX.)
(0.03937
HEIGHT
mm
±0.0010
micrometers
microinches)
Stock
inch)
1.00
94.00 (3.7008
1.5
(60
Head
the injector nozzle
from
all gasket surfaces.
1.5-3.2
inch)
(MIN.)
Removal
microme-
J9109-134
seat
with
Wash the cylinder head in hot soapy water solution
(88°C
or
140°F).
After
rinsing,
use
compressed air to dry the
cylin-
der head.
Polish
an
orbital
the gasket surface
sander
or sanding block to maintain a flat
with
400
grid
paper.
Use
surface.
Fig. 9 Cylinder
REFACINQ
HEm
Head
Combustion
Measurement
SURFACE
Deck
Face
The cylinder head combustion deck may be refaced
in
whatever increments
necessary
to
clean
up the
INSTALLATION
(1)
The cylinder block and head must be clean and
dry.
(2)
Make
Position
sure
the
the
gasket onto
gasket
the
is
correctly aligned
dowels (Fig. 11).
holes in the cylinder block.
(3)
Carefully and cylinder block. Make installed
11).
(4)
Install
put the cylinder head onto the gasket
sure
the
cylinder head
onto the dowels in the cylinder block (Fig.
the push rods and rocker levers.
with
the
is
Page 82
5JL
(10)
Install
(DIESEL)
the
valve covers. Tighten
ENGINES
24 N-m (18 ft. lbs.) torque.
(11)
Install
to
Group 14, Fuel System).
(12)
Install
the injector nozzles and the
fuel
filter
(refer
to
System for the proper procedures).
(13)
Install
11,
Exhaust System and Intake
(14)
Install
(15)
Connect the radiator and
(16) Fill
drained coolant (refer
the
the
exhaust
the
turbocharger.
engine
manifold
with
new coolant
to
Group 7,
Manifold). heater
Cooling
the proper procedure).
(17) Fill
to
Group
the engine
0,
Lubrication and Maintenance).
with
clean
lubricating
9
- 19
the
bolts
fuel
lines (refer
Group 14, Fuel
(refer
to
Group
hoses.
or the
clean
System for
oil
(refer
to
Fig.
11
Cylinder
(5)
Use
clean engine oil
head
bolt
threads
(6)
The cylinder head bolts
stall
the bolts in the proper hole. Tighten the bolts
Head/Gasket
and under
Alignment
to
lubricate
the
bolt
heads.
are 3
different
the
cylinder
sizes.
follows:
Step
1—Tighten all bolts, in
90
N-m
(88 ft. lbs.) torque. Check the torque.
than 90 N-m (66 ft.
Step
2—Tighten all 12 mm bolts, in
12),
to 120 N-m (89 ft. lbs.) torque. Check the torque.
If
lower than
120
lbs.),
N-m
(89 ft.
sequence
tighten
to
this torque.
lbs.),
tighten
(Fig. 12),
If
sequence
torque.
Step
3—Tighten all bolts, in
additional
90°.
sequence
(Fig. 12),
lower
(Fig.
to
this
In-
as
to
an
PISTON/CONNECTING ROD
The turbocharged intercooler piston has
insert
with a keystone
ring.
The new piston
mm
longer piston pin. The 1991V2 pistons can not
interchanged
PISTON
with
COOLING NOZZLES
The piston cooling nozzles (Fig. 13) engine ities. terchanged
are a
new design
The 1991V2 piston
with
Fig.
13
has a
earlier models.
earlier models.
Piston
ISSEilLY
profile
new design
with
cooling
Cooling
for the
top
bowl
on the
increased
nozzles
Nozzles
flow
can
a
compression
Ni-Resist
and a
be
1991V2
capabil-
not
be
in-
7
Fig.
12
Cylinder Head Tightening Sequence
(7)
Be
sure
to
clean engine oil.
(8)
Install
tighten
(9)
Adjust
the
to
24 N-m (18 ft. lbs.) torque.
the
J9109-36
lubricate
the
push rod
sockets
rocker lever pedestal bolts
valve clearance.
with
and
OIL
PU1P
The 1991V2 oil pump can
be
used on earlier model
engines. However, earlier oil pumps can not
on
1991V2
OIL
PRESSURE
When
kPa (65 psi), the regulator valve
drain
OIL
COOLER
The terchanged model
engines.
oil
pressure
back into
ELE1ENT/G1SKET
1991V2
filter
filter
with
head/coolers
REGULATOR
from
the
pan.
head/cooler assembly
VALVE/SPRING
the
oil pump
opens
exceeds
to
allow
can be
earlier models. However, earlier
can
not
be
used
on
engines.
be
used
448
oil
to
in-
1991V2
Page 83
9
• 20 5.9L
(DIESEL)
ENGINES
— *
SPECIFICATIONS—5.9L DIESEL
VALVE
TRAIN
Valve Clearance
Vaive Guide
Valve Stem
Valve Seat Angle
Valve
Valve Spring
Valve Rim Valve Seat
Depth
Thickness
Diameter
Diameter
(Installed)
(AAin.)
Width
ENGINES
ENGINE
SPECIFICATIONS
0.25 mm
0.51 mm
.8.019
mm
8.089
mm
.7.935
mm
7.960
mm
0.99 mm
.
1.52 mm
55.63
mm (2.19 inch)
1.00 mm
.49.25
mm
289.32
N
0.79 mm
...
1.50 mm
2.00 mm
30° 45°
(0.010
inch)
(0.020
inch)
(0.3157
inch)
(0.3185
inch)
(0.3126
inch)
(0.3134
inch)
(0.039
inch)
(0.060
inch)
(0.039
inch) (1.94 inch) (65 lbs.) (0.031
inch)
(0.060
inch) (0.080
inch)
CYLINDER
Cylinder Head
Max.
GEAR
CAMSHAFT
Valve
Lobes Intake Exhaust
Lift Pump Lobe (AAin.
f
APPffS
Stem
Diameter
ROCKER
Rocker
Lever Bore
CYLINDER
Cylinder Bore Out of Round
Taper
(Max.)
HEAD
Flatness
Variation
50.8 mm (2.0 inch)
TRAIN
(Min.
