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

SERVICE

MANUAL

SUPPLEMENT

DIESEL ENGINE

REAR

WHEEL

DRIVE

TRUCK

D& W 250-350

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.

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

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-

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

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

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

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

Attachment—Engine Attachment—Servo

System

Electrical

Control Switch Test .... 8H-5

Test 8H-6

Input 14-2

—Engine

Controller

Input .... 14-3

Output

Controller

. 14-8

8E-1

Tests 8H-4

... 14-5

.. 8H-7

... 8H-7

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

Clutch

Compounder

Clutch

And

....

21-2

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

•

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

the power steering pump into a single

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

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

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

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

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

(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

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

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

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

•

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

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

MOML

All

SPECIFICATIONS

COOLING

RADIATOR

m

WIDTH INCHES

A

•

26

IHKK-

NISS

2.25 3

2.25

SYSTEM

ROWS

OF

TUBES

3

CAPACITIES

HNS

DIAMETBR

MR

INCH

INCHES

13 22.0

NO.

OP

BLADES

7

FAN

PITCH

INCH

•NOAOIMINT

T1MMRATURI

2.20

CLWTCH

140°F

140

°F

CAPACITY

QUARTS

17.0

16.0 15.1

units

39107

16.1

881

•

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

•

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

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-

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

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

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

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

•

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

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

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

red

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

8H - 6

SPEED

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

4

2

4

2

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

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

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

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

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-

•

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

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

• 16

.21 .21

.22

-5

.6

30

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

24

System

.24

24

•

Wiring

Diagram

Name \ ^ Sheet Number

Windshield

Fuse Ground Motor Switch Washer

Wiper

System

23

Motor

23

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

(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

R9 6BK*

WIRING

DIAGRAMS

GROUND

(ON ENGINE)

8W - 5

CHARGING

J918W-13 5.9L ENGINE

SYSTEM

WITH

DIESEL

(SEE

SH 21)

AD 2

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

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

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

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

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

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

•

•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

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

TO

LEFT

PRINTED

BOARD CONNECTOR

(SEE

CIRCUIT

SH

DIESEL ENGINE WIRING

m

go]

G7

20WT

OR*

52)

J918W-13

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

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

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

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

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*

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

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

•

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

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)

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

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

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

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

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

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

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-

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

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

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

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

R.W.A.L.

(SEE

SWITCH

(BULB TEST)

(SEE

SWITCH

VACUUM

(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

FUEL

SH

26)

32)

IGNITION-

22)

SWITCH

(DIESEL)

MODULE

12V

H4>1 I SPLICE

FUEL

TANK

J918W-13

FEED

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

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

•

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

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

(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

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

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

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

CONDITIONING

LAMP INDICATOR FEED

TEMPERATURE SENDING UNIT

SIGNAL

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

FLASHER

(2

WIRES)

MOTOR

LAMP

MOTOR

DAMPED

MOTOR MOTOR

RUN

CIRCUIT

CIRCUITS

WIRES)

MODULE)

(DIESEL)

(2

WIRES)

(2

WIRES)

SWITCH

PRESSURE SWITCH

AD

33

50-WAY

BULKHEAD

DISCONNECT

J918W-13

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

WHEEL

IGNITION-RUN & START

IGNITION IGNITION

INDICATOR FEED

TURN

FLASHER

LAMPS

LAMP

WASHER

START

LAMP

WARNING

IN

FUEL

DRIVE

SENSOR

LOCKOUT

FEED

SWITCH SWITCH

LAMP

(DRL

LAMP GAUGE-SEND

FEED

LAMP

SWITCH

(2

CIRCUITS

MOTOR

BEAM

LAMP

MODULE)

SIGNAL

MOTOR

SWITCH

(DIESEL

WIRES)

SWITCH

LOW

(B1) (B3)

UNIT

LAMP

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)

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

8W

- 38

WIRING

DIAGRAMS

VIEWED

END OF

SHORT

I

i i I i I i i I i 1/

LONG

FROM

WIRE

CONNECTOR

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

#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 10 10

10

-

9,15

9

_

15

_

10

_

9

15

8 6 8

-

_

AD

35

ENGINE

SINGLE

BOARD

CONTROLLER CONNECTOR (DIESEL)

J918W-13

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

—5—3—^-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

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

Swirl

Aluminum

ENGINES

(400 ft. lbs.) @ 1750 rpm

Filtration

Filter

• (16 Quarts)

Hardened-Forged Steel

Combustion Bowl

Cast

Iron

(17 Quarts!

Quart)

J9109-255

•

5.9L

(DIESEL)

ENGINES 9 - 3

GENERAL

Engine

causes

of

routine

chanical engine

tune-ups.

These

idles

CONDITION

LUBRICATING PRESSURE

INFORMATION

diagnosis

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

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

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

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.

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

•

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

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

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

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

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

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

•

—•———————

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

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

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

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

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

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

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

de-

Oil

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

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.

I

- 14 5.9L

(DIESEL)

ENGINES

Fig. 8 Marking Converter

Alignment Reference

(23)

Disconnect all electrical connections

engine. Put

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-

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

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

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),

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

to

If

an

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

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-

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

±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

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

•

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

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.

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

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

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

(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

(Max.)

0.01 mm

(0.0004

diameter

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

(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)

CONNECTING

!

Pin Bore

|

Side Clearance

Diameter

ROD

(Max.)

. . 40.053

0.10-0.30

mm

(1.5769

inch)

(0.004-0.012

inch)

J9109-246

—

5.9L

(DIESEL) ENGINES

9 - 21

PISTONS

Skirt

Diameter (AAin.)

Ring Groove

Ring

End

Gap

CRANKSHAFT

Main

Bearing Journal

Connecting

(Max.)

Rod

Diameter

Journal

ENGINE

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

(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

(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

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

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

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.

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

Nuts

................

Mount

Isolator

Mount

Through Bolt

Mount

to Block . .•

Access

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

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

5.9L

(DIESEL) ENGINES

9 - 23

TORQUE

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.

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

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

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

•

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

(32 ft.

the

sealing surfaces.

exhaust

manifold

lbs.) torque (Fig.

turbocharger (Fig. turbocharger mounting nuts torque.

Intercool&r

and gaskets

bolts

4).

2).

to 32

N-m

Inlet

Duct

(Fig.

in sequence to

Tighten

the

(24 ft. lbs.)

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

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.

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).

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

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

•

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

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.

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

square

scribe marks the compressor housing anti-seize compound Tighten against ence.

the

Again

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.

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

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

(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

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

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

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

........ 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 Input

page

2

Controller

......... 3

Controller

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

\

}

Controller

receives

different

Inputs

sensor

(

cl

various

outputs

60-WAY

,tmmam

CAVITY

Y

>

v

J9114-6

inputs.

based

The

on

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

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

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

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

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

signal when

located

at the

(Fig. 7). The

controller when

controller

the

to