(AAin.)
LEVER
BORES
Diameter
(Max.)
within
Diameter
Diameter
(Max.)
(Max.)
0.01 mm
(0.0004
diameter
at Peak of Lobe)
at Peak of Lobe)
inch) in any
area.
.0.030
mm
0.08-0.33
0.152-0.254
53.962
mm
47.040
mm
46.770
mm
35.50
mm
15.925
mm
19.05 mm
18.94 mm
102.116
0.038
mm
0.076
mm
mm
mm
mm
(0.012
inch)
(0.003-0.013 (0.006-0.010
(2.1245
inch)
(1.852
inch)
(1.841
inch)
(1.398
inch)
(0.627
inch)
(0.75 inch) (0.746
inch)
(4.0203
inch)
(0.0015
inch)
(0.003
inch)
inch)
inch)
CONNECTING
!
Pin Bore
|
Side Clearance
Diameter
ROD
(Max.)
. . 40.053
0.10-0.30
mm
mm
(1.5769
inch)
(0.004-0.012
inch)
J9109-246
Page 84
5.9L
(DIESEL) ENGINES
9 - 21
PISTONS
Skirt
Diameter (AAin.)
Ring Groove
Ring
End
Gap
CRANKSHAFT
Main
Bearing Journal
Connecting
(Max.)
Rod
Diameter
Journal
SPECIFICATIONS
...........
..
....
..
. 0.013 mm
(CONT.)
101.880
40.025 mm
.0.15
.......0.13 mm
39.99 mm
.0.40-0.70 .0.25-0.55 mm
0.25-0.55
82.962 mm
82.712 mm
82.462 mm
.82.212 mm
81.962 mm
0.050
0.013 mm .0.119 mm .0.13-0.30
.68.962 mm
68.712 mm .68.462 mm
68.212 mm
67.962 mm
.0.050
0.089
mm
101.823 mm
mm
mm
mm
mm
mm
mm
mm
(4.0110
inch)
(4.0088
inch)
(1.5758
inch)
(0.006
inch)
(0.005
inch)
(1.5744
inch)
(0.016-0.0275 (0.010-0.0215 (0.010-0.0215
(3.2662
inch)
(3.2564
inch)
(3.2465
inch)
(3.2367
inch)
(3.2269
inch)
(0.002
inch)
(0.0005
inch)
(0.0047
inch)
(0.005-0.012
(2.7150
inch)
(2.7052
inch)
(2.6954
inch)
(2.6855
inch)
(2.6757
inch)
(0.002
inch)
(0.0005
inch)
(0.0035
inch)
inch) inch) inch)
inch)
CYLINDER
Top Surface
Max. Variation any 50 mm
(2
inch)
Refacing Combustion Deck
First Second
Main
Bearing Bore
with
Camshaft Bore
#1
with
#2 thru #7 54.133 mm
OIL PUMP
Tip Clearance Gerotor Drive/Planetary Gerotor Planetary Gear
Backlash
BLOCK
Flatness
Diameter
Reface .0.15
Reface
Total
bearing installed
Bushing
(Max.)
Area
Diameter
Diameter
(Used Pump)
(Max.)
to Port
to
Body Bore Clearance
(Max.)
Plate Clearance
(Max.). .0.127 mm
(Max.)
.0.010
.0.35
.83.106 mm
.0.1778 mm
.0.381
0.075
mm
mm
mm mm
0.50 mm
1.5-3.2
micrometers
57.258 mm
54.133 mm
16.055 mm
mm
0.08-0.38
mm
(0.003
inch)
(0.0004
inch)
(0.0058
inch)
(0.0138
inch)
(0.0197
inch)
(60-126
microinch)
(3.2719
inch)
(2.2543
inch)
(2.1312
inch)
(2.1312
inch)
(0.632
inch)
(0.007
inch)
(0.005
inch)
(0.015
inch)
(0.003-0.015
inch)
| J9109-247
Page 85
9
- 22 SJL
(DIESEL)
ENGINES
— —
COMPONENT
Air Fuel Control Banjo Screw (In Pump) Air Fuel Control Fitting (In Head) Alternator Ground Cable Alternator Alternator Pulley Alternator Support
Battery Cable Belt Tensioner Block
Cab Cab Camshaft Thrust Plate Clutch Connecting Rod
Cooling Fan Crossover
Cylinder Head
Mounting
(Negative)
Mounting
Heater
Mounting
Heater
Hose Clamp
Heater
Tubing Clamp
Cover
Mounting
(Alternately Stepl ' Step 2
........
Step 3
Mounting
Clamp (Air)
Mounting
1. All Bolts
2. Long Bolts
3. Tighten All Bolts An Additional
Mounting
to
Water
(Upper)
Mounting
Mounting
to Flywheel
'
to Fan Clutch . .
Bolts
Pump
tighten
to Block
Inlet
to Block ....
in 3 steps)
TORQUE
......
SPECIFICATIONS
12 Nvn
8 Nvn 24 Nvn 41 Nvn
80 Nvn
24 Nvn
77 Nvn 43 Nvn
12 Nvn
4 Nvn 24 Nvn 24 Nvn 23 Nvn
35 Nvn 70 Nvn
100 Nvn
20 Nvn
5
Nvn
90 Nvn
120 Nvn
TOIQUE
9 ft. lbs. 6 ft. lbs.
18 ft. lbs. 30 ft. lbs. 60 ft. lbs.
18 ft. lbs.
57 ft. lbs. 32 ft. lbs.
9 ft. lbs.
(35 in. lbs.)
18 ft. lbs.
18 ft. lbs.
17 ft. lbs.
26 ft. lbs.
51 ft. lbs.
73 ft. lbs.
15 ft. lbs.
(44 in. lbs.)
66 ft. lbs.
89 ft. lbs.
90°
Exhaust
Manifold
Exhaust
Outlet
Pipe - V Band Clamp
Exhaust
Pipe Clamp
Exhaust
Pipe Steady Rest
Fan
Clutch Mounting/Fan Hub (L Hand Threads).
Fan
Hub Bracket
Fan
Hub Bearing Retaining Capscrew
Fan
Pulley to Fan Hub
Fan
Pulley Crankshaft
Fan
Shroud
Mounting Flywheel Bolts Flywheel Housing - Adaptor Front Engine Front Engine Front Engine Front Oil Filler Pipe ­Fuel
Banjo Screw (In Fuel Pump)
Fuel
Banjo Screw (In Head)
Fuel
Banjo Screw (In Injector)
Fuel
Filter '
Fuel
Heater
Assembly
Fuel
Heater
Ground
Fuel
Link Fitting
Fuel
Low
Pressure
Fuel
Pump Drive Gear
Fuel
Pump Lock (Bosch)
Mounting
Mounting
Mounting
Nuts
................
Mount
Isolator
Mount
Through Bolt
Mount
to Block . .•
Access
Mounting
Mounting
(High
Pressure)
Supply
(With
to Trans ....
Mounting
Cover
Pump Unlocked)...
to
Intake
to
Manifold
Mount.
43 Nvn
8 Nvn 27 Nvn 68 Nvn
57 Nvn 24 Nvn 77 Nvn
9 Nvn
9 Nvn
11 Nvn
137 Nvn
60 Nvn
109 Nvn
41 Nvn 60 Nvn
32 Nvn 24 Nvn
8 Nvn
32 Nvn
12 Nvn 24 Nvn 24 Nvn 65 Nvn 30 Nvn
Hand Tighten
V%
Turn
after
32 ft. lbs.
(72 in. lbs.)
20 ft. lbs. 50 ft. lbs.
42 ft. lbs.
18 ft. lbs.
57 ft. lbs.
7 ft. lbs. 7 ft. lbs.
(95 in. lbs.)
101 ft. lbs.
44 ft. lbs. 80 ft. lbs. 30 ft. lbs. 44 ft. lbs.
24 ft. lbs. 18 ft. lbs.
6 ft. lbs.
contact
24 ft. lbs.
9 ft. lbs. 18 ft. lbs. 18 ft. lbs.
48 ft. lbs. 22 ft. lbs.
J9109-261
Page 86
5.9L
(DIESEL) ENGINES
9 - 23
mmmmEm
SPECIFICATIONS
.
Step
1
Step 2
(CONT.)
24
N-m
43
N-m
24
N-m
13
N-m
8 N-m
24
N-m
24
N-m
60
N-m
24
N-m
2
N-m
8 N-m
24
N-m
77
N-m
60
N-m
119
N-m
176
N-m
24
N-m
43
N-m
80
N-m
24
N-m
80
N-m
16
N-m
24
N-m
24
N-m
24
N-m
%
TORQUE
Turn
after
18 ft. lbs.
32 ft. lbs.
18 ft. lbs. 10 ft. lbs. '
6 ft. lbs.
18 ft. lbs. 18 ft. lbs.
44
ft.
18 ft. lbs.
(17 (72
18 ft. lbs. 57 ft. lbs.
45 ft. lbs.
88 ft. lbs.
129 ft. lbs.
18 ft. lbs. 32 ft. lbs.
contact
60 ft. 18 ft. lbs. 60 ft. lbs.
12 ft. lbs.
18 ft. lbs. 18 ft. lbs.
18 ft. lbs.
in. in.
lbs.
lbs.)
lbs.)
lbs.
Power
Steering
Refrigerant
Throttle
Bracket
Torque
Converter
Transfer
Case
Pump
to
Compressor
Mounting
Access
Linkage
Vacuum
Pump
Lines - Flange
to
Mounting
Cover
Plate
Bracket
Mounting/Trans
Mounting
Mounting
Bracket...
Mounting
24
N-m
4 N-m
11 N-m
9
N-m
,
20 N-m 15 ft. lbs.
47
N-m
24
N-m
24
N-m
43
N-m
22
N-m
5 N-m
24
N-m
24
N-m
24
N-m
24
N-m
10
N-m
5
N-m
..
4 N-m
.. 41 N-m
47
N-m
18 ft. lbs.
(35 in. lbs.)
(95 in. lbs.)
7 ft. lbs.
35 ft. lbs.
18 ft. lbs. 18 ft. lbs.
32 ft. lbs.
16 ft. lbs.
(44 in. lbs.)
18 ft. lbs. 18 ft.
lbs.
18 ft.
lbs.
18 ft. lbs.
73
ft. lbs.
(44 in.
lbs.)
(35 in. lbs.)
30 ft. lbs. 35 ft. lbs.
J9109-262
Page 87
9
- 24 5.9L (DIESEL)
ENGINES
Trans
Cooler
Transmission
Tubing
Oil
to
Mounting
Air
Cooler
to
Hose
Oil
Pan
Clamps
TOtfQiJE
Flange
SPECIFICATIONS {CONST.}
24 N-m
68 N°m 68 Nvn 50 ft. lbs. 68 N-m 50 ft. lbs.
41 N-m 54 Nvn
6 N-m
2 N-m 47 N-m 35 ft. lbs. 47 N-m
11 N-m
8.5 N-m
32 N-m 24 N-m
15 Nvn
9 N-m
77 Nvn
24 Nvn
125 N-m
4 Nvn 43 N-m
24 N-m
50 Nvn 37
fOiCJtJl
18 ft. lbs.
50 ft. lbs.
30 ft. lbs. 40 ft. lbs.
(50 in. lbs.)
(18 in. lbs.)
35 ft. lbs.
8 ft. lbs.
(75 in. lbs.)
24 ft. lbs. 18 ft. lbs.
11
ft.
lbs.
7 ft. lbs.
57 ft. lbs. 18 ft. lbs. 92 ft. lbs.
(35 in. lbs.)
32 ft. lbs. 18 ft. lbs.
ft.
lbs.
J9109-263
Page 88
EXHAUST
SYSTEM
AND
INTAKE
MANIFOLD
11 - 1
AND
COHTEHTS
page page
SERVICE
PROCEDURES
(DIESEL
SERWICE PROCEDURES {DIESEL
ENGINES)
.. 1
SPECIFICATIONS
EHOIHES1
INDEX
page
Exhaust Manifold . 1 Intake Manifold Cover/Air Intake Heater 2
EXHAUST
REMOVAL
(1)
(Fig.
(2)
the oil drain tube
(3)
turbocharger
(4) (5)
MANIFOLD
Disconnect
1). Disconnect
Disconnect
(Fig. Remove Remove
the the cab heater
the air
the
from
the
intake
and
turbocharger oil supply
the
turbocharger
intercooler
inlet
2).
turbocharger
and
supply
exhaust pipes
line
(Fig.
2).
duct
from
gasket.
and
return lines.
and the
Intercooler 8 Turbocharger 3
9
page
Fig.
1 Air
intake
Pipe,
Turbocharger
Exhaust
Pipe
and
Fig,
2 Oil
(6)
Remove
Supply
the
Line
and
exhaust
manifold
3). (7)
Clean
INSTALLATION
(1)
Install
3).
Tighten
43 N-m
(2)
Install
the
the
the
(32 ft.
the
sealing surfaces.
exhaust
exhaust
manifold
manifold
lbs.) torque (Fig.
turbocharger (Fig. turbocharger mounting nuts torque.
Intercool&r
and gaskets
and gaskets
bolts
4).
2).
to 32
N-m
Inlet
Duct
(Fig.
(Fig.
in sequence to
Tighten
the
(24 ft. lbs.)
Page 89
Fig. 8 Exhaust Manifold
(3)
Position the intercooler inlet duct to the turbo-'
charger (Fig. 2).
With
the clamp in position, tighten
and
Gaskets
the clamp nut to 8 N-m (72 in. lbs.) torque.
(4)
Position the air intake pipe and the
exhaust pipe onto the turbocharger (Fig. 1). Tighten the clamps to 8 N-m (72 in. lbs.) torque.
(5)
Install the oil drain tube and oil supply line to the turbocharger (Fig. 2).- Tighten the drain tube bolts to 24 N-m (18 ft. lbs.) torque. Tighten the oil
supply line
(6)
Connect the cab
Tighten
(7)
Operate
fitting
nut to 15 N-m (11 ft. lbs.) torque.
heater
supply and return lines.
the line nuts to 24 N-m (18 ft. lbs.) torque.
the engine to check for leaks.
Fig.
5 Air
Inlet
Tube
and
Heater
Ground
(4)
Disconnect the air intake
heater lines (Fig. 6). Remove the air intake kets
(Fig. 6). Clean the mounting surface of the in-
Wire
power supply
heater
take manifold cover.
and
gas-
INTAKE
REMmmL
inlet
ground
MANIFOLD
(1)
Remove the intercooler outlet duct
COVER/AIR
INTAKE
tube (Fig. 5).
(2)
Remove the high
(3)
Disconnect and remove the air intake
pressure
fuel
wire (Fig. 5).
EXHAUST
HEATER
from
lines.
the air
heater
Fig.
6 Air
(5)
Disconnect the
from
the intake manifold cover (Fig. 7).
(6)
Disconnect the air temperature switch
Intake
charge
Heater
air temperature
intake manifold cover (Fig. 7).
(7)
Disconnect the
fuel
heater
ground wire
take manifold cover (Fig. 8).
(8)
Remove the manifold intake cover and
(Fig.
8). Keep the
terial
out of the air intake.
(9)
Clean the sealing surface.
gasket
material and any other ma-
sensor
from
the
from
in-
gasket
Fig, 4 fr'haust
Manifold
Bolt
Tightening
Sequence
Page 90
EXHAUST
supply
inlet
SYSTEM
(9)
Install
nuts
(10)
Position the intercooler outlet duct onto the air
tube
(Fig.
Ail
INTAKE
MANIFOLD
and tighten the air intake to
14 Nrn (10 ft. lbs.) torque.
5). Tighten the intercooler outlet duct
clamps to 8 Nun (72 in. lbs.) torque.
(11)
Install
Tighten
and bleed the
the
high
pressure
high
fuel
pressure
line
nuts
(18 ft. lbs.) torque.
TURBOCHARGER
REMOVAL
.
(1) Disconnect the battery negative cables.
(2)
Disconnect the air intake pipe and exhaust pipe
(Fig.
9).
11 - 3
heater
fuel
to 24
power
lines.
Nun
Fig. 7 Charge
INSTALLATION
(1)
Using a new
Mir
Temperature Sensor
Temperature Switch
gasket,
install
cover (Fig. 8).
(2)
Install
Tighten
(3)
Connect
take
manifold
(4)
Connect
the intake
(5)
Some drilled flon
sealant
the
fuel
heater
the
bolt
to 12 N-m (110 in. lbs.) torque.
the air
temperature switch
cover (Fig. 7).
the
charge
manifold
air
cover (Fig. 7).
of - the intake
through and must be
to
the bolts.
Install
manifold
cover bolts. Tighten the bolts torque.
(6)
Install heater a new
(7)
Install air
inlet
(8)
Connect the intake (Fig.
5).
MANIFOLD
INTAKE
a new
and the intake
gasket
on
the air
tube bolts
gasket
manifold
top
of the air intake
inlet
tube (Fig. 5). Tighten
to
24
N*m
between
manifold
FUEL HEATER
GROUND
and
the intake
ground
wire
manifold
(Fig.
to the
temperature
sealed.
the intake
to
24 N-m (18 ft. lbs.)
bolt
Apply
sensor
holes
liquid
manifold
the air
cover
(Fig.
6).
heater
(Fig.
(18 ft. lbs.) torque.
heater
ground
Mir
8). in-
to
are
te-
intake Install
6).
the
wire
WIRE
Fig.
9 Air
(3)
Remove the oil drain tube bolts.
(4)
Remove the oil supply
(5)
Disconnect
Intake
Pipe,
Turbocharger
the
intercooler
Exhaust
line
(Fig. 10).
inlet
turbocharger (Fig. 10).
(6)
Remove
the
turbocharger mounting nuts
the turbocharger.
(7)
If the turbocharger
diately,
falling
cover
the
into the
(8)
Clean and inspect the sealing surface.
manifold.
is
opening
not to be installed imme-
to
prevent material
Pipe
duct
and
from
the
and
from
Fig. 8 Manifold Intake Cower
Ground
Wire
and
Fuel
Heater
DISASSEMBLY
(1)
Scribe the housing so they can be assembled in
the
same
position.
(2)
Clamp the turbocharger in a bench vise.
Page 91
11
- 4
EXHAUST
SYSTEM
AID
INTAKE
MANIFOLD
ring
Fig.
12
Diffuser
and
(10)
Remove the oil slinger and discard the piston
(Fig.
13).
(11)
Inspect for cracks and excessive wear.
Lockplate
Fig.
10 Oil
(3)
Remove the compressor housing
(Fig.
11).
(4)
Remove the compressor housing and inspect for
impeller
(5)
Remove the
(6)
Remove the
peller
nut to the
have
left
Fig.
(7)
Remove the
Supply
Line
contact
(Fig.
11).
square
impeller
right
hand threads.
11
Compressor
Homing
impeller
and
Intercooler Inlet Duct
cut
nut
O-ring
(Fig.
V-Band
(Fig.
11).
11).
Turn
clamps
the
im-
to loosen. The nut and shaft
and
Impeller
and inspect the blades for damage. The wheel and shaft assembly is balanced as a
unit.
If
the
impeller
sembly
12).
(Fig.
must be replaced.
(8)
Remove the diffuser bolts and lockplate (Fig.
~
(9)
Remove the diffuser and discard the
13).
is damaged the complete as-
O-ring
O-RING
(Fig.
clamp
OIL
Fig.
13
Diffuser,
(12)
Remove the oil
(13)
Remove the thrust bearing and retainer screws
14). Do not
(14)
Remove the thrust
(15)
Inspect the
(16)
Remove the turbine housing
plates
(17)
Remove the bearing housing
(18)
Remove the turbine shaft and
(Fig.
Q-Ring
baffle
(Fig.
reuse
the thrust bearing.
collar
collar
for excessive wear.
15).
and Oil
14).
(Fig.
14).
lock
(Fig.
heat
Slinger
plates and
15). shield (Fig.
16). (19)
Inspect the turbine blades and the shaft for ex-
cessive wear.
(20)
Remove and discard the piston
(Fig.
16).
ring
type seal
Page 92
EXHAUST
(28)
17).
SYSTEM
Fig.
17
Snap Rings
AND
INTAKE
and
MANIFOLD
Shaft Bearing
Remove and'discard the inner
snap
rings (Fig.
11 - 5
J9111-14
Fig.
15
Turbine Housing Lock Plates
Plates
Fig,
IS
Turbine Wheel Shaft
CAUTION: anced damaged,
(21)
Remove and discard the outer retainer rings
(Fig.
17).
(22)
Remove and discard the turbocharger shaft
as a
The
unit.
the
complete
wheel
If the
and
turbine
assembly
and
shaft
and
Heat Shield
assembly
blades
must
or
shaft
be
replaced.
bearings (Fig. 17).
Clamp
is
bal-
are
CLEMMING
Use a
stiff
bristle
all
parts. Do not use a
wheel.
a
sene
to
INSPECTION
sembly,
Do not bead blast the parts.
Remove
scraper
Polish
the,
and
the bearing surfaces
or diesel
After
rinsing
dry the parts.
In
addition to the inspection specified during disas-
inspect all parts after cleaning.
nylon
brush and solvent to clean
wire
brush on the compressor
carbon
a-240
build
grit
up
emery
with
from
the housing
cloth.
crocus and kero-
fuel.
in clean solvent, use compressed air
Measure the shaft bearing diameter (Fig. 18). The
minimum
diameter should be 10.97 mm (0.432
SHAFT
BEARING
J9111-15
Fig.
18
Shaft Bearing Diameter
inch).
with
Page 93
11 - e
EXHAUST
SYSTEM
AND
INTAKE
MANIFOLD
0
ASSEMBLE
The balance marks must be aligned to make
the wheel and shaft assembly is balanced.
(1)
Install
with
engine oil.
(2)
Install
TURBINE
SHAFT
Fig.
(3)
Clamp a socket in a soft jawed vice and position
19
the piston
the
heat
BREAKING,
HOUSING
Turbine
Shaft/Heat
ring
and lubricate the groove
shield (Fig. 19).
HEAT
SHIELD
Shield
Housing
to
Bearing
the shaft in the socket.
(4)
Install
the inner retainer rings. The beveled
face must be towards the bearing (Fig. 20).
RETAINING
sure
J9111-18
INNER
RING
Fig.
21
(10)
Install
alignment.
(11)
Install
slinger
(Fig. 22).
Beveled
Face
the oil
the piston
of
Outer
Retainer Ring
baffle.
Check the balance mark
ring
type
seal
OUTER
RETAINING
RING
J9111-17
on the oil
PISTON
RING
TYPE SEAL
Fig.
20
Beveled
(5)
Lubricate the turbocharger bearing
oil
and
install
(6)
Install
the outer retainer
Face
of
Inner Retainer Ring
with
the bearings in the housing.
ring.
The beveled face
engine
must be towards the bearings (Fig. 21).
(7)
Assemble the turbine shaft and
heat
shield to
the bearing housing (Fig. 19). Rotating the housing
as you
the piston
mark top surface verified
and
to
press
downward
will
assist
ring.
(8)
Install
with
(9)
Lubricate the thrust bearing
install
the thrust collar.
the balance mark on the shaft.
with
a marker pen so alignment can be
after
installing
the thrust bearing.
it on the housing. Tighten the torx bolts
4.5 Nun (40 in. lbs.) torque.
in properly seating
Align
the balance
Mark
with
engine oil
the
OIL
SLINGER
Fig.
22
Piston
Ring
Type
Seal
(12)
Mark
with
the balance mark.
(13)
Lubricate the oil slinger
install
(14)
Install
(15)
Install
on
the shaft and the oil slinger (Fig. 23). (16)
Align
ler
(Fig. 24). Be careful not to move the bearing
the top surface of the oil slinger
with
it into the diffuser.
the O-ring into the diffuser.
the diffuser.
Align
the balance marks
the balance mark and
engine oil and
install
J9111-19
the
line
impel-
housing.
(17)
Do not
ing
the nut. The impeller nut and the shaft
LEFT
hand threads. Tighten the nut to 14 Nun (129
in.
lbs.) torque.
(18)
Install
turbine
(19)
Align
(20)
Apply
(21)
Install
(Fig.
26). Tighten the bolts to 11.3 Nun (100 in. lbs.)
allow
the impeller to
turn
when
the bearing housing assembly into the
housing (Fig. 25).
the scribe marks (Fig. 25).
anti-seize compound to the
the clamp plates,
lock
bolt
plates and bolts
install-
have
threads.
torque.
Page 94
EXHAUST
SYSTEM
AND
11 - 7
Fig.
23
IMPELLER
Align
Balance
DIFFUSER
ALIGN
BALANCE
MARKS
Marks—Shaft
and Oil
J9111-20
Slinger
DIFFUSER
J9111-23
Fig.
26
Install
Clamp
Plates/Lock
LOCK
PLATE
Plates
Fig.
TURBINE
HOUSING
BEARING
HOUSING
Fig.
25
Bearing
(22)
Install
fuser (Fig.
(23)
After
lbs.)
torque, bend
Be
sure
the
24
Align
Balance
Housing
the
lock
27). tightening
the
scribe marks
DIFFUSER
Marks—Impeller
\
Assembly/Turbine
plates
lockplate
the
are
and
bolts
to 5.7
tabs
aligned.
bolts into
to
J9111-21
ALIGNMENT
'
MARKS
J9111-22
Housing
the
N-m
lock
the
ALIGN
BALANCE
MARKS
dif-
(50 in.
bolts.
TURBINE
HOUSING
Fig.
27
Diffuser
(24)
Measure charger play
with a serial number before 840638
should For turbocharger after
the end
0.003
inch).
(25)
Measure radial
The
clearance
the
end
be
0.102-0.152 with a serial number of 840638 and
play should
clearance
should
be
inch).
(26) (27)
Install Be
sure
the
the
square
scribe marks the compressor housing anti-seize compound Tighten against ence.
the
the
Again
clamp
clamp
tighten
to the
to 8
on 4 places
the
torque.
INSTALLATION
(1)
Install a new
pound
to
(2)
Install
the
mounting
the
gasket
turbocharger. Tighten
charger mounting nuts
For
the
(Fig.
J9111-9
turbo-
end
(0.001-
28).
LOCKPLATE
and
Lockplate
play (Fig.
mm
(0.004-0.006 inch).
be
0.026-0.076 mm
of the shaft
28).
0.300-0.460 mm (0.012-0.018 cut
O-ring.
are
aligned. Install
and
V-Band clamp.
V-Band bolt
Nun (72 in. lbs.) torque.
clamp
and
around
to 8
apply anti-seize com-
its
Nun (72 in.
Apply
threads.
Tap
circumfer-
lbs.)
studs.
the
turbo-
to
32 N#m (24 ft. lbs.) torque.
Page 95
11 - 8
Tighten ft.
clean engine
50-60 cc (2-3 ounces) of
EXHAUST
Fig.
28 End
(3)
Use a new gasket and connect the drain
the drain
SYSTEM
Play/Radial
line
connection bolts to 24
AND
Clearance
INTAKE
of
lbs.) torque.
(4)
New turbocharger must be pre-lubricated
lubricating
oil before start up. Pour
oil
into
supply
MANIFOLD
Shaft
N»m
fitting.
line.
(18
with
(1)
Remove the
grille
proper procedure).
(2)
Remove the
(3)
If the vehicle is equipped
front
support bracket
remove the condenser as
(a)
Discharge the air conditioning system (see
Group
24, Heating and Air
proper procedures).
(b)
Remove the
bolt
29). (c)
Remove the nuts intercooler plate assembly away
(Fig.
29).
Lift
from
(see Group 23, Body for the
(Fig.
29).
with
air
conditioning,
follows:
Conditioning
from
the sealing plate (Fig.
holding
the condenser to the
for the
the condenser and sealing
the intercooler.
WARNING:
THE
TURBINE
(5)
Rotate the turbine wheel to
DO NOT USE
WHEEL.
YOUR
FINGER TO
allow
oil to enter
the turbocharger.
(6)
Install
ply
line
(7)
Position the intercooler
charger.
clamp
(8)
Position the air intake pipe and the exhaust
pipe
onto the turbocharger. Tighten the clamps to 8
N*m
(72 in. lbs.) torque.
(9)
Operate the engine and check for leaks.
INTERCOOLER
Intake
into
the turbocharger compressor housing.
ized
air
through
tor.
From the intercooler the air
intake
The intercooler is a
flow
to bocharger increases. creases
the oil supply
fitting
With
nut to 15 N#m (11 ft. lbs.) torque.
the clamp in position, tighten the
line.
Tighten the oil sup-
inlet
duct to the turbo-
nut to 8 N«m (72 in. lbs.) torque.
air is drawn through the air cleaner and
from
the turbocharger then
the intercooler located in
front
flows
flows
of the radia-
back
manifold.
heat
exchanger that
dissipate
engine
heat
increases
Lowering
efficiency
from
the intake air. As the tur-
air
pressure,
the air temperature
the intake air temperature in-
and power.
TURN
Pressur-
forward into
the
uses
air
Fig.
29
Condenser
(4)
Remove the
tercooler
(5)
intercooler
INSTALLATION
(1)
bolts
(Fig.
Remove the intercooler bolts
forward
Position the intercooler (Fig. 29).
and tighten to 2 N«m (17 in. lbs.) torque.
inlet
30).
and
Intercooler
and outlet ducts
(Fig.
and up to remove.
from
the in-
29). Pivot the
Install
the
REMOVAL
WARNING: OFF,
THE
HOT.
IF THE
INTAKE
ENGINE
AND OUTLET DUCTS MAY BE
WAS JUST
TURNED
Fig.
30
Intercooler
Ducts
Page 96
(2)
Install
cooler
(Fig.
the
clamp
(3)
If
the
install
the condenser as
(a)
Position sembly the
nuts
(b)
Connect
onto
the
inlet
and
outlet
30).
With
the
clamps
nut to 8 Nun (72
vehicle
is
equipped
follows:
the condenser and
the
intercooler
and
tighten.
the
halves
of the
ducts in
in.
lbs.)
with
studs
sealing
TORQUE
to the
position,
inter-
tighten
torque.
air
conditioning,
sealing
(Fig.
plate
29). plate
as-
Install
(Fig.
SPECIFICATIONS
SPECIFICATIONS
EIHAUST SYSTEM AND INTAKE
29).
Install
(c)
Charge
24,
Heating
procedures).
(4)
Install
stall
and
(5)
Install
proper
(DIESEL
the
bolt
and
tighten.
the air
and Air
the
tighten
the
conditioning
front
support
the
bolts.
grille
Conditioning
(see
procedure).
ENGINES!
MANIFOLD
system
bracket
Group
23,
11-9
(see
for the
(Fig.
Body
Group
proper
29). In-
for the
COMPONENT
Air Heater Power Supply Nuts
Cab
Heater Supply/Return Line Nuts
Exhaust
Manifold
Fuel
Heater Ground Bolt
Fuel
Line Nuts
Intake
Manifold Intercooler Attaching Bolts Intercooler Duct Clamp Nuts
Throttle
Control Bracket
Thrust
Bearing Torx Bolts Turbo Bearing Housing/Diffuser Bolts Turbo Bearing Housing/Turbine Housing Bolts Turbo
Mounting Turbo Impeller Nut Turbo Oil Drain Tube Bolts Turbo Oil Supply Line Fitting Nut Turbo V-Band Clamp
Bolts
Cover Bolts
Mounting
Nuts .
Bolts
14 N-m
24 N-m
43 N-m
12
N-m
24 N-m
24 N-m
2 N-m 8 N-m
24 N-m
4.5 N-m
5.7 N-m
11.3 N-m 32 N-m
14 N-m
24 N-m
15 N-m
8.5 N-m
TORQUE
10 ft. lbs.
18 ft. lbs.
32 ft. lbs.
(110 in. lbs.)
18 ft. lbs.
18 ft. lbs. (17 in. lbs.) (72 in. lbs.)
18 ft. lbs. (40 in. lbs.) (50 in. lbs.)
(100 in. lbs.)
'
24 ft. lbs.
(129 in. lbs.)
18 ft. lbs.
11 ft. lbs. (75 in. lbs.)
J9111-57
Page 97
Page 98
FUEL
CONTENTS
page page
SYSTEM
DIESEL GENERAL DIAGNOSIS-DIESEL ,8
FUEL INJECTION ................. 1 SERVICE PROCEDURES .................. 21
IIESEL
FUEL
INDEI
INJECTION
page
Air
Intake
Heater Relays—Engine
Controller
Output 4 Battery Brake Switch—Engine Charge
Crank Engine General
Ignition
Voltage—Engine
Air
Input
Temperature Sensor—Engine
2
Signal—Engine
Controller
......................... 1
Information
Sense—Engine
Controller Input
Controller Input
........ 2
......... 2
Controller
Controller Input
.......... 2
. . 1
Controller Input
......... 2
KSB Solenoid 5 Overdrive
Input
Overdrive
Override
Switchitch—Engine
Controller
2
Solenoid—Engine
Controller
Output .... 5
Park/Neutral SCi Receive and SCI Transmit—Engine
Output ................................ 5
Speed Speed System System Throttle
Input
Vehicle
Input Wait-To-Start Water-ln-Fuel Water-ln-Fuel
Switch—Engine
Control—Engine Control—Engine
Controller Input
Controller Input Controller
Output . 5
Diagnosis ......................... 1
Operation ......................... 5
Position
Sensor
(TPS)—Engine
................................. 3
Distance
(Speed)
Sensor—Engine
. 3
Lamp—Engine
Lamp—Engine Sensor—Engine
Controller
Controller
Controller Input
page
2
Controller
......... 3
Controller
Controller
Output ... 5
Output ... 5
... 3
GENERAL INFORiATION
Beginning
gine
controller
tem.
This injection service engine
SYSTEM DIAGNOSIS
The
engine
for
faults.
message
in mid 1991
group
system.
manual
regulates
contains
The 1991
describes
model
the
controller.
controller
monitors
If a fault is found, the
in
memory.
Use the DRB II to
messages.
ENGINE CONTROLLER
•The
Single
lates
the fuel injection
to the
SBEC
controller
tal
computer
intake
heater control. The in
fuel
lamp
Board
is a
Engine
as the
engine
pre-programmed,
(Fig. 1). The
relays,
engine
controller
and wait to
system.
overdrive
start
year, a Chrysler
diesel
fuel injection
information
Rear
Wheel
1991
vehicles
many
controller
Controller
This
controller.
microprocessor
controller
solenoid,
also
powers
lamp
about
the fuel
Drive Truck
without an
of it
systems
stores
access
(SBEC).regu-
manual
operates
v
The
and
the
refers
engine
the air
speed water
en-
sys-
a
fault
digi-
SBEC I!
- The
engine engine these
controller
inputs.
Engine
Controller
• water-in-fuel
charge
vehicle
air
temperature
speed
_____
( ( ( f (
C
Fig. 1 Engine
controller
activates
sensor
sensor
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Controller
receives
different
Inputs
sensor
(
cl
various
outputs
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based
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on
Page 99
14
- 2 FUEL SYSTEM
throttle position
overdrive override switch
crank signal
park/neutral switch
©
brake
speed
©
ignition
©
battery voltage
switch
control
sense
sensor
Engine Controller Outputs
water-in-fuel lamp
wait-to-start lamp
sci transmit
sci receive
overdrive solenoid
air intake
speed
heater
control.
relays
Fig. 2 Charge
Air
Temperature
Sensor
BATTERY
The battery input provides power to gine controller. The input when the checks nal. If that the low cle of the air intake
BRAKE
If
put while the
able
CHARGE CONTROLLER
The
of
the intake manifold (Fig. 2). It provides an input to the ture in the manifold. perature when to
also the tion.
CRANK
The crank signal input informs the ler that the ceiving energizes cle as heater does Heaters
VOLTAGE—ENGINE
engine
is running. The
battery voltage after it
battery voltage is
engine
is running. If battery voltage is be-
12.66 volts the controller
CONTROLLER
also
receives
above
12.66 volts it
aborts
INPUT
operate
the en-
tells the controller
engine
controller
a crank sig-
assumes
the
post-heat
heaters.
SWITCH-ENGINE
the
engine
speed
charge
engine
controller
speed
control
control.
AIR TEMPERATURE SENSOR-ENGINE
INPUT
air
temperature
controller that indicates air
input, the
energize
tells the
heaters.
the air intake
engine
Refer to Air Intake
CONTROLLER
INPUT
receives a brake
Based
engine
system
on the
is on, it
sensor
is located on top
charge
controller
heaters.
determines
The input
controller how long to
Heaters
in this
switch in-
will
dis-
tempera-
air tem-
operate
sec-
SIGNAL-ENGINE
starter
relay has
the crank input the
the air intake
needed.
cycle
The
will
not begin if the
CONTROLLER
been
heaters
post-heat
engaged.
engine
for the
stage
engine
INPUT
engine
control-
After
controller
post-heat
of the intake
controller
not receive a crank signal. Refer to Air Intake
in this section.
cy-
re­ cy-
OVERDRIVE
CONTROLLER
On
vehicles equipped controller downshift
OVERRIDE
SWITCHITCH
EMGINIE
INPUT
with
overdrive, the
regulates
the 3-4 overdrive upshift and
through the overdrive solenoid. An over-
engine
ride switch is located on the instrument panel.
The overdrive override switch is normally closed. It
opens
when the transmission ator
presses downshifts while
if
in overdrive.
The overdrive switch circuit
will
operator
not
presses
enter
overdrive when the
the switch. The
oper-
the override switch. The transmission
the
operator
presses
the override switch
contains
two other
switches; a transmission thermo-switch and a coolant temperature transmission
downshift
COOLMMT
The coolant when the coolant When the coolant thermo-switch sion
will
switch. When either switch
will
not shift into overdrive or
opens,
the
will
if already in overdrive.
TEMPERATURE
temperature
temperature
SWITCH
switch (Fig. 3)
is below 16°C
opens,
the transmis-
opens
(60°F).
not shift into overdrive. The transmission downshifts if it is in overdrive when the coolant switch
opens.
do not
have
TRANSMISSION
The transmission thermo-switch transmission (273°F). mission
Vehicles
with
a manual transmission
a coolant switch.
THERMO-SWITCH
opens
fluid
When the thermo-switch
will
not shift into overdrive. The transmis-
temperature
is
opens,
when the
above
the
134°C
trans-
sion downshifts if it is in overdrive when the thermo­switch
opens.
not
close
to 116°C
Once
until
transmission
(240°F).
the thermo-switch
fluid
opens,
temperature
The switch is located in the
it
will
drops
trans-
mission to radiator cooling line.
IGNITION
The
ignition
troller
that the
SENSE-ENGINE
sense
input informs the
ignition
switch is in the run position.
CONTROLLER
engine
INPUT
con-
PARK/NEUTRAL INPUT
SWITCH-ENGINE
CONTROLLER
The park/neutral switch (Fig. 4) is located on the
Page 100
FUEL
SYSTEM
14 - 3
Fig. 3 Coolant Temperature Switch
automatic transmission housing. It provides an input to
the
engine automatic transmission is in gear
selection.
If
the transmission is in overdrive and the
shifts
the
gear,
the transmission
gine controller
The
engine
input
when determining engine erator control
controller
shifts the transmission into neutral. The
will
controller. The input indicates if
Park,
Neutral or a drive
vehicle into neutral
will
determines
controller
uses
speed
will
disable
have
to be
and
then back into
enter
overdrive if the en-
all conditions
the park/neutral switch
speed
reset
control
once
strategy.
control if the op-
the
operator
are
vehicle
the
met.
The
speed
is
placed back into drive.
The park neutral switch
as
the
neutral
safety
Transmissions, for adjustment,
is
sometimes
switch. Refer
replacement,
referred
to
group
and
to
21
test
information.
operating fect ®
park/neutral switch
©
vehicle
©
throttle position
THROTTLE CONTROLLER
The throttle position
speed
range
is
from
35 to 35 mph. Inputs that ef-
control operation
distance
(speed)
sensor
POSITION
INPUT
SENSOR
sensor
are:
sensor
(TPS)—ENGINE
(TPS)
is
mounted
on the top of the fuel injection pump (Fig. 5). The TPS provides ranges sensor idle
an
input
from
approximately
senses
how
position). The
to
the
far the
engine
engine
zero
throttle
controller
controller. The input
to
five
is
uses
open
volts.
the TPS in-
(past
The
the
put when determining the 3-4 upshift (overdrive) and the
4-3
downshift. Only vehicles
transmissions
The TPS
have a TPS.
is a supplies 5 volts gine controller idle
to
3.5 volts
potentiometer. The to
the
sensor.
varies
from
approximately
at
wide open throttle
with
automatic
engine
controller
TPS output to the en-
1.0
volt
at
(WOT).
SPEEI
The
system
Fig. 4 Neutral Safety Switch
CONTROL-ENGINE CONTROLLER
engine
based
controller
on inputs it
regulates
receives.
the
The
INPUT
speed
speed
control
control
Fig. 5 Throttle Position Sensor
VEHICLE
CONTROLLER
The
sion housing of the transmission. The
ler
DISTANCE
distance
uses
the TPS and
INPUT
sensor
(SPEED)
(Fig. 6)
distance
SENSOR
is
located in the exten-
—ENGINE
engine
sensor
control-
inputs
determine when to shift into and out of overdrive.
The speed set
speed
distance control
sensor
set,
is
also
decelerate,
used
accelerate,
(85 mph), and minimum set
in
determining
maximum
speed
(35 mph)
operations.
WATER-IN-FUEL
SENSOR
—ENGINE
CONTROLLER
INPUT
The water-in-fuel (WIF) bottom of the fuel/water sensor it
senses
looks
sends
at the
an
water
in the
water-in-fuel
input
sensor
separator
to the
fuel.
The
sensor
is
filter
engine
engine
signal when
located
at the
(Fig. 7). The
controller when
controller
the
to
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